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PRIORITY OF INVENTION
This application claims priority of invention under 35 U.S.C. §119 from Russian Patent Number 2129867 filed Jun. 10, 1998, and allowed May 10, 1999.
BACKGROUND OF THE INVENTION
Russian patent number 2005475 (1994) discloses compositions comprising polyprenil phosphate which are reported to possess antiviral activity.
L. L. Danilov, et al., Archivum Immunologiae and Thrapiae Experimentalis, 1996, 44, 395-400 disclose a polyprenyl phosphate composition (PHOSPRENYL) that has antiviral and immunomodulatory activity. A. N. Narovlyansky, et al., Abstracts of the Second Joint Meeting of the International Cytokine Society and International Society for Interferon and Cytokine research, Jerusalem, Israel, Oct. 25-30 1998, and A. V. Sanin, et al., Abstracts of VII International Conference on AIDS, Amsterdam, the Netherlands, Jul. 19-24, 1992, also describe similar biological activity for PHOSPRENYL.
A. V. Sanin, et al. Abstracts of the meeting “Dolichols and Related Lipids”, Aug. 11-13, 1993, Zakopane, Poland, disclose a phosphorylated polyisoprenoid composition P16 that is reported to be a novel immunomodulatory agent and antiviral drug that might be promising in immunotherapy of infectious diseases. The composition is reported to modulate NK activity, enhance X-ray resistance, modulate GM-CSF levels, stimulate hematopoietic stem cell migration, stimulate interferon activity, and to possess mild adjuvant activity. The composition is also disclosed to possess a strong dose-dependent inhibitory activity against HIV-1 infection in MT4 cells, and to inhibit hepatitis A virus, bovine leukemia virus, adenovirus, and tick encephalitis.
Additionally, European Patent Application 0 350 801 discloses polyprenols and polyprenyl phosphates that are useful for the inhibition of tumor metastasis.
Despite the above disclosures, there is currently a need for additional therapeutic agents with antiviral and immunomodulatory activity. In particular, there is a need for agents that have improved activity or improved physical characteristics compared to known agents. For example, the PHOSPRENYL composition identified above is limited for therapeutic purposes by a low solubility in water and other polar solvents.
SUMMARY OF THE INVENTION
Applicant has discovered certain compositions that are useful for the prevention, treatment, and liquidation of consequences of diseases, including viral, chlamidial, bacterial related diseases, oncology related diseases, diseases related to the liver, gastrointestinal, urologic and reproductive systems, and diseases related to the function of the immune system. The compositions are also useful in the treatment of wounds, bums, and stresses, and are useful for medical (human) and veterinary applications. The pyrophosphate containing compositions of the invention have improved solubility compared to related known compositions, and as a result, demonstrate improved levels of activity against certain diseases.
Accordingly, the invention provides a composition comprising, 1) polyprenol monophosphates of the formula H—[—CH2-C(CH3)═CH—CH2]n-O—P(═O)(OH)2 wherein n is an integer from 6-19 inclusive or a salt thereof, and 2) polyprenol pyrophosphates of the formula H—[—CH2-C(CH3)═CH—CH 2 ] m —O—P(═O)(OH)—O—P(═O)(OH) 2 wherein m is an integer from 6-19 inclusive, or a salt thereof.
The invention also provides a composition comprising polyprenol pyrophosphates of the formula H—[—CH2-C(CH3)═CH—CH 2 ] m —O—P(═O)(OH)—O—P(═O)(OH) 2 wherein m is an integer from 6-19 inclusive, or a salt thereof.
The invention also provides a pharmaceutical composition comprising 1) polyprenol monophosphates of the formula H—[—CH2-C(CH3)═CH—CH2]n-O—P(═O)(OH)2 wherein n is an integer from 6-19 inclusive or a salt thereof, and 2) polyprenol pyrophosphates of the formula H—[—CH2-C(CH3)═CH—CH 2 ] m —O—P(═O)(OH)—O—P(═O)(OH) 2 wherein m is an integer from 6-19 inclusive or a salt thereof; and a pharmaceutically acceptable carrier.
The invention also provides a pharmaceutical composition comprising polyprenol pyrophosphates of the formula H—[—CH2-C(CH3)═CH—CH 2 ] m —O—P(═O)(OH)—O—P(═O) (OH) 2 wherein m is an integer from 6-19 inclusive, or a salt thereof; and a pharmaceutically acceptable carrier.
The invention also provides a method for producing an antiviral effect in an animal comprising administering to an animal in need of such treatment, an effective antiviral amount of a composition comprising 1) polyprenol monophosphates of the formula H—[—CH2-C(CH3)═CH—CH2]n-O—P(═O)(OH)2 wherein n is an integer from 6-19 inclusive or a salt thereof, and 2) polyprenol pyrophosphates of the formula H—[—CH2-C(CH3)═CH—CH2] m —O—P(═O)(OH)—O—P(═O)(OH) 2 wherein m is an integer from 6-19 inclusive or a salt thereof. As used herein “animal” includes for example mammals (e.g. a dog, cow, cat, or human), birds (e.g. poultry), and other animals that can effectively be treated with the compositions of the invention.
The invention also provides a method for producing an antiviral effect in an animal comprising administering to an animal in need of such treatment, an effective antiviral amount of a composition comprising polyprenol pyrophosphates of the formula H—[—CH2-C(CH3)═CH—CH 2 ] m —O—P(═O)(OH)—O—P(═O)(OH) 2 wherein m is an integer from 6-19 inclusive or a salt thereof.
The invention also provides a method for modulating (e.g. normalizing or upregulating) the immune system of an animal comprising administering to an animal in need of such treatment, an effective immunomodulatory amount of a composition comprising 1) polyprenol monophosphates of the formula H—[—CH2-C(CH3)═CH—CH2]n-O—P(═O)(OH)2 wherein n is an integer from 6-19 inclusive or a salt thereof, and 2) polyprenol pyrophosphates of the formula H—[—CH2-C(CH3)═CH—CH 2 ] m —O—P(═O)(OH)—O—P(═O)(OH) 2 wherein m is an integer from 6-19 inclusive or a salt thereof.
The invention also provides a method for modulating (e.g. normalizing or upregulating) the immune system of an animal comprising administering to an animal in need of such treatment, an effective immunomodulatory amount of a composition comprising polyprenol pyrophosphates of the formula H—[—CH2-C(CH3)═CH—CH 2 ] m —O—P(═O)(OH)—O—P(═O)(OH) 2 wherein m is an integer from 6-19 inclusive or a salt thereof.
The invention also provides a method for the treatment of disease caused by distemper virus (DV), canine enteritis (parvo, rota, and corona viruses; CEV), canine infectious hepatitis (CIH), feline infectious gastroenteritis (panleukopenia, FIE), feline infectious rhinotracheitis (agent—herpes virus; FIR), feline infectious enteritis and peritonitis (agent—corona virus, FIP), swine transmissive gastroenteritis (agent—rotavirus; STG), murine ectromelia (ME), cattle leukemia (CL), calf mixed viral infection (agents—parvo, adeno, and corona viruses; CMVI), western equestrian encephalomyelitis (WEE), or rabies (RV), comprising administering to an animal in need of such treatment, an effective therapeutic amount of a composition comprising 1) polyprenol monophosphates of the formula H—[—CH2-C(CH3)═CH—CH2]n-O—P(═O)(OH)2 wherein n is an integer from 6-19 inclusive or a salt thereof, and 2) polyprenol pyrophosphates of the formula H—[—CH2-C(CH3)═CH—CH 2 ] m —O—P(═O)(OH)—O—P(═O)(OH) 2 wherein m is an integer from 6-19 inclusive or a salt thereof.
The invention also provides a method for the treatment of distemper virus (DV), canine enteritis (parvo, rota, and corona viruses; CEV), canine infectious hepatitis (CIH), feline infectious gastroenteritis (panleukopenia, FIE), feline infectious rhinotracheitis (agent—herpes virus; FIR), feline infectious enteritis and peritonitis (agent—corona virus, FIP), swine transmissive gastroenteritis (agent—rotavirus; STG), murine ectromelia (ME), cattle leukemia (CL), calf mixed viral infection (agents—parvo, adeno, and corona viruses; CMVI), western equestrian encephalomyelitis (WEE), or rabies (RV), comprising administering to an animal in need of such treatment, an effective therapeutic amount of a composition comprising polyprenol pyrophosphates of the formula H—[—CH2-C(CH3)═CH—CH 2 ] m —O—P(═O)(OH)—O—P(═O)(OH) 2 wherein m is an integer from 6-19 inclusive or a salt thereof.
The invention also provides a method for upregulating the Th1 (cell immunity) system in an animal comprising administering to an animal in need of such treatment, an effective amount of a composition comprising 1) polyprenol monophosphates of the formula H—[—CH2-C(CH3)═CH—CH2]n-O—P(═O)(OH)2 wherein n is an integer from 6-19 inclusive or a salt thereof, and 2) polyprenol pyrophosphates of the formula H—[—CH2-C(CH3)═CH—CH 2 ] m —O—P(═O)(OH)—O—P(═O)(OH) 2 wherein m is an integer from 6-19 inclusive or a salt thereof.
The invention also provides a method for upregulating the Th1 (cell immunity) system in an animal comprising administering to an animal in need of such treatment, an effective amount of a composition comprising polyprenol pyrophosphates of the formula H—[—CH2-C(CH3)═CH—CH 2 ] m —O—P(═O)(OH)—O—P(═O)(OH) 2 wherein m is an integer from 6-19 inclusive or a salt thereof.
The invention also provides a method for enhancing the protective effects of a vaccine comprising administering the vaccine to an animal in need of such treatment in combination with an amount of a composition comprising 1) polyprenol monophosphates of the formula H—[—CH2-C(CH3)═CH—CH2]n-O—P(═O)(OH)2 wherein n is an integer from 6-19 inclusive or a salt thereof, and 2) polyprenol pyrophosphates of the formula H—[—CH2-C(CH3)═CH—CH 2 ] m —O—P(═O)(OH)—O—P(═O)(OH) 2 wherein m is an integer from 6-19 inclusive or a salt thereof, effective to enhance the effect of the vaccine. As used herein, “enhansing the effect of a vaccine” means increasing the protective effect of the vaccine by a significant and measureable amount.
The invention also provides a method for enhancing the protective effects of a vaccine comprising administering the vaccine to an animal in need of such treatment in combination with an amount of a composition comprising polyprenol pyrophosphates of the formula H—[—CH2-C(CH3)═CH—CH 2 ] m —O—P(═O)(OH)—O—P(═O)(OH) 2 wherein m is an integer from 6-19 inclusive or a salt thereof, effective to enhance the effect of the vaccine.
The invention also provides a method to correct an individual immune system comprising administering to an animal in need of such treatment, an effective amount of a composition comprising 1) polyprenol monophosphates of the formula H—[—CH2-C(CH3)═CH—CH2]n-O—P(═O)(OH)2 wherein n is an integer from 6-19 inclusive or a salt thereof, and 2) polyprenol pyrophosphates of the formula H—[—CH2-C(CH3)═CH—CH 2 ] m —O—P(═O)(OH)—O—P(═O)(OH) 2 wherein m is an integer from 6-19 inclusive or a salt thereof.
The invention also provides a method to correct an individual immune system comprising administering to an animal in need of such treatment, an effective amount of a composition comprising polyprenol pyrophosphates of the formula H—[—CH2-C(CH3)═CH—CH 2 ] m —O—P(═O)(OH)—O—P(═O)(OH) 2 wherein m is an integer from 6-19 inclusive or a salt thereof.
DETAILED DESCRIPTION
It will be appreciated by those skilled in the art that polyprenes possess double bonds which may exist in cis, or trans configurations. It is to be understood that the present invention encompasses any stereoisomeric form of the polyenes as well as mixtures thereof, which possess the useful properties described herein.
Specific and preferred values listed below are for illustration only; they do not exclude other defined values or other values within defined ranges for the radicals and substituents.
A specific composition of the invention is a composition wherein n is at least 7, wherein the polyprenol monophosphate comprises at least 90% of the weight of the composition and the and polyprenol pyrophosphate comprises less 10% of the weight.
A specific composition of the invention is a composition wherein n is 9, 10, 11, 12, 13, or 14 in greater than 50% of the polyprenol monophosphates.
A specific composition of the invention is a composition wherein m is 9, 10, 11, 12, 13, or 14 in greater than 50% of the polyprenol pyrophosphates.
A specific composition of the invention is a composition wherein the weight percent of polyprenol monophosphates is greater than the weight percent of the polyprenol pyrophosphates.
A specific composition of the invention is a composition wherein the weight percent of polyprenol monophosphates is not more than about 2 times greater than the weight percent of the polyprenol pyrophosphates.
A specific composition of the invention is a composition wherein the weight percent of polyprenol monophosphates is not more than about 4 times greater than the weight percent of the polyprenol pyrophosphates.
A specific composition of the invention is a composition wherein the weight percent of polyprenol monophosphates is not more than about 5 times greater than the weight percent of the polyprenol pyrophosphates.
A specific composition of the invention is a composition wherein the weight percent of polyprenol monophosphates is not more than about 10 times greater than the weight percent of the polyprenol pyrophosphates.
A specific composition of the invention is a composition wherein the weight percent of polyprenol monophosphates is not more than about 20 times greater than the weight percent of the polyprenol pyrophosphates.
A specific composition of the invention is a composition wherein n is 11 in at least 80% of the polyprenol monophosphates present.
A specific composition of the invention is a composition wherein m is 11 in at least 80% of the polyprenol pyrophosphates present.
A specific composition of the invention is a composition wherein n is 11 in at least 80% of the polyprenol monophosphates present, and m is 11 in at least 80% of the polyprenol pyrophosphates present.
A specific composition of the invention is a composition wherein n is 11 in at least 80% of the polyprenol monophosphates present, m is 11 in at least 80% of the polyprenol pyrophosphates present, and the weight percent of polyprenol monophosphates is about 10 times greater than the weight percent of the polyprenol pyrophosphates.
A specific composition of the invention is a composition wherein n is 11 in at least 90% of the polyprenol monophosphates present.
A specific composition of the invention is a composition wherein m is 11 in at least 90% of the polyprenol pyrophosphates present.
A specific composition of the invention is a composition wherein n is 11 in at least 90% of the polyprenol monophosphates present, and m is 11 in at least 90% of the polyprenol pyrophosphates present.
A specific composition of the invention is a composition wherein n is 11 in at least 90% of the polyprenol monophosphates present, m is 11 in at least 90% of the polyprenol pyrophosphates present, and the weight percent of polyprenol monophosphates is about 10 times greater than the weight percent of the polyprenol pyrophosphates.
It is to be understood that specific compositions of the invention can also comprise up to about 10 percent by weight unphosphorylated polyprenols.
The polyprenol phosphates and pyrophosphates can be prepared from polyprenol using procedures similar to those known in the art. For example see V. N. Shibaev, and L. L. Danilov, Biochem. Cell Biol., 1992, 70, 429-437 and European Patent Application Number 0 350 801.
Polyprenols can be isolated from natural sources using procedures similar to those described by, Danilov L. L. and Shibaev V. N. (1991): Phosphopolyprenols and their glycosyl esters: chemical synthesis and biochemical application, Atta-ur-Rahman (ed): Studies in natural products chemistry, Elsevier, Amsterdam—Oxford—New York—Tokyo, 8, 63-114; T. Choinacki, Acta. Chem. And Biochem Polonica, 1984, 21, 3-25; and F. Takaki et al., European Patent Application 0166436A2.
Administration of the compounds as salts may be appropriate. Examples of acceptable salts include alkali metal (for example, sodium, potassium or lithium) or alkaline earth metal (for example calcium) salts, however, any salt that is non-toxic and effective when administered to the animal being treated is acceptable.
Acceptable salts may be obtained using standard procedures well known in the art, for example by reacting a sufficiently acidic compound with a suitable base affording a physiologically acceptable anion.
The compositions of the invention can be formulated as pharmaceutical compositions and administered to an animal host, such as a human patient in a variety of forms adapted to the chosen route of administration, i.e., orally or parenterally, by intravenous, intramuscular, topical or subcutaneous routes.
Thus, the present compounds may be systemically administered, e.g., orally, in combination with a pharmaceutically acceptable vehicle such as an inert diluent or an assimilable edible carrier. They may be enclosed in hard or soft shell gelatin capsules, may be compressed into tablets, or may be incorporated directly with the food of the patient's diet. For oral therapeutic administration, the active compound may be combined with one or more excipients and used in the form of ingestible tablets, buccal tablets, troches, capsules, elixirs, suspensions, syrups, wafers, and the like. Such compositions and preparations should contain at least 0.1% of active compound. The percentage of the compositions and preparations may, of course, be varied and may conveniently be between about 2 to about 60% of the weight of a given unit dosage form. The amount of active compound in such therapeutically useful compositions is such that an effective dosage level will be obtained. When administered orally, the compositions of the invention can preferably be administered in a gelatin capsule.
The tablets, troches, pills, capsules, and the like may also contain the following: binders such as gum tragacanth, acacia, corn starch or gelatin; excipients such as dicalcium phosphate; a disintegrating agent such as corn starch, potato starch, alginic acid and the like; a lubricant such as magnesium stearate; and a sweetening agent such as sucrose, fructose, lactose or aspartame or a flavoring agent such as peppermint, oil of wintergreen, or cherry flavoring may be added. When the unit dosage form is a capsule, it may contain, in addition to materials of the above type, a liquid carrier, such as a vegetable oil or a polyethylene glycol. Various other materials may be present as coatings or to otherwise modify the physical form of the solid unit dosage form. For instance, tablets, pills, or capsules may be coated with gelatin, wax, shellac or sugar and the like. A syrup or elixir may contain the active compound, sucrose or fructose as a sweetening agent, methyl and propylparabens as preservatives, a dye and flavoring such as cherry or orange flavor. Of course, any material used in preparing any unit dosage form should be pharmaceutically acceptable and substantially non-toxic in the amounts employed. In addition, the active compound may be incorporated into sustained-release preparations and devices.
The compositions of the invention may also be administered intravenously or intraperitoneally by infusion or injection. Solutions of the active composition can be prepared in water, optionally mixed with a nontoxic surfactant. Dispersions can also be prepared in glycerol, liquid polyethylene glycols, triacetin, and mixtures thereof and in oils. Under ordinary conditions of storage and use, these preparations contain a preservative to prevent the growth of microorganisms.
The pharmaceutical dosage forms suitable for injection or infusion can include sterile aqueous solutions or dispersions or sterile powders comprising the active ingredient which are adapted for the extemporaneous preparation of sterile injectable or infusible solutions or dispersions, optionally encapsulated in liposomes. In all cases, the ultimate dosage form should be sterile, fluid and stable under the conditions of manufacture and storage. The liquid carrier or vehicle can be a solvent or liquid dispersion medium comprising, for example, water, ethanol, a polyol (for example, glycerol, propylene glycol, liquid polyethylene glycols, and the like), vegetable oils, nontoxic glyceryl esters, and suitable mixtures thereof. The proper fluidity can be maintained, for example, by the formation of liposomes, by the maintenance of the required particle size in the case of dispersions or by the use of surfactants. The prevention of the action of microorganisms can be brought about by various antibacterial and antifungal agents, for example, parabens, chlorobutanol, phenol, sorbic acid, thimerosal, and the like. In many cases, it will be preferable to include isotonic agents, for example, sugars, buffers or sodium chloride. Prolonged absorption of the injectable compositions can be brought about by the use in the compositions of agents delaying absorption, for example, aluminum monostearate and gelatin.
Sterile injectable solutions are prepared by incorporating the active composition in the required amount in the appropriate solvent with various of the other ingredients enumerated above, as required, followed by filter sterilization. In the case of sterile powders for the preparation of sterile injectable solutions, the preferred methods of preparation are vacuum drying and the freeze drying techniques, which yield a powder of the active ingredient plus any additional desired ingredient present in the previously sterile-filtered solutions.
For topical administration, the present compositions may be applied in pure form, i.e., when they are liquids. However, it will generally be desirable to administer them to the skin as compositions or formulations, in combination with a dermatologically acceptable carrier, which may be a solid or a liquid.
Useful solid carriers include finely divided solids such as talc, clay, microcrystalline cellulose, silica, alumina and the like. Useful liquid carriers include water, alcohols or glycols or water-alcohol/glycol blends, in which the present compounds can be dissolved or dispersed at effective levels, optionally with the aid of non-toxic surfactants. Adjuvants such as fragrances and additional antimicrobial agents can be added to optimize the properties for a given use. The resultant liquid compositions can be applied from absorbent pads, used to impregnate bandages and other dressings, or sprayed onto the affected area using pump-type or aerosol sprayers.
Thickeners such as synthetic polymers, fatty acids, fatty acid salts and esters, fatty alcohols, modified celluloses or modified mineral materials can also be employed with liquid carriers to form spreadable pastes, gels, ointments, soaps, and the like, for application directly to the skin of the user.
Examples of useful dermatological compositions which can be used to deliver the compounds of formula I to the skin are known to the art; for example, see Jacquet et al. (U.S. Pat. No. 4,608,392), Geria (U.S. Pat. No. 4,992,478), Smith et al. (U.S. Pat. No. 4,559,157) and Wortzman (U.S. Pat. No. 4,820,508).
Useful dosages of the compounds of formula I can be determined by comparing their in vitro activity, and in vivo activity in animal models. Methods for the extrapolation of effective dosages in mice, and other animals, to humans are known to the art; for example, see U.S. Pat. No. 4,938,949.
Generally, the concentration of the compositions of the invention in a liquid composition, such as a lotion, will be from about 0.1-50 wt-%, preferably from about 0.5-5 wt %. The concentration in a semi-solid or solid composition such as a gel or a powder will be about 0.1-5 wt-%, preferably about 0.5-2.5 wt-%.
The amount of the composition required for use in treatment will vary not only with the particular salt selected but also with the route of administration, the nature of the condition being treated and the age and condition of the patient and will be ultimately at the discretion of the attendant physician or clinician.
In general, however, a suitable dose will be in the range of from about 0.5 to about 100 mg/kg, e.g., from about 10 to about 75 mg/kg of body weight per day, such as 3 to about 50 mg per kilogram body weight of the recipient per day, preferably in the range of 6 to 90 mg/kg/day, most preferably in the range of 15 to 60 mg/kg/day.
The compositions are conveniently administered in unit dosage form; for example, containing 5 to 1000 mg, conveniently 10 to 750 mg, most conveniently, 50 to 500 mg of active ingredient per unit dosage form.
Ideally, the active ingredient should be administered to achieve peak plasma concentrations of the active compound of from about 0.5 to about 75 μM, preferably, about 1 to 50 μM, most preferably, about 2 to about 30 μM. This may be achieved, for example, by the intravenous injection of a 0.05 to 5% solution of the active ingredient, optionally in saline, or orally administered as a bolus containing about 1-100 mg of the active ingredient. Desirable blood levels may be maintained by continuous infusion to provide about 0.01-5.0 mg/kg/hr or by intermittent infusions containing about 0.4-15 mg/kg of the active ingredient(s).
The desired dose may conveniently be presented in a single dose or as divided doses administered at appropriate intervals, for example, as two, three, four or more sub-doses per day. The sub-dose itself may be further divided, e.g., into a number of discrete loosely spaced administrations; such as multiple inhalations from an insufflator or by application of a plurality of drops into the eye.
The compositions of the invention are poly-functional both at the cellular and at the organism levels. At the cellular level, they are incorporated in cellular membranes, enhancing their permeability. They also normalize and activate processes of cell surface glycoprotein biosynthesis, normalizing cell reproduction intracellular, and, as a result, intertussue interactions. In the organism on the whole they normalize immune system functioning, improve the function of individual organs, enhances blood generation function, and facilitate tissue regeneration.
The compositions of the invention are useful for prevention, treatment and liquidation of consequences of diseases, including viral, clamidial, bacterial, oncology, liver, gastrointestinal, urologic and reproductive system, immune system, wounds, burns, and stresses.
Following i.m. administration, the compositions of the invention enter the blood stream within about 10-15 minutes and reach a maximum concentration in the blood within one hour of administration, at which point they can be found throughout the circulatory related organs.
The antiviral activity of the compositions of the invention can be determined using assays that are known in the art, or can be determined using assays similar to those described in the following examples.
The compositions of the invention can be used for the treatment of animal diseases caused by numerous viruses including distemper virus (DV), canine enteritis (parvo, rota, and corona viruses; CEV), canine infectious hepatitis (CIH), feline infectious gastroenteritis (panleukopenia, FIE), feline infectious rhinotracheitis (agent—herpes virus; FIR), feline infectious enteritis and peritonitis (agent—corona virus, FIP), swine transmissive gastroenteritis (agent—rotavirus; STG), murine ectromelia (ME), cattle leukemia (CL), calf mixed viral infection (agents—parvo, adeno, and corona viruses; CMVI), western equestrian encephalomyelitis (WEE), and rabies (RV).
As used in the examples hereinbelow, “the Substance” is a composition of the invention wherein n is II in at least 80% of the polyprenol monophosphates present, m is 11 in at least 80% of the polyprenol pyrophosphates present, and the weight percent of polyprenol monophosphates is about 10 times greater than the weight percent of the polyprenol pyrophosphates.
EXAMPLE 1
Effect on DV
DV sensitive cell culture 4647 was infected with Strain Rockborn; simultaneously with the virus, the Substance was introduced into the flask in the doses of 20 and 200 ug/ml. Into the cell monolayer in 50-ml flasks applied was 0.1 ml of DV with the titer of 2.4 lg PFU (Plague Forming Units)/ml, incubated at +34° C. for 2 h (adsorption period), after which agar layer was applied. Before the application of agar, it was mixed with the Substance to final concentrations of 20 and 200 μg/ml. Cultures treated by the Substance in the same concentrations (without DV) served as toxicity controls. The experiments were repeated three times. Mean results are presented in Table 1.
Substance concentration, μg/
ml
DV titer, 1 g PFU/ml
Toxicity
0
4.18
None
20
3.20
None
200
0
None
Thus, the Substance has a high, dose-dependent inhibitory effect to DV. 100% inhibitory effect is observed with the Substance dose 200 μg/ml.
EXAMPLE 2
Therapeutic Evaluation of the Substance Activity in Distemper in Dogs
To evaluate therapeutic activity of the Substance, a model of distemper in dogs of Tibetan Terrier breed (12-13 weeks of age) was used. Experimental (5 animals) and control (5 animals) dogs were infected with DV (Snyder-Hill strain) intracerebrally with 50 LD 50 in 0.3 ml. Control group puppies were treated according to standard symptomatic treatment plan. Experimental dogs, along with symptomatic treatment, were injected intramuscularly with the Substance in the dose of 500 μg/kg body mass following the treatment plan:
First 2 days—4 injections daily (every 6 hours)
Days 3-10—3 injections daily (every 8 hours)
Days 11-13—2 injections daily (every 12 hours),
Days 14 and 15—1 daily injection.
All control group animals died at days 18-21 after infection with the clinical picture of distemper (neural form).
All experimental group animals survived: treatment with the substance completely protected animals from viral infection and also to decrease severity of the course of the infection. For instance, even by days 16-20 after the infection, treatment with the Substance led to significant improvement of general condition of the puppies, and starting with day 26 from the infection, the condition of the animals was evaluated as normal. A similar picture was observed during clinical trials of the Substance in dogs with distemper (250 animals of different breeds and ages), which were observed and treated at different veterinarian practices in Moscow and other cities in Russia: application of the Substance together with symptomatic treatment allowed to significantly decrease lethality and severity of distemper in different forms (subacute, intestinal, pulmonary, neural with initial symptoms, and neural with a marked convulsion syndrome) (Table 2. ).
TABLE 2
Efficacy of treatment (%) of different forms of distemper with the
Substance.
Neural,
Neural,
with
Clinical
with
a marked
form of the
initial
convulsion
disease
Subacute
Intestinal
Pulmonary
symptoms
syndrome
Treatment
70
50
50
10
10
without the
substance
Treatment
100
95
83
55
23
with the
substance
EXAMPLE 3
Therapeutic Activity of the Substance for Treatment of CVE
Efficacy of treatment of viral enterites of parvo-, rota-, and corona viral nature by the Substance in combination with symptomatic treatment was 90% (78 cases in dogs of different breeds and ages, observed and treated at veterinary practices in Moscow), whereas efficacy of treatment with standard symptomatic drugs does not exceed 50-60%. Treatment plan for the substance application in enterites is similar to that in distemper.
EXAMPLE 4
Therapeutic Activity of the Substance in CIH
Efficacy of treatment with the Substance in combination with symptomatic therapy was 95-100% (over 50 cases in dogs of different breeds and ages observed and treated at veterinary practices in Moscow). Treatment plan:
Day 1 (or first 2-3 days)—3 injections daily
Day 2 (or days 3-5)—2 injections daily
Day 3 (or days 5-7)—1 injection daily.
For the treatment of all above-mentioned viral infections in dogs the Substance was prescribed in the following doses:
0.1 ml for dogs with body mass under 1 kg
0.25 ml—1-5 kg
0.5 ml—5-10 kg
1.0 ml—10-20 kg
1.5 ml—20-30 kg
2.0 ml—30-45 kg
EXAMPLE 5
Therapeutic Activity of the Substance in FIE
Efficacy of the treatment with the Substance administered intramuscularly to the kittens less than 7 months of age diagnosed with panleukopenia (34 cases) was 100%. At the same time, efficacy of standard symptomatic treatment does not exceed 10%.
Treatment plan with the Substance in FIE: intramuscular injections of the preparation
Day 1—4 injections (with 4-6 hour intervals)
Day 2—3 injections (with 4-6 hour intervals)
Day 3—3 injections (with 4-6 hour intervals)
Days 4 through 6—2 injections (8 hour interval)
For treatment of cats the Substance was prescribed in following doses:
1. Intramuscular injections:
0.2 ml for body mass under 1 kg
0.5 ml for 2-5 kg
1 ml for over 6 kg
2. Peroral administration:
0.4 ml for body mass under 1 kg
1 ml for 2-5 kg
2 ml for over 6 kg
EXAMPLE 6
Therapeutic Activity of the Substance in FIR
Efficacy of treatment of 68 cats of different ages diagnosed with herpetic rhinotracheitis with the Substance (in combination with symptomatic therapy) was 95%. Efficacy of treatment under standard symptomatic treatment plan does not exceed 80%. The Substance was administered intramuscularly according to the plan provided in Example 4, and as applications onto virus-affected eye areas (2-3 times a day for 2-4 days).
EXAMPLE 7
Therapeutic Activity of the Substance in FIP
Efficacy of treatment of 12 kittens less than 4 months of age diagnosed with coronaviral peritonitis with the Substance (in combination with symptomatic therapy) was 50%. Efficacy of animal treatment with regular symptomatic medications does not exceed 1%. The Substance was applied according to the plan provided in Example 4.
EXAMPLE 8
Therapeutic Activity of the Substance in STG
Clinical trials of the Substance efficacy were carried out at the swine (breeding) facility “Krekshino”, Naro-Fominsk Area, Moscow Region. Trials included 50 piglets with body mass less than 7 kg with laboratory-proven diagnosis of rotaviral gastroenteritis.
Twenty-five out of 50 animals were treated according to the standard symptomatic treatment plan; 25 experimental animals were treated, in addition to symptomatic medication, by intramuscular administration of 0.5 ml of the Substance according to the following plan:
Days of
1
2
3
4
5
6
7
disease
Number
4
3
3
3
2
2
1
of
injections
per day
Study results revealed that efficacy of treatment with the Substance reached 92% (23 animals completely recovered, 2 animals died), while in the control group treatment efficacy was only 40% (15 animals died, 10 recovered).
EXAMPLE 9
Activity of the Substance in ME
Line Balb/c mice with clinical picture of developed ectromelia (swollen faces, swollen eyelids and extremities, ulcerated tails) were subject to a one time intramuscular or intraperitoneal administration of the Substance in the dose of 500 μg/0.1 ml. Control group was treated with placebo. The animals were monitored for one month and longer.
In the group of sick mice treated with the Substance fast recovery was observed (on the average within 3-7 days), while in the control group 100% of mice died.
Therefore, the Substance has a high therapeutic activity in ectromelia.
EXAMPLE 10
The Substance Activity in MH
The trials were carried out on non-breed male mice, 10-12 g body mass. In the study, murine hepatitis virus strain Mesherin was used. The virus was introduced by two ways:
Intraperitoneally in a dose of 10 LD 50 ;
Perorally in the dose of 100 LD 50 .
The substance was administered to the animals also in two ways:
Intramuscularly, 200 μg per mouse daily injections for 14 days after the infection;
Perorally, using similar plan.
Lethality percentages were calculated for control and experimental groups.
TABLE 3
Efficacy of murine hepatitis treatment with the Substance.
Substance
Group name and #
Infection mode
administration way
Lethality, %
1. Control
Intraperitoneal
Not administered
100
2. Control
Peroral
Not administered
80
3. Experimental
Intraperitoneal
Intramuscular
60
4. Experimental
Intraperitoneal
Peroral
20
Data presented in Table 3 show that the Substance has a pronounced protective activity in murine hepatitis. For instance, its intramuscular administration led to 40% of animal survival rate, whereas no animals survived in control. Even more dramatic effect was achieved by peroral administration of the substance—80% of mice survived.
EXAMPLE 11
Substance Activity Against WEE (Western Equestrian Encephalomyelitis)
Strain California, studied in mice. Results show a high antiviral efficacy in the vivo experiment.
EXAMPLE 12
Substance Activity Against CMVI
In vivo studies on calves showed the substance was efficacious.
EXAMPLE 13
Substance Activity Against CL
In vitro studies on a CL-sensitive cell line showed about 50% protection.
EXAMPLE 14
Therapeutic Activity of the Substance Against RV
In vivo studies in mice showed therapeutic efficacy.
As illustrated by the following examples, the compositions of the invention are also effective in humans against diseases caused by viruses, such as for example, Human immunodeficiency (HIV), Herpes simplex, type 1 (HSV-1), Measles (MV), Parotitis (PV), Hepatitis A (HAV), Tick-borne encephalitis (TBE), Yellow fever (YFV), and Influenza (IV).
EXAMPLE 15
Antiviral Activity of the Substance in HIV, HSV-1, MV, PV, and HAV
In vivo studies in a murine model (HSV) and in vitro studies (all other viruses) showed antiviral activity of the substance.
EXAMPLE 16
Therapeutic Activity of the Substance Against TBE, YFV, and IV
In vivo studies in mice showed a pronounced protective effect of the substance.
As illustrated by the following example, the compositions of the invention are also effective for Preventing of Viral Infections.
EXAMPLE 17
The Substance was tested as preventative for the decrease of risk of the development of viral infections in dogs (distemper, enteritis, hepatitis) and cats (panleucopenia, rhinotracheitis, coronaviral enteritis, peritonitis). The Substance was found to be effective as preventative agent.
As illustrated by the following examples, the compositions of the invention are also effective for the Enhancement of Vaccination Efficacy.
EXAMPLE 18
Correction of Secondary Immune Deficiencies Induced by Different Enviornmental Factors: Viral Infection, Stress and Radiation in Mice
Results show that the Substance possesses a strong immune corrective activity (independent of the nature of the factor) and can restore functions of the immune system.
As illustrated by the following example, the compositions of the invention are also effective as an Immunocorrective agent.
EXAMPLE 19
Use as a Stimulator of Factors of Natural Body Resistance: Interleukins (IL), Interferons (IFN), Tumor Necrosis Factor (TNF)
Results are shown in the following table.
Cause of secondary immune
deficiency (SID)
Characteristics of SID
Effect of Substance
Tachiny virus
Supression of antibody
100% restoration of APC
producing cells (APC), type B
function
2.5 fold
Prolonged hypokinesia
Supression of APC functions
97% restoration of APC
12-fold
function
Irradiation (900 rad)
Death of 20% of animals in 30
IM administration led to a
days after impact. Inhibition
50% increase in survival,
of bone marrow stem cell
normalization of bone marrow
proliferation
stem cell proliferation
EXAMPLE 20
Use of the Substance as a Stimulator of Body Natural Resistance Factors: Interleukins (IL), Interferons (IFN), Tumor Necrosis Factor (TNF)
In mice, the substance showed TNF increase in 1 h and 2 days; IL-1 increase after 24 h, and IFN increase in blood serum between 2 and 72 h.
As illustrated by the following example, the compositions of the invention also promote wound healing.
EXAMPLE 21
In Vivo Studies in Guinea Pigs Showed Efficacy of the Substance for the Promotion of Wound Healing
The Substance was used to treat guinea pigs with aceptic wounds on skin of the right hind thigh by cutting skin patch 1 cm in diameter. Each group consisted of 4 animals.
Group 1 was treated with erythromycin ointment
Group 2 was treated with 5% ACTOVEGIN ointment
Group 4 received placebo (50% lanolin solution)
Group 4 was treated with the Substance (0.4% solution in 50% lanolin).
Wound size was imprinted daily on a cellophane film, the imprints were cut out and weighted. Dynamics (weight in mg) is shown in the following table.
Group
0 day
1 day
2 days
5 days
8 days
1
8.5
7.75
8.85
10
5.25
2
9.1
7.6
7.67
8.3
5
3
6.33
5.66
6.33
5.66
5.5
4
9
4.33
4.33
3
2.66
EXAMPLE 22
Assessed Hemoglobin Content of Blood in Calves Infected with CMVI
As illustrated by the following example, the compositions of the invention are also effective as antitumor agents.
EXAMPLE 23
Studied by Measuring of Induced Tumor Sizes in Mice with Melanoma B-16 or Lewis Lung Carcinoma. Showed Antitumor Activity of the Substance
As illustrated by the following example, the compositions of the invention are also possess hepatoprotective activity.
EXAMPLE 24
Studies in Green Monkeys with Worm Invasion in Liver Showed Hepatoprotective Activity
The data from the above examples demonstrates that a representative composition of the invention has significant antiviral activity in infections of humans and animals (including threatening infections in humans caused by HIV, rabies and tick-borne encephalitis viruses), is a highly efficient preventative substance, is effective to increases vaccination efficacy, stimulates body natural resistance factors, is a good immunocorrector, normalizes physiological parameters of the body, speeds up wound healing, has an antitumor activity, and has hepatoprotective activity.
EXAMPLE 25
Studies in Mice Infected with Type A Influenza Virus
Experiments were carried out on mice, Line C57B1/6, intranasally infected with the Type A Influenza Virus (H1N1), strain WSN in the dose of 5 LD 50 . Simultaneously with the infection, a single dose of polyprenol monophosphate, or polyprenol monophosphate with polyprenol polyphosphate (97:3, w/w) as 0.4% solution in the dose of 5 ug per mouse was administered.
Average life span of the animals, treated with polyprenol monophosphate, was 6.6 days, animals treated with polyprenol monophosphate with polyprenol polyphosphate lived 8.7 days. This shows a higher efficacy of polyprenol monophosphate with polyprenol polyphosphate compared to polyprenol monophosphate.
EXAMPLE 26
The substance induces in vitro biosynthesis of mRNA of cytokines IL-1, IL-2, i.e. the cascade characteristic of the Th1 immune response and inhibits constitutive biosynthesis of mRNA of tumor necrosis factor (TNF).
The method of screening for substance activity was based in the assessment of the induction of interferon biosynthesis in vivo. Therefore, the substances were classified as interferon inducers.
The in vitro effects of the substance on the induction of mRNA biosynthesis for a number of cytokines was studied. The method of research was RT-PCR. Treatment of cell cultures with the preparations led to the induction of biosynthesis of mRNAs for IL-1 and IL-2. The profile of cytokine response points out to the involvement of the Th1 type immune system in response to the treatment.
Research was carried out in human osteogenic hypotriploid sarcoma cell line MG-63 (ATCC CRL-1427), which has a constitutive production of interferon alpha (IFN). The cells were grown in Eagle Minimal Eagle Medium (MEM) supplemented with 2 mM glutamine and Earle BSS (1.5 g/l sodium bicarbonate, 0.1 mM non-essential aminoacids, 1.0 mM sodium piruvate, and 10% fetel bovine serum).
The substance was introduced into culture media in the final concentrations of 200 and 250 g/ml, respectively. The cells were harvested at 2, 24, 48, and 72 h after induction, and total RNA was isolated using Rneasy Total RNA kit (Qiagen, Santa Clara, Calif.). RNA concentration was measured in total RNA preparations, and cDNA was synthesized from 2.0 g total RNA using oligo dT primers and AMV reverse transcriptase (both from New England Biolabs, Bedford, Mass.). Equalized amounts of cDNA were used as templates for PCR reactions with the primer pairs specific to IFN, IFN, IL-1, IL-2, IL-4, IL-6, IL-10, TNF, and actin (served as control). Thermal cycling procedure included 2 min at 94 C., 35 cycles of 1 min at 94 C., 2 min at 55 C., and 2 min at 72 C., followed by 5 min at 72 C. PCR products were resolved by electrophoresis in 3% agarose gels.
The Substance induced biosynthesis of IL-1 and IL-2 mRNA. The cell line expressed IFN and TNF mRNA constututively, at high levels. No mRNA induction was observed for IFN, IL-4, IL-6 or IL-10. The highest levels of IL-1 mRNA were observed at 2 and 24 h after the induction and decreased after 48 h after induction. IL-2 mRNA biosynthesis was at its peak at 24 and 48 h after the induction. The substance inhibited constitutive expression of TNF mRNA.
These results suggest that (1) immune system is a target for action of the Substance; (2) treatment of cells with the Substance leads to the induction of transcription of the Th1 cytokine mRNA (IL-1, IL-2) and can also inhibit transcription of TNF mRNA; (3) biological activity of the the Substance is due to the upregulation of Th1 type immune response.
These results of the above examples show that a representative compositions of the invention is useful to provide antiviral response induction and neoplastic development inhibition. The compositions of the invention may be particularly useful for the treatment of viruses that naturally induce Th1 immune response.
All publications, patents, and patent documents are incorporated by reference herein, as though individually incorporated by reference. The invention has been described with reference to various specific and preferred embodiments and techniques. However, it should be understood that many variations and modifications may be made while remaining within the spirit and scope of the invention. | The invention provides composition comprising, 1) polyprenol monophosphates of the formula H—[—CH2-C(CH3)═CH—CH2]n-O—P(═O)(OH)2 wherein n is an integer from 6-19 inclusive or a salt thereof, and 2) polyprenol pyrophosphates of the formula H—[—CH2-C(CH3)═CH—CH 2 ] m —O—P(═O)(OH)—O—P(═O)(OH) 2 wherein m is an integer from 6-19 inclusive or a salt thereof, which is useful as an antiviral agent, as an immunomodulatory agent, and for treating cancer. The invention also provides pharmaceutical compositions comprising the compositions of the invention as well as therapeutic methods for using the the compositions. | 0 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a continuation of, and claims the benefit of, and priority to, U.S. patent application Ser. No. 12/862,689, filed on Aug. 24, 2010, and entitled “DEBRIS TRAP FOR A DRAIN,” the disclosure of which is hereby incorporated herein in its entirety by this reference.
BACKGROUND
Field of the Invention
The present disclosure relates generally to drains, such as for tiled showers and the like. More particularly, the present disclosure relates to a removable debris trap for a drain.
Related Art
There are a variety of styles and types of floor drains for showers and the like. Both round and square or rectangular drains are available, and there are a variety of mechanisms for connecting drain structures with associated drainage pipes. There are also a variety of materials and finishes that have been used for drains and drain grates. For many years, floor drains and grates have been made of non-corrosive metals, such as brass and stainless steel. More recently, because of their low cost and ease of use, polymer materials have been used for drain structures and drain grates, often in combination with metal structures. For example, drains comprising a polymer drain body and a metal drain grate are quite common. Drain grates comprising a polymer structure with a sheet metal cladding are also available.
One challenge with floor drains and other drains is the potential for clogs of hair and other debris. To prevent clogs of hair and other debris, hair traps and debris traps have been developed for drains. There are a variety of designs and configurations for hair and debris traps. However, with many of these, removal can be difficult and time-consuming, and cleaning can be a difficult and disgusting task. Additionally, some hair trap devices present an aesthetically undesirable appearance in or near a drain.
SUMMARY
It has been recognized that it would be advantageous to develop a debris trap for a drain that is effective at trapping hair and the like.
It has also been recognized that it would be advantageous to develop a debris trap for a drain that is easy to remove, clean, and replace.
In accordance with one embodiment thereof, the present invention provides a debris trap for a drain. The debris trap includes an annular rim, defining a center, with a plurality of radial prongs, extending from the rim toward the center, and oriented to catch debris in the drainage pathway. The debris trap is removably disposable within a drainage pathway of a drain body, below a removable drain grate of the drain.
In accordance with another aspect thereof, the invention provides a drain system, including a drain body and a debris trap. The drain body includes a circular lower portion defining an outlet, which is configured to mate with an underdrain structure, and an upper portion defining an inlet, configured to receive a drain grate in a frictional fit. The drain body also includes a circular recess below the upper portion and concentric with the outlet, having a diameter larger than an inner diameter of the outlet. The debris trap is configured to be disposed in the circular recess, and includes an annular rim defining a center, and a plurality of radial prongs extending from the rim toward the center, oriented to catch debris in the drainage pathway.
In accordance with yet another aspect thereof, the invention provides a method for removing debris from a drain. The method includes the steps of removing a drain grate from a drain body of the drain, removing a debris trap from a resting position within a drainage pathway of the drain body and below a level of the drain grate, removing debris from the debris trap, replacing the debris trap within the drain body, and replacing the grate. The debris trap includes an annular rim defining a center and a plurality of radial prongs extending from the rim to a free distal end a distance from the center, and removing debris from the debris trap comprises removing debris from the prongs.
BRIEF DESCRIPTION OF THE DRAWINGS
Additional features and advantages of the invention will be apparent from the detailed description which follows, taken in conjunction with the accompanying drawings, which together illustrate, by way of example, features of the invention, and wherein:
FIG. 1 is a perspective view of one embodiment of a floor drain body with a drain grate in place;
FIG. 2 is a perspective view of the drain grate of FIG. 1 with the grate removed, showing a central recess above the outlet within the drain body;
FIG. 3 is a perspective view like that of FIG. 2 , showing one embodiment of a removable debris trap disposed in the recess within the drain body;
FIG. 4 is a perspective view of an embodiment of a debris trap in accordance with the present disclosure;
FIG 5 is a side view of the debris trap of FIG. 4 ;
FIG. 6 is a top view of the debris trap of FIG. 4 ;
FIG. 7 is a close-up, perspective, partially sectional view of the debris trap of FIG. 4 ;
FIG. 8 is a perspective view of another embodiment of a debris trap in accordance with the present disclosure;
FIG. 9 is a side, cross-sectional view of the debris trap of FIG. 8 ; and
FIG. 10 is a close-up, perspective, partially sectional view of the debris trap of FIG. 8 .
DETAILED DESCRIPTION
Reference will now be made to exemplary embodiments illustrated in the drawings, and specific language will be used herein to describe the same. it will nevertheless be understood that no limitation of the scope of the invention is thereby intended. Alterations and further modifications of the inventive features illustrated herein, and additional applications of the principles of the inventions as illustrated herein, which would occur to one skilled in the relevant art and having possession of this disclosure, are to be considered within the scope of the invention.
Shown in FIG. 1 is a drain body or riser 10 with a grate 12 having drain openings 13 . The drain body is shown with the grate removed in FIG. 2 . This drain body 10 is a one-piece unit, having a generally rectangular upper portion 14 defining an inlet, and a circular lower portion 16 defining an outlet and being configured to mate with an underdrain structure. It is to be understood that, while the drain body shown in FIGS. 1 and 2 has a rectangular inlet, drain bodies having inlets of other shapes, such as circular, can also be used. The lower portion of the drain body includes external helical threads 18 for connection to the underdrain, allowing the height of the drain inlet to be adjusted by rotating the drain body. The drain body can be of an injection-molded polymer, such as ABS (Acrylonitrile Butadiene Styrene) plastic, allowing it to be strong and lightweight.
The inlet portion 14 of the drain body 10 includes a shoulder 20 on its inner perimeter, for supporting the drain grate 12 . Surrounding the shoulder is a grout rim 22 that is integral with the drain body. The grate 12 is supported only around it's perimeter by a narrow shelf (i.e. shoulder 20 ) in the drain body 10 . Just inside and below that shelf is a near-vertical surface 21 that extends down to the floor of the bowl 30 . Against this surface an inner perimeter rib or wall of the grate frame can make a light friction fit. The inner surface of the grout rim includes 90 degree filleted corners 26 . This configuration helps reduce binding of the grate and allows for a wide selection of grate opening configurations. The drain body can also include a step or recess 28 in the bawl floor 30 , which can allow for the inclusion of a debris trap device 50 (shown in FIG. 3 ).
By design, the bowl 30 of the drain body 10 is relatively deep (compared to the size of the grate openings 13 ). This helps create a shadow and a blacked-out effect that is very desirable, especially where the drain body is black or some other dark color. When viewed from the top through the openings 13 in the grate 12 , the visibility of any build-up of soap scum, scale and hair will be substantially reduced. The grate looks clean and beautiful and is not detracted by a view of scum build up just below the surface.
The grout rim 22 provides a sharp termination at the top edge of the drain body 10 , and becomes substantially hidden to the eye when embedded into an adjacent grout line. When a drain grate 12 is inserted into the inlet portion 14 and supported by the shoulder 20 , friction between the Vertical surface 21 and a perimeter rib (not shown) of the drain grates frame holds the grate in place. A small clearance can be maintained between the grate 12 and the grout rim 22 to allow for drainage immediately around the slightly elevated grate.
Around the outer sides 34 of the inlet portion 14 of this embodiment of the drain body 10 are undercut grout locking features that help anchor the drain body with surrounding mortar and grout material. The undercut grout locking features can include a horizontal undercut edge 42 , and tapered or dovetail surfaces associated with vertical buttresses 36 , to cause the buttresses to interlock with surrounding grout, allowing the grout to capture the drain body and hold it in position in a dovetail arrangement. The buttresses have a dovetail shape that becomes wider as the buttress extends away from the sidewall 34 of the drain body. This provides dovetail surfaces that are angled toward the drain body, so that a mechanical interlock is created with grout material that surrounds the drain body. Since the dovetail surfaces of the buttresses are angled with respect to a vertical plane, and the angled undercut surface of the undercut edge 42 is angled with respect to a horizontal plane, the undercut edge and the dovetail buttresses combine to anchor the drain body with respect to both vertical and horizontal movement.
The outer sides 34 of the drain body can also include vertical darts 48 below or along the horizontal undercut 42 to improve plastic flow to thin wall sections during the molding process, as well as to add rigidity. Given their angular faces, the darts also help provide additional anchorage of the drain body in the surrounding grout material, while their small size in relation to the buttresses does not weaken the anchoring grout material between the buttresses.
Since it is installed using only a light friction fit and no screws or other fasteners, the drain grate 12 can be easily removed, such as by using a T-handle grate removal tool (not shown), or other suitable tool. During installation of the drain body and construction of the surrounding floor structure, a solid flat plug can be installed in the drain body in place of the grate to prevent construction debris from falling into the drain, prevent damage to the grate, and to stabilize the knife edge rim 22 of the drain body and help maintain the shape of the inlet.
As noted above, hair clogs are a constant challenge with drains. There are a variety of types of hair and debris traps that have been used with floor drains and other drains. Unfortunately, many of these are difficult to retrieve and remove from a drain or pipe, and can present a smelly and disgusting task to remove hair and debris tangled around steel tines, etc.
Advantageously, the inventor has developed a debris trap for a drain, various embodiments of which are shown in the figures. While the debris trap disclosed herein is shown in the context of a floor drain, it is to be understood that it can be used with a variety of types of drains, in addition to floor drains. As shown in FIG. 3 one embodiment of a circular debris trap device 50 can be placed in a shallow, circular recess 28 in the floor 30 of the bowl of the drain body 10 . Viewing FIGS. 3-7 , this debris trap embodiment 50 is a unitary piece of injection-molded plastic, and includes an annular outer ring or rim 52 , with a series of integral radial spokes or prongs 54 that extend toward the center of the ring, but leave a clear opening 56 in the middle. The circular rim 52 can include a raised protuberance 57 , disposed along an exterior edge of the rim. This protuberance helps ensure that the debris trap is placed in the drain right-side-up (i.e. with the curvature of the prongs 54 oriented upward). If the debris trap were to be placed into the recess 28 in the drain body upside down, the protuberance 57 would cause it to not lie flat and secure, thus signaling to a user to change the orientation.
The debris trap 50 with prongs 54 helps catch hair and other debris that drops through the drain grate 12 , without significantly obstructing the flow of water through the drain body 10 . Since hair and heavier debris will tend to drop through the outer openings of the drain grate 12 , it will tend to be washed nearer the perimeter of the bowl of the drain body, and be caught by the prongs 54 of the debris trap 50 . On the other hand, water that flows and drops straight through the center of the grate, and thus the center opening 56 of the debris trap, is believed to be less likely to include hair and other debris.
As noted above, in the drain embodiment shown in FIGS. 1 and 2 , the drain grate 12 is designed to be removable just by pulling it out of the drain body 10 , allmving a user periodically to lift the debris trap out of the drain body, remove the hair and clean die debris trap, then replace the debris trap and the grate. It is to be understood, however, that the debris trap disclosed herein can be used with drains having a different configuration than that shown in FIGS. 1 and 2 . Cleaning the debris trap is simple and straightforward. Hair and debris can be slid toward the open center 56 , where it slides off the prongs 54 . This allows easy, unrestricted removal of debris from this debris trap.
The prongs 54 are resilient and springy, and curved upward. Each prong has an upwardly-curved free end 58 near the center, indicated at 60 . The number, spacing, and thickness of the prongs 54 can vary. In one embodiment, a debris trap having a diameter of 3″ has been produced with 36 prongs spaced every 10 degrees, each prong being about 0.05″ wide at the distal tip 58 , and about 0.1″ wide at the base (the junction with the rim 52 ). Different numbers and sizes of prongs can be used. The size of the center opening 56 can vary also. To provide good drainage, it is desirable that the center opening be larger than about 0.5″ in diameter. In one embodiment, this opening is about 0.8″ in diameter. With a 3″ diameter debris trap and a 0.8″ diameter center opening, each prong will be less than about 1″ long, measured in the plan view. The upward curvature of the prongs can have a radius of about 0.4″ . It is to be appreciated that different curvature designs can be used, and the prongs can also be straight, with no curvature.
The cross-sectional shape of the prongs 54 can also vary. FIG. 7 provides a partial sectional view of the debris trap 50 taken through some of the prongs 54 , showing one embodiment of a cross-sectional shape that can be used. In this embodiment, the prongs have a substantially flat top surface 62 , which encourages hair strands to bridge between tines rather than to pass through or between them, and a rounded or curved bottom surface 64 , which is believed to help to accelerate water flow.
Another embodiment of a debris trap in accordance with the present disclosure is shown in FIGS. 8-10 . In this embodiment, the debris trap 100 comprises a cylindrical ring 102 , having a plurality of radial tines or prongs 104 extending toward its center, indicated at 106 . The prongs 104 are flexible and resilient, and curve upward toward their free ends 108 near the center. These prongs are substantially like the prongs 54 described above, and include a flat top surface 110 , a rounded bottom surface 112 , and an upwardly curved distal end 108 .
In this embodiment, the perimeter ring 102 of the debris trap 100 has a significantly greater vertical dimension H, and is configured to slide or snap into a corresponding cylindrical recess in a drain body (not shown). Alternatively, the debris trap 100 can be configured to fit into an opening of a circular conduit. The ring 102 provides an upwardly oriented, cylindrical flange, which press-fits into a circular recess within the drain body. This makes the debris trap more secure and stable in its installed position. The ring 102 includes a top flange 114 that helps hold the debris trap in place, and gives the debris trap a minimum diameter that is larger than the diameter of the drainage opening or conduit beyond, thus ensuring that it cannot be lost down the drain.
In the embodiment of FIGS. 3-7 , the size, shape and placement of the debris trap 50 ensure that it cannot be lost down the drain and contribute to its aesthetic appeal. The debris trap sits within the circular recess 28 above the outlet of the drain body 10 . It has been found that gravity alone is sufficient to keep this embodiment of the debris trap securely in place. The diameter of the debris trap 50 is larger than the diameter of the interior of the outlet 16 of the drain body 10 , thus preventing the debris trap from being washed down the drain in any orientation. Also, because the debris trap 50 is designed to fit into a recessed pocket 28 within the drain body and below the drain grate 12 , it is substantially out of sight, thus contributing to the aesthetics of the drain installation.
This disclosure thus provides a simple debris trap device that is effective at trapping hair and debris in a drain, and is easy to retrieve and remove from the drain. Cleaning of the debris trap is also simple and easy. This debris trap can be injection molded as a single unitary piece, making it very economical. Indeed, the simplicity and low cost makes disposability of this type of debris trap an option. That is, rather than removing, cleaning and replacing the device periodically, a user can remove and discard the debris trap device and replace it with a new one whenever desired.
It is to be understood that the above-referenced arrangements are illustrative of the application of the principles of the present invention. It will be apparent to those of ordinary skill in the all that numerous modifications can be made without departing from the principles and concepts of the invention as set forth in the claims. | A debris trap for a floor drain includes a rim defining an outer diameter, an inner diameter, a center, and a rim portion extending upwardly from an upper surface portion of the rim at or near the outer diameter. Prongs are integrally formed with the rim and spaced along at least part of the inner diameter. Each prong has a proximal portion extending radially inward from the rim, a free distal end that is only upwardly curved from the proximal portion toward the center, and a width that varies along a length of the prong. | 4 |
RELATED APPLICATION
This is a continuation of U.S. application Ser. No. 13/657,335, filed Oct. 22, 2014, entitled SYSTEMS AND METHODS FOR BRAKING AN ELECTRIC MOTOR which is hereby incorporated by reference into the present application in its entirety.
FIELD
The present disclosure relates to systems and methods for braking electric motors.
BACKGROUND
Electric motors commonly include a stationary component called a stator and a rotating component called a rotor. The rotor rotates within (or around) the stator when the motor is energized with a driving waveform. When the driving waveform is removed from the motor, the rotor may coast to a standstill over time due to the inertia of the rotor and anything coupled to the rotor.
In many motor applications, it is desirable to stop rotation of the rotor as soon as the driving waveform is removed from the motor. For example, in washing machine applications, it is desirable to stop rotation of the washing machine motor after a high speed spin cycle so that the washing machine may be unloaded or switched to a slower speed wash or rinse cycle.
Accordingly, various techniques have been developed for braking electric motors. One such technique uses brake pads, pulleys, and/or other friction braking systems. Unfortunately, friction brakes add cost to a motor and are therefore not desirable for low cost applications such as washing machines. Friction brakes also eventually wear out with use and require repair or replacement.
Thus, many motor applications employ electric braking systems rather than friction brakes. One type of electric braking system employs regenerative braking technology. Although such technology is effective and energy efficient, it is far too complicated and expensive for lower cost applications such as washing machine motors. Another type of electric braking system is DC injection braking in which a direct current (DC) voltage is applied to a motor's stator windings to brake the rotor. The DC voltage creates a stationary magnetic field which applies a static torque to the rotor. This slows and eventually halts rotation of the rotor. As long as the DC voltage remains on the stator windings, the rotor is held in position and resists rotation. DC injection braking is relatively simple, cost-effective, and maintenance free and is therefore a popular choice of braking for many motor applications; however, it has not been used effectively in some applications as described below.
It is also often desirable to determine when a motor's rotor has stopped rotating so the rotor can be driven in the opposite direction, at a different speed, etc. This can be accomplished with a motor shaft sensor such as a Hall effect sensor, but such sensors increase the cost and complexity of motors and are therefore not desirable for many lower cost applications such as washing machine motors.
Thus, sensorless techniques for determining motor speed have been developed. One type of sensorless speed detection employs various algorithms for estimating when a rotor stops based on measured electrical parameters. However, the measured electrical parameters, and thus the results of the algorithms, are less accurate when the motor is being braked with the above-described DC injection braking techniques. Thus, DC injection braking techniques generally require a motor shaft sensor.
Another sensorless technique to ensure a motor has stopped rotating is to simply have a time delay that must lapse after power is removed from the motor. A similar technique uses DC injection braking to slow the motor as described above and continues the DC injection until a time delay has lapsed. The first of these methods unfortunately wastes time between motor cycles because the time delay must account for the maximum possible coast time of a motor, and the second of these methods wastes energy and time because the DC injection braking must be maintained longer to account for the maximum possible breaking time even though the motor may in fact stop sooner.
The above section provides background information related to the present disclosure which is not necessarily prior art.
SUMMARY
Embodiments of the present invention solve the above described problems by providing improved systems and methods for braking electric motors and for determining when the rotors of the motors have stopped rotating. For example, embodiments of the invention provide systems and methods for quickly and efficiently braking an electric motor with DC injection braking without the use of a motor speed sensor and without requiring time delays.
A motor assembly constructed in accordance with an embodiment of the present invention may be used in a washing machine, HVAC system, pump system or any other application. The motor assembly broadly comprises an electric motor and a motor controller for powering and controlling the motor. The motor may be any type of motor and includes a stator and a rotor. In one embodiment, the motor may be a three phase AC induction motor. The motor controller powers and controls the motor and is programmed or otherwise configured to perform at least some of the methods described herein. In one embodiment, the motor controller is programmed or configured to apply a DC injection braking waveform to the stator of the motor while the rotor is rotating, monitor a reactive power of the stator, detect an increase in the reactive power of the stator to determine the rotor has substantially stopped rotating, and remove the applied braking waveform from the stator in response to detecting the increase in the reactive power.
In a related embodiment, the motor controller monitors both the reactive power and active power of the stator, determines a ratio between the reactive power and the active power to determine the power factor of the stator, and uses the power factor to determine when the rotor has substantially stopped rotating. In one embodiment, the motor controller determines the rotor has stopped rotating when the power factor is approximately 1 . Determining that the rotor has stopped by monitoring the power factor is advantageous because the power factor level that indicates the rotor has stopped is the same regardless of the magnitude of the DC injection braking waveform.
In another embodiment of the invention, the braking waveform is a controlled current waveform. The motor controller is programmed or configured in this embodiment to apply the controlled current braking waveform to the stator while the rotor is rotating, determine when the rotor has substantially stopped rotating, and remove the applied controlled current braking waveform from the stator in response to determining the rotor has substantially stopped rotating.
In yet another embodiment of the invention, the motor or the motor controller includes one or more current shunts. The motor controller is programmed or configured in this embodiment to apply a braking waveform to the stator while the stator is rotating, monitor a current through one of the current shunts while the braking waveform is applied to the stator, determine whether the rotor has substantially stopped rotating using the monitored current through the current shunt, and remove the applied braking waveform from the stator in response to determining the rotor has substantially stopped rotating.
This summary is provided to introduce a selection of concepts in a simplified form that are further described in the detailed description below. This summary is not intended to identify key features or essential features of the claimed subject matter, nor is it intended to be used to limit the scope of the claimed subject matter. Other aspects and advantages of the present invention will be apparent from the following detailed description of the embodiments and the accompanying drawing figures.
DRAWINGS
Embodiments of the present invention are described in detail below with reference to the attached drawing figures, wherein:
FIG. 1 is a block diagram of a motor assembly constructed in accordance with an embodiment of the invention.
FIG. 2 is a schematic representation of the stator and rotor of the motor in the motor assembly of FIG. 1 .
FIG. 3 is a graph of rotor speed over a time period according to one exemplary embodiment of the present disclosure.
FIG. 4 is a graph of stator reactive power over the same time period as FIG. 3 .
FIG. 5 is a flow diagram depicting steps in a method of the invention and/or code segments of a computer program of the invention.
FIG. 6 is a flow diagram depicting steps in another method of the invention and/or code segments of another computer program of the invention.
FIG. 7 is a flow diagram depicting steps in yet another method of the invention and/or code segments of another computer program of the invention.
The drawing figures do not limit the present invention to the specific embodiments disclosed and described herein. The drawings are not necessarily to scale, emphasis instead being placed upon clearly illustrating the principles of the invention.
DETAILED DESCRIPTION
The following detailed description of embodiments of the invention references the accompanying drawings. The embodiments are intended to describe aspects of the invention in sufficient detail to enable those skilled in the art to practice the invention. Other embodiments can be utilized and changes can be made without departing from the scope of the claims. The following detailed description is, therefore, not to be taken in a limiting sense. The scope of the present invention is defined only by the appended claims, along with the full scope of equivalents to which such claims are entitled.
In this description, references to “one embodiment”, “an embodiment”, or “embodiments” mean that the feature or features being referred to are included in at least one embodiment of the technology. Separate references to “one embodiment”, “an embodiment”, or “embodiments” in this description do not necessarily refer to the same embodiment and are also not mutually exclusive unless so stated and/or except as will be readily apparent to those skilled in the art from the description. For example, a feature, structure, act, etc. described in one embodiment may also be included in other embodiments, but is not necessarily included. Thus, the present technology can include a variety of combinations and/or integrations of the embodiments described herein.
Turning now to the drawing figures, and initially FIG. 1 , a motor assembly 10 constructed in accordance with embodiments of the invention is illustrated. The motor assembly 10 may be used in any application, such as in a washing machine, HVAC system, pump system, or appliance. In one particular embodiment, the motor assembly 10 is designed for use with a horizontal axis, front-loading washing machine, but the principles of the present invention are equally applicable to all uses of the motor assembly.
An embodiment of the motor assembly 10 broadly includes an electric motor 12 and a motor controller 14 . The motor assembly 10 may also include or be coupled with other components not relevant to the present invention.
As best illustrated in FIG. 2 , the electric motor 12 includes a rotor 16 and a stator 18 . The motor 12 may operate on direct current (DC) or alternating current (AC), may be synchronous or asynchronous, and may be single phase or three phase. The motor 12 may be of any type, including but not limited to, a brushed DC motor, a switched reluctance motor, a coreless or ironless DC motor, a series wound universal motor, an induction motor, a torque motor, or a stepper motor. Moreover, the motor may be fixed speed, multi-speed, or variable speed and may have any horsepower (HP) rating. In one particular embodiment of the invention, the motor 12 is a ⅓-1 HP, three phase, reversible and variable speed switched reluctance type motor. Such a motor provides maximum drive performance at a competitive price for washing machine applications which require a wide range of operating speeds and a high start-up torque. However, the principles of the present invention are not limited to any particular motor type, technology, or size.
The motor controller 14 provides power to and controls operation of the electric motor 12 and is programmed or otherwise configured to perform one or more of the function or methods described below. The motor controller 14 may include any combination of circuitry, hardware, firmware, and/or software. In one particular embodiment, the motor controller 14 includes a custom application specific integrated circuit (ASIC) with a microprocessor that controls and drives a 3-phase inverter and various other electronic components.
As shown in FIG. 1 , the motor controller 14 may receive power from a single phase AC supply voltage at 115 VAC supplied by connections L 1 and N, where L 1 represents the “hot” side of the AC supply and N represents neutral, which is typically at earth potential. The AC supply voltage may also be 230 VAC, in which case the neutral line would be replaced with another hot supply line. The AC supply voltage may also be three phase 480 VAC.
The motor controller 14 may receive commands or operating instructions from one or more controls 20 such as a keypad, switches, or buttons as are commonly found on washing machines and other appliances and devices. The controls may be one or more separate components or may be integrated in the motor controller 14 .
The motor controller 14 may also be coupled to a single current shunt 22 for determining a stator current as described below. This single current shunt 22 may be a discrete component coupled to the printed circuit board of the motor controller ASIC or may be incorporated in the stator of the motor or the inverter module of the motor controller.
Aspects of the invention may be implemented with one or more computer programs stored in or on computer-readable medium residing on or accessible by the microprocessor of the motor controller 14 . Each computer program preferably comprises an ordered listing of executable instructions for implementing logical functions in the motor controller 14 . Each computer program can be embodied in any non-transitory computer-readable medium for use by or in connection with an instruction execution system, apparatus, or device, such as a computer-based system, processor-containing system, or other system that can fetch the instructions from the instruction execution system, apparatus, or device, and execute the instructions. In the context of this application, a “computer-readable medium” can be any non-transitory means that can store the program for use by or in connection with the instruction execution system, apparatus, or device. The computer-readable medium can be, for example, but not limited to, an electronic, magnetic, optical, electro-magnetic, infrared, or semi-conductor system, apparatus, or device. More specific, although not inclusive, examples of the computer-readable medium would include the following: an electrical connection having one or more wires, a portable computer diskette, a random access memory (RAM), a read-only memory (ROM), an erasable, programmable, read-only memory (EPROM or Flash memory), an optical fiber, and a portable compact disk read-only memory (CDROM).
According to one aspect of this disclosure, the motor controller 14 is programmed or otherwise configured to implement a method 500 of braking the electric motor 12 . The method broadly includes the steps of energizing the stator 18 of the motor 12 , with a braking waveform determining a reactive power of the stator 18 , detecting an increase in the determined reactive power of the stator 18 , and removing the braking waveform from the stator 18 in response to detecting the increase in the determined reactive power of the stator. The increase in reactive power indicates that the rotor 16 has substantially stopped rotating.
In a related embodiment, the motor controller monitors both the reactive power and active power of the stator, determines a ratio between the reactive power and the active power to determine the power factor of the stator, and uses the power factor to determine when the rotor has substantially stopped rotating. In one embodiment, the motor controller determines the rotor has stopped rotating when the power factor is approximately 1. Determining that the rotor has stopped by monitoring the power factor is advantageous because the power factor level that indicates the rotor has stopped is the same regardless of the magnitude of the DC injection braking waveform.
The flow chart of FIG. 5 shows the functionality and operation of a preferred implementation of the above described method 500 in more detail. In this regard, some of the blocks of the flow chart may represent the method 500 and/or a module segment or portion of code of the computer programs of the present invention. In some alternative implementations, the functions noted in the various blocks may occur out of the order depicted in FIG. 5 . For example, two blocks shown in succession in FIG. 5 may in fact be executed substantially concurrently, or the blocks may sometimes be executed in the reverse order depending upon the functionality involved.
The method 500 begins while the rotor 16 of the motor 12 is moving as depicted in box 502 . For example, in the embodiment in which the motor assembly 10 is used in a washing machine, the motor 12 may be operating at a high RPM during a spin cycle.
While or shortly after the motor 12 is de-energized and begins to coast, the motor controller 14 may receive or internally process a brake signal as depicted in box 504 . For example, the motor controller 14 may receive a signal from an internal or external timing circuit that indicates a spin cycle or other motor cycle has ended and that the rotor should be slowed or stopped.
In response to the brake signal or other indication that the motor 12 has been de-energized, the motor controller 14 energizes the stator 18 to apply a braking force to the rotor in order to brake the rotor as depicted in box 506 . The stator 18 may be energized by driving the stator with a controlled current waveform as described in more detail below in connection with the method 600 . Alternatively, the stator 18 may be driven with a voltage controlled waveform.
The motor controller 14 then determines a reactive power of the stator 18 as depicted in box 508 . The reactive power may be determined in any conventional manner. For example, the reactive power may be determined based on detecting current through the current shunt 22 as described in more detail below in connection with the method 700 . The reactive power may also be determined through multiple current shunts, etc.
The motor controller 14 then detects an increase in the reactive power of the stator 18 as depicted in box 510 . The increase in the reactive power indicates the rotor 16 has substantially stopped rotating. As a part of this step, the motor controller may detect an increase in the magnitude of the stator reactive power. Alternatively, the motor controller may detect an increase in a ratio of the determined reactive power and a determined active power of the stator to determine the rotor has stopped rotating.
FIGS. 3 and 4 show graphs that illustrate a specific embodiment of the method 500 . FIG. 3 shows a motor's rotor speed over a time period, and FIG. 4 shows the stator's reactive power over the same time period. During a first time period 100 , the rotor 16 rotates and the stator 18 reactive power is zero. Braking begins at the beginning of a second time period 102 as the stator 18 is energized with a braking waveform, causing the rotor 16 to slow down. At the end of the second time period 102 , the rotor 16 approaches zero speed and the stator reactive power increases. The motor controller 14 detects the increase in stator reactive power, and at the end of a third period 104 , the motor controller 14 removes the braking waveform from the stator in response to the detected increase in stator reactive power.
The example shown in FIGS. 3 and 4 may be altered without departing from the scope of the present invention. For example, the stator reactive power may be greater than zero during the first period 100 . Also, the stator reactive power may be zero during the second period 102 . The third period 104 may be very brief to minimize the power dissipated in the stator.
The above-described method 500 provides numerous advantages. For example, the method minimizes the time that the stator 18 is energized with the braking waveform in order to save energy and minimize power dissipation that may damage the stator. Specifically, stator power dissipation is minimized by de-energizing the stator 18 when the rotor 16 has substantially stopped rotating. Also, a shorter braking cycle time increases the throughput of devices driven by the electric motor 12 . For example, when the motor assembly 10 is used in a washing machine, the method 500 allows quick and efficient braking of the motor 12 after a high speed spin cycle so that the washing machine can be unloaded or operated in a different cycle.
According to another aspect of this disclosure, the motor controller 14 may be programmed or otherwise configured to implement another method 600 of braking the electric motor 12 . As with the method 500 , the method 600 broadly includes the steps of energizing the stator 18 of the motor 12 to brake the motor, determining a reactive power of the stator 18 , detecting an increase in the determined reactive power of the stator 18 , and removing the braking waveform from the stator in response to detecting the increase in the determined reactive power of the stator. As explained in more detail below, the method 600 energizes the stator of the motor with a controlled current braking waveform.
The flow chart of FIG. 6 shows the functionality and operation of a preferred implementation of the above described method 600 in more detail. In this regard, some of the blocks of the flow chart may represent the method 600 and/or a module segment or portion of code of the computer programs of the present invention. In some alternative implementations, the functions noted in the various blocks may occur out of the order depicted in FIG. 6 . For example, two blocks shown in succession in FIG. 6 may in fact be executed substantially concurrently, or the blocks may sometimes be executed in the reverse order depending upon the functionality involved.
Steps 602 , 604 , 608 , 610 , and 612 of method 600 are substantially identical to steps 502 , 504 , 508 , 510 , and 512 , respectively, of method 500 and will therefore not be described again.
In step 606 of the method 600 , the motor controller 14 energizes the stator 18 with a controlled current waveform to apply a braking force to the rotor 16 in order to brake the rotor. The motor controller 14 may also vary the amplitude of the controlled current waveform. In one embodiment, the amplitude of the controlled current waveform is varied at a fixed frequency. The fixed frequency is preferably between about 1 Hz and about 10 Hz. More preferably the fixed frequency is about 2 Hz.
Energizing the stator 18 with a controlled current waveform to brake the rotor 16 is superior to braking the motor with a controlled voltage. This is because the stator generates a magnetic field based on the stator current (not based on the stator voltage) and it is the magnetic field that interacts with the rotor to brake the rotor. A controlled stator voltage may generate variable stator current since the stator resistance changes as the stator heats. Thus, a controlled stator current will result in more consistent rotor braking than would a controlled stator voltage.
According to another aspect of this disclosure, the motor controller 14 is programmed or otherwise configured to implement another method 700 of braking the electric motor 12 . The method 700 broadly includes the steps of energizing the stator of the motor to brake the motor, determining when the rotor stops rotating, and de-energizing the stator 18 in response to determining that the rotor has stopped. As explained in more detail below, the method 700 determines the rotor 16 has stopped rotating by monitoring the current shunt 22 .
The flow chart of FIG. 7 shows the functionality and operation of a preferred implementation of the above described method 700 in more detail. In this regard, some of the blocks of the flow chart may represent the method 700 and/or a module segment or portion of code of the computer programs of the present invention. In some alternative implementations, the functions noted in the various blocks may occur out of the order depicted in FIG. 7 . For example, two blocks shown in succession in FIG. 6 may in fact be executed substantially concurrently, or the blocks may sometimes be executed in the reverse order depending upon the functionality involved.
Steps 702 , 704 , and 706 of method 700 are substantially identical to steps 502 , 504 , and 506 , respectively, of method 500 and will therefore not be described again.
In step 708 of the method 700 , the motor controller 14 determines a current through the single current shunt 22 . This step may include computing one or more motor phase currents as a function of the signal on the current shunt. The computed phase currents may provide the indication that the rotor has substantially stopped rotating. Further, the signal on the single current shunt may indicate an increase of a reactive power of the stator. Alternatively, the signal may indicate an increase of the motor power factor, etc.
A single current shunt is lower cost than multiple current shunts; accordingly, implementing this method may be lower cost than implementing a method that requires multiple current shunts.
In step 710 of the method 700 , the motor controller 14 de-energizes the stator 18 to remove the braking force on the rotor 16 . This may be done in response to a signal on the current shunt 22 indicating that the rotor 16 has stopped rotating.
Although the invention has been described with reference to the preferred embodiment illustrated in the attached drawing figures, it is noted that equivalents may be employed and substitutions made herein without departing from the scope of the invention as recited in the claims. | A motor controller for an electric motor having a stator and a rotor. The motor controller includes a power input for receiving AC power from a power source; a control input for receiving a control signal from a control; and circuitry for switching power from the power source to the electric motor in response to the control signal. The circuitry is operable to: apply a braking waveform to the stator while the rotor is rotating; monitor a reactive power of the stator; detect an increase in the reactive power of the stator to determine the rotor has substantially stopped rotating; and remove the braking waveform from the stator in response to detecting the increase in the reactive power. | 7 |
This application is a Divisional of Ser. No. 11/324,484, filed Jan. 3, 2006, now U.S. Pat. No. 7,379,767 issued May 27, 2008.
BACKGROUND OF THE INVENTION
This invention relates to electrodes for laryngeal electromyography and in particular to an electrode that is attachable to an insert device of sorts and that is size adjustable to fit the particular application, and in particular for use in pediatrics.
During thyroid surgery there is a substantial hazard that the recurrent laryngeal nerve may be severed, stretched or bruised during surgery on, about or near the thyroid gland. The hazard is a result of several factors, including the fact that the recurrent laryngeal nerve lies just posterior to the most inferior portion of the thyroid gland, and is very small and delicate. It can be quite difficult to distinguish this nerve from the background tissue when the area about the thyroid gland is inflamed, as well as covered with blood following the initial incision. As the result, the risk of vocal cord damage or paralysis following thyroid surgery is very high, and also is quite serious in that it can result in the patient's complete loss of speech. Even if the laryngeal nerve has simply been stretched or bruised, the loss of speech may last for several months. In the unfortunate cases where the nerve is completely severed, the paralysis is permanent, and surgical attempts to repair the same have not yet proven successful.
The use of laryngeal electromyography with surface electrodes to locate the recurrent laryngeal nerve has proven successful, as discussed in U.S. Pat. No. 5,178,145 issued to Rea. But the types and sizes of electrodes available are limited. Most electrodes are self retaining in that they have some sort of “built in” means for insertion, such as a paddle or handle. Most electrodes are also fixed in size and may not be adaptable for use on all patients and in particular pediatric patients, small children, and in some cases small adults.
SUMMARY OF THE INVENTION
In general, the attachable and size adjustable surface electrode for laryngeal electromyography generally consists of a flexible plate having an anterior and a posterior surface specifically for insertion into the human laryngopharynx adjacent to the cricothyroideus muscles (the vocal cords). An electrical conductive plate is mounted on the anterior surface to provide an electric contact with the cricothyroideus muscles. An insulated wire extends from the electrical conductive plate for monitoring or delivering electrical pulses to the cricothyroideus muscles. There are graduations parallel to a center line on the electrical conductive plate for cutting and sizing the flexible plate and electrical conductive plate to the size of the patient's laryngopharynx. There is an adhesive material on the posterior surface of the flexible plate for attachment of the attachable and size adjustable surface electrode to an endotracheal tube, insert device, postcricoid paddle or other such device.
The principal object of the present invention is to provide an electrode and method for laryngeal electromyography to locate a recurrent laryngeal nerve, and in particular an electrode that can be directly attached to an endotracheal tube, insert device, postcricoid paddle or other such device, so it must be flexible and bendable, rather then being self retaining or permanently fixed to some sort of device for insertion.
Another object is to provide such an electrode and method for continuous intraoperative laryngeal nerve location monitoring during thyroid surgery.
Yet another object is to provide such an electrode and method that is easily attached to an insert device and thus easily inserted in the patient, and in particular small adults, children, and for use in pediatrics, and that is adapted for reliable operation.
Another object is to provide such an electrode and method that is simple and accurate in operation whereby surgeons without extensive experience in thyroid surgery may conduct the surgery, yet avoid damage to the laryngeal nerve.
Still another object is to provide such an electrode and method to allow monitoring of the cricothyroideus muscles, a muscle innervated by the recurrent laryngeal nerve, without resort to needle invasion of other laryngeal musculature.
Even another object is to provide such an electrode and method for accurately and securely placing the electrode through the pharynx (throat) into the patient's postcricoid space without interfering with other equipment.
And yet another object is to provide such an electrode that is economical to manufacture, efficient in use, and particularly well adapted for the proposed use.
Other objects and advantages of this invention will become apparent from the following description taken in connection with the accompanying drawings wherein are set forth, by way of illustration and example, certain embodiments of this invention.
The drawings constitute a part of this specification and include exemplary embodiments of the present invention and illustrate various objects and features thereof.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of the primary embodiment of an attachable and size adjustable surface electrode for laryngeal electromyography embodying the present invention wrapped around and attached to an endotracheal tube.
FIG. 2 is a top view of the primary embodiment of attachable and size adjustable surface electrode for laryngeal electromyography embodying the present invention.
FIG. 2A is a cross sectional view of the attachable and size adjustable surface electrode as illustrated in FIG. 2 .
FIG. 3 shows the attachable and size adjustable surface electrode being trimmed or size adjusted by cutting with scissors.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring more in detail to the drawings, the detailed embodiments of the present invention are disclosed herein, however, it is to be understood that the disclosed embodiments are merely exemplary of the invention which may be embodied in various forms. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a basis for the claims and is a representative basis for teaching one skilled in the art to variously employ the present invention and virtually any appropriately detailed structure.
The reference numeral 10 generally designates the attachable and size adjustable surface electrode for laryngeal electromyography of the present invention. The attachable and size adjustable surface electrode 10 generally consists of a flexible plate 12 having an anterior surface 14 and a posterior surface 16 specifically for inserting in the human laryngopharynx adjacent to the cricothyroideus muscles (the vocal cords). An electrical conductive plate 18 is mounted on the anterior surface 14 , to provide an electric contact with the cricothyroideus muscles. A wire 20 extends from the electrical conductive plate 18 for monitoring or delivering electrical pulses to the cricothyroideus muscles. The other end of the wire 20 is attachable to an electromyographic monitor. There are graduations 22 parallel to a center line marked on the electrical conductive plate 18 , or posterior side 16 of the flexible plate 12 , for cutting and sizing the flexible plate 12 and electrical conductive plate 18 to the size of the patient's laryngopharynx. There is an adhesive material 24 on the posterior surface 16 of the flexible plate 12 for attachment of the attachable and size adjustable surface electrode 10 to an endotracheal tube, insert device, postcricoid paddle or other such device 8 .
No other known device is flexible and size adjusting by cutting, and attachable to an endotracheal tube, insert device, postcricoid paddle or other such device 8 by wrapping the attachable and size adjustable surface electrode 10 around the endotracheal tube, insert device, postcricoid paddle or other such device 8 and attaching via the adhesive 24 .
The flexible plate 12 has an anterior surface 14 and a posterior surface 16 specifically for inserting in the human laryngopharynx adjacent to the cricothyroideus muscles (the vocal cords). The flexible plate 12 is made from a non-conductive material that is flexible and bendable so it can be wrapped about and attached to an endotracheal tube, insert device, postcricoid paddle, or other such device 8 . It could be made from a variety of material, but the preferred embodiment it is made of a thin layer of polyethylene, foam polyethylene, or some other medical grade material. Typically, the initial dimensions are 24 millimeters (mm) in width and 45 mm in length in the preferred embodiment. However, different sizes and different materials can be made based upon the intended use, size of the patient, and by market forces.
The electrical conductive plate 18 is mounted on the anterior surface 14 of the flexible plate 12 , to provide an electric contact with the cricothyroideus muscles. The electrical conductive plate 18 is constructed of a metallic conductive layer of silver ink, flexograph silver deposition, or similar electrically conductive medium. The electrical conductive plate 18 can be attached with the adhesive properties of the conductive material itself or it may be attached with silver loaded conductive adhesive, nonconductive acrylic resin, or other type of material or adhesive that adheres to both the electrical conductive plate 18 and the flexible plate 12 . The dimensions of the electrical conductive plate 18 are somewhat smaller than the outer dimensions of the flexible plate 12 . However, after the attachable and size adjustable surface electrode 10 is cut to size, the width of both will be approximately equal. Both the flexible plate 12 and electrical conductive plate 18 will be cut simultaneously so they should be the same width after sizing.
A wire 20 extends from the electrical conductive plate 18 for monitoring or delivering electrical pulses from/to the cricothyroideus muscles. One end of the wire 20 is in electrical contact with the electrical conductive plate 18 . Preferably, the wire 20 is in electrical contact with the back side along a center line of the electrical conductive plate 18 between the flexible plate 12 and the electrical conductive plate 18 . In this location the electrical contact is protected and provides a mechanically sound connection location. The wire 20 may be attached with silver loaded conductive adhesive or any other electrical conductive means. The other end of wire 20 is adapted for connection to an electrical signal receiver and monitor, such as an electromyographic monitor instrument 6 . The wire 20 typically is a flexible conductive wire in the nature of 40 gauge more or less with an insulating covering. The wire 20 is very fine in the nature and with a length of approximately 6 inches or longer to facilitate threading the same into the patient's laryngopharynx. The main purpose of the wire 20 is to provide the input of electrical signals to or from electrical conductive plate 18 to an electromyographic monitor instrument 6 . In this regard, any wire of any gauge or length fulfilling this purpose is within the scope of the invention.
There are a plurality of graduations 22 parallel to and on both sides of a center line on the electrical conductive plate 18 , in the preferred embodiment. The graduations 22 are for cutting and sizing the flexible plate 12 and electrical conductive plate 18 to the size of the endotracheal tube or insert device 8 appropriate for the patient's laryngopharynx. The attachable and size adjustable surface electrode 10 is easily cut and sized using scissors 4 or some other cutting device. The graduations 22 could also be marked on the posterior surface 16 of the flexible plate 12 or back side of the removable plastic film or paper 26 in other embodiments, that are not shown. The graduations 22 are typically marked on one side of center in a spaced relationship to graduations 22 marked on the other side of center. This is so an equal amount can be cut off on each side of center. The graduations 22 may or may not be marked with alphanumerical characters 28 for ease of identifying corresponding graduation marks on the opposite sides of center. Typically, the graduations 22 and alphanumerical characters if any, can be marked with ink, paint, etching, stamping, or by any method that readily shows the graduations 22 and alphanumerical characters. Any means used for marking the graduation should be considered within the scope of the invention.
There is a non conductive adhesive material 24 on the posterior surface 16 of the flexible plate 12 for attachment of the attachable and size adjustable surface electrode 10 to an endotracheal tube, insert device, postcricoid paddle or other such device 8 . In the preferred embodiment, the adhesive is covered with a thin film of plastic or paper 26 . The thin plastic film is peeled off so the attachable and size adjustable surface electrode 10 can be wrapped around and attached via the adhesive to an endotracheal tube, insert device, postcricoid paddle or other such device 8 . Any type of adhesive that functions to attach the attachable and size adjustable surface electrode 10 to an endotracheal tube, insert device, postcricoid paddle or other such device 8 is within the scope of the invention.
In use:
The first step is to determine the size of the patient's trachea and larynx and the type of insert device to be used. As used here an insert device 8 can be an endotracheal tube, insert device, postcricoid paddle, or other such device. The attachable and size adjustable surface electrode 10 is cut to size along graduations 22 using scissors 4 or some other cutting device. The adhesive backing is peeled off and the attachable and size adjustable surface electrode 10 is wrapped around and attached to the insert device 8 .
The patient is then anesthetized and the insert device 8 with the attachable and size adjustable surface electrode 10 is inserted into the patient's mouth and into his trachea. The attachable and size adjustable surface electrode 10 is positioned between the vocal cords with the attachable and size adjustable surface electrode 10 making contact with the cricothyroideus muscles. The outer end of the wire 20 is attached to an electromyographic monitor 6 . Typically, the insert device 8 has an opening longitudinally through the device to allow the patient to breathe.
The electromyographic monitor 6 generally is a device that will receive an electrical signal originating in the cricothyroideus muscles and transmitted thereto through the wire 20 , and provide a display of the signal. The signal receiver and monitor may comprise an oscilloscope or the like, and is preferably a mechanism which provides an audible alarm upon receipt of the electrical signal, whereby the location of the recurrent laryngeal nerve can be determined while the surgeon maintains continuous sight observation of the area of surgery.
The electromyographic monitor 6 or signal generator typically includes a probe and provides means for applying an electrical signal to the recurrent laryngeal nerve 22 . The signal is of a relatively low voltage, in the nature of five to forty volts, and is preferably a repetitive stimuli of low frequency, short pulses, in the nature of 4 pulses per second stimulation rate.
After the surgeon has made his initial incision, and is approaching the area of the recurrent laryngeal nerve, he simply applies the probe to the area in which he believes the nerve to be located. If the probe contacts the laryngeal nerve, the signal applied thereto by the signal generator 6 is transmitted through the laryngeal nerve to the cricothyroideus muscles which in turn is thereby excited. Excitement of the cricothyroideus muscles causes an electrical impulse to be generated therein and is transmitted through the electrical conductive plates 18 and the wire 20 to the signal receiver and monitor. The electrical conductive plate 20 serves as an electrical ground for the signal receiver and monitor. In the case of an audio monitor, the device shall emit popping sounds in a frequency which corresponds to the recognized warning tone emitted by signal receiver and monitor. The surgeon need only recognize the characteristic frequency of these popping sounds to know that he has located the recurrent laryngeal nerve. After having determined the location of the nerve, the surgeon can work very slowly and carefully in this area so as to insure the nerve is not injured.
The attachable and size adjustable surface electrode 10 may be removed from the patient by simply pulling on the insert device 8 , thereby removing the insert device 8 and the attachable and size adjustable surface electrode 10 distally through the patient's mouth.
It is to be understood that while we have illustrated and described certain form of our invention, it is not to be limited to the specific forms or arrangements herein described and shown. | An electrode for laryngeal electromyography that is adhesively secured to an insert device, endotracheal tube or other similar device. The attachable surface electrode of this invention consists of a flexible substrate having an anterior and a posterior surface specifically for insertion along the human laryngopharynx and adjacent to the cricothyroideus muscles (the vocal cords). One or more electrically conductive structures are mounted on or formed on the anterior surface of the substrate to provide an electric contact with the cricothyroideus muscles. Insulated wires extend from the electrical conductive structures for transmitting electrical pulses to the cricothyroideus muscles. There is an adhesive material on the posterior surface of the flexible substrate for attachment to an endotracheal tube, insert device, postcricoid paddle or other such device of the attachable substrate so that the electrically conductive structures thereon are properly positioned for laryngeal electromyography. | 0 |
BACKGROUND
[0001] A wiki is a collaboration tool that is gaining popularity for the online sharing and editing of a wide variety of topics. Wikis have the concept of proto links where the author of a wiki page, while authoring content, creates the proto link (or placeholder) to a non-existent page, which proto link can be denoted by a special dotted underline. The proto link serves as a reminder that a page on a particular topic is empty and invites collaboration from other users of the wiki who may be able to contribute to this topic. When a user selects the proto link, a page is automatically created that is the target page for the proto link. The user is navigated to the target page where content can be authored.
[0002] Although this feature behavior may be common, it is noted that most wikis are designed to be online and do not have off-lining capabilities. This means that a proto link target resolution will always result in a single page being created. The ability to provide the same wiki proto link behavior both online and offline, however, is problematic. This can result in multiple offline clients resolving the same proto link offline, thus, creating multiple proto page targets for the same link. When the offline clients come back online and synchronization occurs, a page conflict will result where there are multiple proto pages for the same link resulting in incorrect and incomplete content and also conflict in resolving the target page for the link.
SUMMARY
[0003] The following presents a simplified summary in order to provide a basic understanding of some novel embodiments described herein. This summary is not an extensive overview, and it is not intended to identify key/critical elements or to delineate the scope thereof. Its sole purpose is to present some concepts in a simplified form as a prelude to the more detailed description that is presented later.
[0004] The disclosed architecture facilitates offline/online interaction with online collaboration documents or pages such as for wikis and/or notebooks. More specifically, for every proto link employed in a page, a unique object ID is provided. The client, whether online or offline, uses the object ID as the page's object ID when a target page is created at the time of resolving the associated proto link (e.g., when a user clicks on a proto link to navigate to the proto page). When an offline client connects to an online state, changes are synchronized (synced). All the pages created offline from the same proto link will have the same object ID and the content of the pages are then synced correctly under the same page ID and name.
[0005] To the accomplishment of the foregoing and related ends, certain illustrative aspects are described herein in connection with the following description and the annexed drawings. These aspects are indicative of the various ways in which the principles disclosed herein can be practiced, all aspects and equivalents of which are intended to be within the scope of the claimed subject matter. Other advantages and novel features will become apparent from the following detailed description when considered in conjunction with the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0006] FIG. 1 illustrates an exemplary management system for a collaboration environment.
[0007] FIG. 2 illustrates a more detailed implementation of an exemplary document management system.
[0008] FIG. 3 illustrates a synchronization component that can be employed for online synchronization of the changes made to offline pages.
[0009] FIG. 4 illustrates a collaborative environment in which proto link generation using object identifiers can be performed.
[0010] FIG. 5 illustrates a screenshot of a dialog panel that can be employed as part of a user interface for exposing entry points to creating proto links.
[0011] FIG. 6 illustrates a screenshot of a popup as an entry point for finding matching elements.
[0012] FIG. 7 illustrates a method of managing documents.
[0013] FIG. 8 illustrates a method of creating a proto link.
[0014] FIG. 9 illustrates a method of searching for elements having matching identifiers.
[0015] FIG. 10 illustrates a block diagram of a computing system operable to execute for proto link creation and processing in accordance with the disclosed architecture.
[0016] FIG. 11 illustrates a schematic block diagram of an exemplary computing environment for proto link creation and document processing using proto links.
DETAILED DESCRIPTION
[0017] Existing online collaboration environments such as wikis and notebooks are purely online-only tools and do not have the notion of resolving proto links offline, which makes mobile scenarios very limiting. A proto link is a link (in a shared document such as in a notebook) that has no existing target page and allows a user to link to non-existent content. In order to follow the link, the target page is automatically created when the link is resolved.
[0018] The disclosed architecture provides the capability to automatically synchronize (sync) and merge conflicts between documents edited offline with the associated online document version. Since wikis and notebooks are primarily intended to be a multi-user authoring and collaboration tools, the automated sync and merge features allow for seamless collaboration that transcends the boundaries of connected vs. unconnected and single vs. multiple authors.
[0019] Reference is now made to the drawings, wherein like reference numerals are used to refer to like elements throughout. In the following description, for purposes of explanation, numerous specific details are set forth in order to provide a thorough understanding thereof. It may be evident, however, that the novel embodiments can be practiced without these specific details. In other instances, well known structures and devices are shown in block diagram form in order to facilitate a description thereof. The intention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the claimed subject matter.
[0020] FIG. 1 illustrates an exemplary management system 100 for a collaboration environment. The system 100 includes a link component 102 for creating a proto link 104 with a title in a collaboration document 106 , and an identifier component 108 for generating and including an object identifier (ID) as part of the proto link 104 . When the proto link 104 is created, the link maps to a non-existent target page. This has an effect of not cluttering up the system with target pages that may or may not ever be used. The target page is only created when the user resolves (selects the proto link 104 to navigate to the target page). Moreover, when the user views existing target pages resolved due to user selection of the proto links of different pages, the user will not needlessly see empty target pages that have yet to receive user content, but will only see target pages that the users have actually caused to be created and will have user content.
[0021] The object identifier is employed for identifying a target page (not shown) associated with the proto link 104 . The proto link 104 can further include a section identifier associated with a section in the collaboration document 106 in which the proto link 104 is located.
[0022] The target page is only created in response to resolving of the proto link 104 during an online process. In one embodiment, the target page is created online, a copy of the online target page is taken offline, changes to the offline target page create a modified target page, and the modified target page is then synchronized to and merged with the target page during an online process based on the object identifier.
[0023] In another embodiment, the target page is created offline, changes to the offline target page create a modified target page, and the modified target page is then synchronized to and merged with the target page during an online process based on the object identifier.
[0024] FIG. 2 illustrates a more detailed implementation of an exemplary document management system 200 . The system 200 include the link component 102 for creating the proto link 104 with the title in a collaboration document 106 , an identifier component for generating and including an object identifier and a section identifier as part of the proto link 104 , the object identifier for identifying a target page associated with the proto link. The system 200 also includes a page generation component 202 for creating an online target page 204 in response to resolving the proto link 104 . The object identifier is assigned to the online target page 204 . The user can then take the online page 204 to an offline situation, and then make changes to the page 204 . The changes to the offline page can then be synchronized to the online page when the user comes back online. This is based on the object identifier in the proto link.
[0025] Alternatively, the user copies the collaboration document 106 , moves to an offline mode, and resolves the proto link 104 in response to which an offline target page 206 is created. The user then adds content, edits or modifies existing content on the offline page 206 , goes online, and the changes are then synchronized to the online page 204 , all based on the object identifier.
[0026] The system 200 further comprises a syntax component 208 for detecting syntax of the proto link as the user is entering the proto link 104 into the document 106 . The syntax component 208 can search for an existing document element based on the syntax. For example, where electronic notebooks are used, the search can be performed on the current notebook page, and then to other pages of the notebook, followed by pages of other notebooks. Alternatively, the syntax component 208 creates a proto link to a non-existent target page if an existing document element is not found.
[0027] FIG. 3 illustrates a synchronization component 300 that can be employed for online synchronization of the changes made to offline pages 302 . The synchronization component 300 synchronizes and merges a modified target page to the target page. The synchronization component 300 also provides conflict resolution during this synchronization process. Here, a first offline page 304 includes a first proto link 306 (having a title, object ID, and section ID), and a second offline document 308 includes a second proto link 310 (having a title, object ID, and section ID). When brought online, changes to the offline pages 302 are synchronized and merged with the online target page 312 based on the object identifier. Moreover, the sections in the offline pages 302 which the respective proto links ( 306 and 310 ) reside can be considered to more accurately synchronize to and merge with the corresponding section in the online target page 312 .
[0028] FIG. 4 illustrates a collaborative environment 400 in which proto link generation using object identifiers can be performed. This is particularly useful in collaborative environments such as network-based wikis and electronic notebooks where document sharing can occur. The environment 400 includes the link component for creating the proto link 104 with a title in the collaboration document 106 , and an identifier component 108 for generating and including an object identifier and section identifier as part of the proto link 104 , at least the object identifier is used for identifying the online target page 312 associated with the proto link 104 . The environment 400 further includes the page generation component 202 for creating the target page 312 in response to resolving the proto link 104 , where the object identifier is assigned to the target page 312 . The synchronization component 300 synchronizes and merges a modified target page to the target page 312 .
[0029] The syntax component 208 detects syntax of the proto link 104 and searches for an existing document element (of a notebook) based on the syntax, or creates the proto link 104 to a non-existent target page if an existing document element is not found.
[0030] As before, the target page 312 can be created online in response to the resolving of the proto link during an online process. The target page 312 can be taken offline, changes made to create the modified target page, and the modified target page synchronized to and merged with the online 312 target page during an online process. Alternatively, the target page 312 is created offline in response to the resolving of the proto link 104 during an offline process, changes to the modified target page are made offline, and the modified target page is synchronized to and merged with the online target page 312 during an online process.
[0031] FIGS. 5 and 6 are screenshots of an example user interface that can be utilized FIG. 5 illustrates a screenshot of a dialog panel 500 that can be employed as part of a user interface for exposing entry points to creating proto links. The dialog panel 500 provides an entry point to link to web pages as well as other notes. The panel shows a view with “Place in Notebook” selected. A current notebook page is highlighted (the dotted line blocks). The user can search by typing in the “Search by Text in title” text box. This shows the narrowed down list of matching titles in the control that the user can choose from. New page can be created (within the current section) using a new page option within the control.
[0032] This displays all the notebook elements with matching title. If the user selects a particular notebook element and hits OK, a link is created to this element. The “Text to Display” text box can also display the user highlighted text. The text on the page does not change unless the user changes the text to display value. An example where the user selects text “cu”. Results include entities having the “cu” string.
[0033] FIG. 6 illustrates a screenshot of a popup 600 as an entry point for finding matching elements. For example, if there is text selected when entering a predefined keystroke combination, the selected text is used for matching titles. For example, if the user highlights the string “customer” on the page and enters the predefined keystroke combination, the behavior of the popup 600 is shown to include entries where the string “customer” is included within the double brackets ([[Customer]]). A list of all matches that contain the string “Customer” is displayed in the popup 600 . The IP is on the first match (sorted by current notebook first). In the example, the IP can be on Customer (V3 Planning)
[0034] Note that for all matches, the hierarchy (including page hierarchy) is shown in detail beside the matched element (e.g., Page Name (Notebook\Section Group\Section)). This aids the user in determining the correct match when there are name collisions. The user can choose to ignore existing matches and create a new page with the same title. Since every wiki link is stored with a unique GUID (globally unique ID), the target linking correctly resolves the page the user linked to even if there is more than one page with the same name. The New page option can be displayed with the user-typed string name. If the user hits esc or clicks away, then the element matching UI is exited and the string is left unchanged with the surrounding brackets.
[0035] Following is a series of flow charts representative of exemplary methodologies for performing novel aspects of the disclosed architecture. While, for purposes of simplicity of explanation, the one or more methodologies shown herein, for example, in the form of a flow chart or flow diagram, are shown and described as a series of acts, it is to be understood and appreciated that the methodologies are not limited by the order of acts, as some acts may, in accordance therewith, occur in a different order and/or concurrently with other acts from that shown and described herein. For example, those skilled in the art will understand and appreciate that a methodology could alternatively be represented as a series of interrelated states or events, such as in a state diagram. Moreover, not all acts illustrated in a methodology may be required for a novel implementation.
[0036] FIG. 7 illustrates a method of managing documents. At 700 , a proto link of a collaboration document is tagged with an object identifier. At 702 , an online proto page is automatically in response to selection of the proto link. At 704 , the object identifier is assigned to the online proto page. At 706 , changes of copies of the online proto page are synchronized to the online proto page based on the object identifier.
[0037] The method can further comprise merging proto page information of another offline proto page to the online proto page as part of the synchronizing. The method can further comprise assigning the identifier to all copies of the proto page taken offline and synchronizing the copies to the online proto page based on the identifier. The method can further comprise assigning the object identifier in combination with a title of the proto link and also assigning a section identifier as part of the proto link. The method can further comprise creating the proto link using syntax that triggers a syntax algorithm to tag the proto link with the object identifier, and denoting the proto link as a placeholder link with a non-existent target page. The proto page can be associated with a wiki network site and/or a server-based notebook.
[0038] The scenarios for creating proto links include using syntax that triggers proto link insertion. For example, syntax such as “[[]]” that is entered when the user is typing content on a page and user starts to type “[[” to denote the beginning of a link indicated the start of link entry. The syntax algorithm looks for string between “[[” and “]]” in the same element (e.g., notebook). Then a match to find an existing element is initiated. If a match is found, then a link is created to the existing element. If the match is not found, a proto link to a non-existent page is created. The details are described below: Following is one example of a syntax algorithm. If user enters “]” and the symbol is preceded by another “]” with no space, then, if there is a preceding “[[” within the same element, then get string between “[[” and “]]”. Note that this is just one example of syntax and techniques for identifying wiki links. Other syntax and techniques can be employed.
[0039] Then check if there is an exact string match in the titles of the elements. The scope of the search can be the current notebook first, followed by all user opened notebooks, followed by unfiled notes. The search can look for exact string matches on the title of all pages (including placeholder/proto pages), sections and section groups, within the search scope described above. If there is a unique match, then the proto link is created to the existing page. If there is not a notebook element with the title match, then a proto link is created to the target page. Proto links will contain an object ID stored with them.
[0040] When a user clicks on a proto link, a page is automatically created using the same proto link object ID. The link can also contain the section ID from where the link is created, in addition to the object ID. The new target page is created with the same object ID in the section denoted by the Section ID.
[0041] When multiple clients are working on a notebook offline and when a proto link is selected, new proto pages are created using the object ID and section ID denoted in the link. When moving back online, even if there are multiple proto pages existing for the same link, the pages will all have the same object ID. The application will detect this as part of the synchronization logic and performs a union merge that consolidates content from all clients that authored this proto page into a single page (using the same object ID) which is the target page for the proto link. This ensures that all proto links are resolved correctly and content in proto pages are complete and correct across online/offline scenarios.
[0042] Note that the proto link, when created, can be shown by a dotted line to denote that this is only a placeholder link (a dotted link) and a corresponding target page does not yet exist. Ex: Customer. In other words, a dotted link is a link in a notebook or wiki that is rendered with a dotted underline as a visual cue to the viewer that this is either a proto link or it links to a placeholder page.
[0043] A placeholder is a page with no content other than a title. Only when a user clicks on this proto link is the new page created as described above. This new page becomes the target page for the proto link. If there is more than one match, then the element matching UI is presented with all the matches. The user can select one or create a new page. The popup 600 of FIG. 6 shows matching to a user entered [[Customer]] on the page.
[0044] FIG. 8 illustrates a method of creating a proto link. At 800 , the method is initiated. At 802 , a proto link is entered in association with proto link syntax. At 804 , the syntax triggers the syntax algorithm. At 806 , a check is performed for an existing notebook element with a title that matches the proto link title. At 808 , if a match is not found, flow is to 810 where the proto link points to a non-existent notebook page. Alternatively, if a match is found, flow is from 808 to 812 where the proto link points to the existing notebook element.
[0045] FIG. 9 illustrates a method of searching for elements having matching identifiers. At 900 , the search for matching identifiers is initiated. At 902 , the current notebook is searched first. At 904 , opened notebooks are searched. At 906 , unfiled notes are searched. At 908 , if a match is not found, flow is to 910 to determine if more than one match is found. If not, flow is from 910 to 912 to create a proto link to a target page and the object identifier for that page. If, however, a match is found at 9089 , flow is to 914 to create the proto link to an existing page. If, at 910 , a match of more than one match is found, flow is to 916 to open a UI showing the matches and let the user select the match.
[0046] As previously indicated, proto links can be shown as dotted links in the notebook/section (in both cases where the user has read-only or read-write permissions). If the proto links are followed and a placeholder page is created, as long as this page remains a placeholder, the link remains dotted. This placeholder page can be shown as a dotted page tab. A dotted page tab is a page rendered with a dotted underline as a visual cue to the viewer that this is a placeholder page. Once this page has content added, the corresponding link becomes an underlined hyperlink. The dotted underline in the page tab can also be removed once the page has content added to it.
[0047] Hyperlinks to placeholder pages can be shown as dotted links to alert the user that the page does not yet have content. Corresponding placeholder pages are denoted as a dotted page tab. Note that the rendering of links or target pages may not occur synchronously with user edits. Thus, there may be a time lag in rendering the current state of some of the links and pages accurately.
[0048] If the user follows a proto link, a new target page for this link is created and the placeholder page appears in the page tab. If the user navigates away from the page and reverts the target page creation, the user can choose a keystroke input (e.g., CTRL-Z) after following the link to the target page. This deletes the page, removes the page from page tab, and keeps the proto link as a dotted link.
[0049] A check is made to determine if there is an existing page with the exact same title match. Only if the page is not available, is a new placeholder page created. This can be a right click menu option and is enabled when there is text selected. Otherwise, this option can remain disabled in the menu.
[0050] As used in this application, the terms “component” and “system” are intended to refer to a computer-related entity, either hardware, a combination of hardware and software, software, or software in execution. For example, a component can be, but is not limited to being, a process running on a processor, a processor, a hard disk drive, multiple storage drives (of optical and/or magnetic storage medium), an object, an executable, a thread of execution, a program, and/or a computer. By way of illustration, both an application running on a server and the server can be a component. One or more components can reside within a process and/or thread of execution, and a component can be localized on one computer and/or distributed between two or more computers. The word “exemplary” may be used herein to mean serving as an example, instance, or illustration. Any aspect or design described herein as “exemplary” is not necessarily to be construed as preferred or advantageous over other aspects or designs.
[0051] Referring now to FIG. 10 , there is illustrated a block diagram of a computing system 1000 operable to execute for proto link creation and processing in accordance with the disclosed architecture. In order to provide additional context for various aspects thereof, FIG. 10 and the following discussion are intended to provide a brief, general description of a suitable computing system 1000 in which the various aspects can be implemented. While the description above is in the general context of computer-executable instructions that may run on one or more computers, those skilled in the art will recognize that a novel embodiment also can be implemented in combination with other program modules and/or as a combination of hardware and software.
[0052] Generally, program modules include routines, programs, components, data structures, etc., that perform particular tasks or implement particular abstract data types. Moreover, those skilled in the art will appreciate that the inventive methods can be practiced with other computer system configurations, including single-processor or multiprocessor computer systems, minicomputers, mainframe computers, as well as personal computers, hand-held computing devices, microprocessor-based or programmable consumer electronics, and the like, each of which can be operatively coupled to one or more associated devices.
[0053] The illustrated aspects can also be practiced in distributed computing environments where certain tasks are performed by remote processing devices that are linked through a communications network. In a distributed computing environment, program modules can be located in both local and remote memory storage devices.
[0054] A computer typically includes a variety of computer-readable media. Computer-readable media can be any available media that can be accessed by the computer and includes volatile and non-volatile media, removable and non-removable media. By way of example, and not limitation, computer-readable media can comprise computer storage media and communication media. Computer storage media includes volatile and non-volatile, 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, CD-ROM, digital video disk (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 be accessed by the computer.
[0055] With reference again to FIG. 10 , the exemplary computing system 1000 for implementing various aspects includes a computer 1002 having a processing unit 1004 , a system memory 1006 and a system bus 1008 . The system bus 1008 provides an interface for system components including, but not limited to, the system memory 1006 to the processing unit 1004 . The processing unit 1004 can be any of various commercially available processors. Dual microprocessors and other multi-processor architectures may also be employed as the processing unit 1004 .
[0056] The system bus 1008 can be any of several types of bus structure that may further interconnect to a memory bus (with or without a memory controller), a peripheral bus, and a local bus using any of a variety of commercially available bus architectures. The system memory 1006 can include non-volatile memory (NON-VOL) 1010 and/or volatile memory 1012 (e.g., random access memory (RAM)). A basic input/output system (BIOS) can be stored in the non-volatile memory 1010 (e.g., ROM, EPROM, EEPROM, etc.), which BIOS are the basic routines that help to transfer information between elements within the computer 1002 , such as during start-up. The volatile memory 1012 can also include a high-speed RAM such as static RAM for caching data.
[0057] The computer 1002 further includes an internal hard disk drive (HDD) 1014 (e.g., EIDE, SATA), which internal HDD 1014 may also be configured for external use in a suitable chassis, a magnetic floppy disk drive (FDD) 1016 , (e.g., to read from or write to a removable diskette 1018 ) and an optical disk drive 1020 , (e.g., reading a CD-ROM disk 1022 or, to read from or write to other high capacity optical media such as a DVD). The HDD 1014 , FDD 1016 and optical disk drive 1020 can be connected to the system bus 1008 by a HDD interface 1024 , an FDD interface 1026 and an optical drive interface 1028 , respectively. The HDD interface 1024 for external drive implementations can include at least one or both of Universal Serial Bus (USB) and IEEE 1394 interface technologies.
[0058] The drives and associated computer-readable media provide nonvolatile storage of data, data structures, computer-executable instructions, and so forth. For the computer 1002 , the drives and media accommodate the storage of any data in a suitable digital format. Although the description of computer-readable media above refers to a HDD, a removable magnetic diskette (e.g., FDD), and a removable optical media such as a CD or DVD, it should be appreciated by those skilled in the art that other types of media which are readable by a computer, such as zip drives, magnetic cassettes, flash memory cards, cartridges, and the like, may also be used in the exemplary operating environment, and further, that any such media may contain computer-executable instructions for performing novel methods of the disclosed architecture.
[0059] A number of program modules can be stored in the drives and volatile memory 1012 , including an operating system 1030 , one or more application programs 1032 , other program modules 1034 , and program data 1036 . Where the computer 1002 supports a collaboration server environment, the one or more application programs 1032 , other program modules 1034 , and program data 1036 can include the link component 102 , identifier component 108 , page (or document) 106 , proto link 104 , page generation component 202 , syntax component 208 , target pages (online page 204 and offline page 206 ), the offline pages 302 and associated links ( 306 and 310 ), the sync component 300 , target page 312 , the collaboration environment 400 (e.g., wiki, notebook, etc.), dialog panel 500 , popup 600 and methods of FIGS. 7 , 8 and 9 , for example.
[0060] All or portions of the operating system, applications, modules, and/or data can also be cached in the volatile memory 1012 . It is to be appreciated that the disclosed architecture can be implemented with various commercially available operating systems or combinations of operating systems.
[0061] A user can enter commands and information into the computer 1002 through one or more wire/wireless input devices, for example, a keyboard 1038 and a pointing device, such as a mouse 1040 . Other input devices (not shown) may include a microphone, an IR remote control, a joystick, a game pad, a stylus pen, touch screen, or the like. These and other input devices are often connected to the processing unit 1004 through an input device interface 1042 that is coupled to the system bus 1008 , but can be connected by other interfaces such as a parallel port, IEEE 1394 serial port, a game port, a USB port, an IR interface, etc.
[0062] A monitor 1044 or other type of display device is also connected to the system bus 1008 via an interface, such as a video adaptor 1046 . In addition to the monitor 1044 , a computer typically includes other peripheral output devices (not shown), such as speakers, printers, etc.
[0063] The computer 1002 may operate in a networked environment using logical connections via wire and/or wireless communications to one or more remote computers, such as a remote computer(s) 1048 . The remote computer(s) 1048 can be a workstation, a server computer, a router, a personal computer, portable computer, microprocessor-based entertainment appliance, a peer device or other common network node, and typically includes many or all of the elements described relative to the computer 1002 , although, for purposes of brevity, only a memory/storage device 1050 is illustrated. The logical connections depicted include wire/wireless connectivity to a local area network (LAN) 1052 and/or larger networks, for example, a wide area network (WAN) 1054 . Such LAN and WAN networking environments are commonplace in offices and companies, and facilitate enterprise-wide computer networks, such as intranets, all of which may connect to a global communications network, for example, the Internet.
[0064] When used in a LAN networking environment, the computer 1002 is connected to the LAN 1052 through a wire and/or wireless communication network interface or adaptor 1056 . The adaptor 1056 can facilitate wire and/or wireless communications to the LAN 1052 , which may also include a wireless access point disposed thereon for communicating with the wireless functionality of the adaptor 1056 .
[0065] When used in a WAN networking environment, the computer 1002 can include a modem 1058 , or is connected to a communications server on the WAN 1054 , or has other means for establishing communications over the WAN 1054 , such as by way of the Internet. The modem 1058 , which can be internal or external and a wire and/or wireless device, is connected to the system bus 1008 via the input device interface 1042 . In a networked environment, program modules depicted relative to the computer 1002 , or portions thereof, can be stored in the remote memory/storage device 1050 . It will be appreciated that the network connections shown are exemplary and other means of establishing a communications link between the computers can be used.
[0066] The computer 1002 is operable to communicate with wire and wireless devices or entities using the IEEE 802 family of standards, such as wireless devices operatively disposed in wireless communication (e.g., IEEE 802.11 over-the-air modulation techniques) with, for example, a printer, scanner, desktop and/or portable computer, personal digital assistant (PDA), communications satellite, any piece of equipment or location associated with a wirelessly detectable tag (e.g., a kiosk, news stand, restroom), and telephone. This includes at least Wi-Fi (or Wireless Fidelity), WiMax, and Bluetooth™ wireless technologies. Thus, the communication can be a predefined structure as with a conventional network or simply an ad hoc communication between at least two devices. Wi-Fi networks use radio technologies called IEEE 802.11x (a, b, g, etc.) to provide secure, reliable, fast wireless connectivity. A Wi-Fi network can be used to connect computers to each other, to the Internet, and to wire networks (which use IEEE 802.3-related media and functions).
[0067] Referring now to FIG. 11 , there is illustrated a schematic block diagram of an exemplary computing environment 1100 for proto link creation and document processing using proto links. The environment 1100 includes one or more client(s) 1102 . The client(s) 1102 can be hardware and/or software (e.g., threads, processes, computing devices). The client(s) 1102 can house cookie(s) and/or associated contextual information, for example.
[0068] The environment 1100 also includes one or more server(s) 1104 . The server(s) 1104 can also be hardware and/or software (e.g., threads, processes, computing devices). The servers 1104 can house threads to perform transformations by employing the architecture, for example. One possible communication between a client 1102 and a server 1104 can be in the form of a data packet adapted to be transmitted between two or more computer processes. The data packet may include a cookie and/or associated contextual information, for example. The environment 1100 includes a communication framework 1106 (e.g., a global communication network such as the Internet) that can be employed to facilitate communications between the client(s) 1102 and the server(s) 1104 .
[0069] Communications can be facilitated via a wire (including optical fiber) and/or wireless technology. The client(s) 1102 are operatively connected to one or more client data store(s) 1108 that can be employed to store information local to the client(s) 1102 (e.g., cookie(s) and/or associated contextual information). Similarly, the server(s) 1104 are operatively connected to one or more server data store(s) 1110 that can be employed to store information local to the servers 1104 .
[0070] What has been described above includes examples of the disclosed architecture. It is, of course, not possible to describe every conceivable combination of components and/or methodologies, but one of ordinary skill in the art may recognize that many further combinations and permutations are possible. Accordingly, the novel architecture is intended to embrace all such alterations, modifications and variations that fall within the spirit and scope of the appended claims. Furthermore, to the extent that the term “includes” is used in either the detailed description or the claims, such term is intended to be inclusive in a manner similar to the term “comprising” as “comprising” is interpreted when employed as a transitional word in a claim. | Architecture that facilitates offline/online interaction with online collaboration documents or pages such as for wikis and/or notebooks. More specifically, for every proto link employed in a page, a unique object ID is provided. The client, whether online or offline, uses the object ID as the page's object ID when a target page is created at the time of resolving the associated proto link (e.g., when a user clicks on a proto link to navigate to the proto page). When an offline client connects to an online state, changes are synchronized (synced). All the pages created offline from the same proto link will have the same object ID and the content of the pages are then synced correctly under the same page ID and name. | 6 |
BACKGROUND OF THE INVENTION
This invention relates generally to devices for mounting antennas, and more specifically relates to a device for mounting an antenna on to a motive vehicle. Still more specifically, the invention relates to a device for mounting an antenna on to various objects and including means to enable the antenna to be moved out of the way of obstructions.
Recently, citizen band (CB) mobile radios are being used extensively throughout the country on passenger cars and trucks, for verbal communications within prescribed small areas. The antenna in a CB system is generally four feet long and attached to a motor vehicle with an antenna mount.
For some of the previously used antenna mounts, holes were drilled into the body of the vehicle, and then the mount was secured with suitable screws and nuts. Other antenna mounts were clamped to the vehicle, and had the advantage of not requiring holes to be made in the vehicle frame. These antenna mounts, for example, were clamped to the lip of a car trunk lid, and the corresponding antenna was positioned normal or perpendicular to the adjacent mounting surface. For the trunk lid having a substantially horizontal surface, the antenna extended in the vertical optimum direction, but for an inclined trunk lid the antenna would also be extending on an incline, which frequently did not provide adequate antenna performance. Also, on many of the late model autos it is sometimes difficult to find a suitable horizontal mounting surface, and consequently the use of such antenna mounts resulted in the antenna extending in an inclined and generally non-optimum direction.
Moreover, with either the aforesaid clamp or screw type antenna mount, the antenna would frequently contact or strike over head obstructions, such as garage doors or small dimensioned tunnels or entranceways leading into loading areas etc., and sometimes would result in permanent damage to the antenna. To avoid this, the antenna was physically removed from the vehicle which was time consuming even for the clamped type antenna mounts, or some antennas were provided with sliding connections for telescoping the antenna segments into a smaller vertical configuration. However, the sliding connections often became corroded and thus formed an electrical insulating barrier, the result of which appreciably reduced antenna performance, and sometimes completely disabled the antenna.
Furthermore, several different types of antenna mounts were required to provide attachment for the variety of different vehicle configurations. Thus, one type of antenna mount was used for attachment to a lip of a car trunk, and another type of antenna mount for a circular bar such, as the a luggage rack or rear view mirror, etc..
Therefore, a primary object of the subject invention is to provide an antenna mount for positioning the antenna in the optimum direction independent of the surface on which the antenna mount is secured.
Another primary object is to provide a movable antenna mount having stationary electrical connections, for transferring electrical signals between the antenna and a receiver or transmitter.
Another primary object of the invention is to provide an antenna mount which may be easily and conveniently pivoted out of the way of an obstruction, for preventing contact therewith.
Another object is to provide an antenna mount, for varying the fixed position of the antenna for optimizing the electrical performance of the antenna.
Another object is to provide an antenna mount capable of being mounted on a plurality of different configurations, such as a planar edge or a cylindrical or rectangular form etc..
Another object of the invention is to provide an antenna mount which can be attached to either a lip of an appendage of a vehicle or to a tubular appendage of a vehicle.
BRIEF DESCRIPTION OF THE DRAWINGS
Referring now to the drawings, in which the same characters of reference are employed to indicate corresponding or similar parts throughout the several figures of the drawings:
FIG. 1 illustrates the antenna mount, embodying the principles of the invention, mounted on the rear window of an automotive vehicle and showing the antenna in phantom in a downward position;
FIG. 2 illustrates the antenna mount secured to the luggage rack on the top of the auto, and showing the antenna in phantom in a downward lateral position;
FIG. 3 is a front view of the antenna mount;
FIG. 4 is an end view of the antenna mount, and showing the antenna segment in phantom being pivoted in opposite directions, and the end view is seen from the plane of the line 4--4 in FIG. 3;
FIG. 5 is a longitudinal sectional view of the mount, and illustrating the mount in a fixed operative position;
FIG. 6 is an exploded view of the component parts of the antenna mount;
FIG. 7 illustrates an elbow adapter connected between the antenna and the spindle of the antenna mount;
FIG. 8 illustrates the attachment of the base plate of the antenna mount to an object having a thickness less than the space between the bent portion and the bottom surface of the base plate;
FIG. 9 illustrates the attachment of the base plate of the antenna mount to a tubular object having a diameter greater than the space between the bent portion and the bottom surface of the base plate;
FIG. 10 illustrates the elongated groove for setting the fixed position for the spindle;
FIG. 11 illustrates the lug of the spindle dis-engaged from the groove prior to the antenna being pivoted to a non-operative position;
FIG. 12 illustrates the outer end of the central conductor of the coaxial cable having a metal sleeve secured thereon; and
FIG. 13 illustrates the lug of the spindle and the groove of the end piece tapered at the same angle.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to the several Figures of the drawings, the reference numeral 10 indicates generally a variable position mounting device for an antenna 12. The device 10 enables the antenna 12 to be pivoted from an upright or vertical fixed, operative-position as shown in FIG. 1 to a downward, non-operative-position shown in phantom, or pivoted from the upright position to the downward lateral position as shown in phantom in FIG. 2.
Turning now more specifically to FIGS. 5 and 6, it will be seen that the device 10 comprises a spindle 14 supported by opposed and spaced apart end pieces 16,18. The spindle 14 includes a threaded opening 20 to receive the threaded bottom end 22 of the antenna 12. The opening 20 is formed transverse or perpendicular to the longitudinal axis of the spindle 14. The spindle 14 is constructed of electrically conductive material suitable for conducting high frequency signals, and the end pieces are constructed of electrically insulative material, such as a suitable teflon or mylar plastic material.
The bottom end 22 of the antenna 12 includes a hex head 24 for engaging a suitable tool when screwing the antenna to the mount 10. The bottom edge of the head 24 may (but need not) lie flush with the flat surface 26 formed adjacent opening 20 in the spindle.
A locking lug 28 protrudes out from one end 29 of the spindle 14 for engagement with an accommodating groove 30 formed inward from the inner edge 31 of the end piece 16. When the lug 28 is received in the groove 30, the end piece 16 is rotated to set the antenna at its operative-position.
A cylindrical rod 32 is integrally formed to the opposite end 33 of the spindle 14 and is positioned inside the hollow cylindrical hole 34 formed in the end piece 18.
The outer surface 36 of the end piece 16 is frusto-conically shaped, tapering in a decreasing cross-sectional circular area from the inner edge 31 to the outer edge 37. The end piece 16 is positioned inside a cavity 38 formed in an end block 40. The defining surface 41 of the cavity 38 is tapered at substantially the same angle as the outer surface 36 of the end piece 16.
A threaded bolt 42 extends through opening 43 in the rear side 44 of the block 40, and is received in the threaded opening 46 formed in the end piece 16. When bolt 42 is loosened or turned to an unlocked-position, end piece 16 is movable inside the block 40 and the spindle 14 is free to rotate. When the bolt 42 is rotated inward or turned to a lock-position, the tapered surface 36 of the end piece 16 tightly engages the tapered surface 41 inside the block 40, and the end piece 16 is no longer movable inside the block 40, and the spindle 14 is thereby locked and unable to be rotated, provided that the lug 28 is retained in the groove 30. The cooperation of the bolt 42 with end piece 16 sets the fixed position for the antenna 12. Since the end piece 16 may be slightly rotated when the bolt 42 is loosened to cause the position of the groove to be slightly varied, the antenna, in turn, is incrementally varied from the original position to another position. If the end piece 16 is rotated a certain angle from an original position, the antenna, will in turn be rotated through the same angle to another position. Securing the lock bolt 42 sets the antenna at a new fixed position.
The end piece 18 includes a cap 48 and a tubular portion 50 extending outward therefrom. The hole 34 extends through both the cap 48 and the tubular portion 50. A compression spring 52 is positioned around the tubular portion 50, and the inner end 53 of the spring abutts the outer edge 54 of the cap 48.
The end piece 18 is positioned inside the cavity 56 formed in an end block 58, which is opposed and spaced apart from the end block 40. A male threaded collar 60 is threadedly received inside the cavity 56 and compresses the spring 52 between the cap edge 54 and the inner edge 62 of the collar 60. The effect of the compressed spring 52 is to resiliently retain or lock the lug 28 inside the groove 30.
When the bolt secures the end piece 16 in position, the fixed position for the antenna is set. If the groove 30 is horizontally positioned as shown in FIGS. 5 and 6, the antenna 12 will be in a fixed vertical position; but if the end piece 16 is rotated so that the groove 30 is angularly positioned with respect to a horizontal or vertical plane, the antenna 12 will also be angularly positioned and held fixed in place by spring 52 locking the lug 28 inside the groove 30.
Turning now specifically to FIG. 5, it will be seen that by applying a side or lateral force F in the direction shown, the spring 52 compresses outward toward the collar 60, and a slight pivoting of the antenna 12 causes the locking lug 28 to disengage from the groove 30. Now, the antenna is free to be rotated from the fixed position determined by the setting of the groove 30. If the force F is removed, the lug 28 will automatically re-lock in groove 30, due to the resilient force of the spring 52 when the antenna 12 is pivoted back to the original fixed position.
A tip 64 extends outward from the locking lug 28 and is received in a central opening 66 formed in the end piece 16 in communication with the groove 30. Even when the locking lug 28 is dis-engaged from the groove 30 as shown in FIG. 12, the tip 64 is still retained in the opening 66, and thereby safeguards the device 10 from jamming when the lug 28 is dis-engaged from the groove 30 and also ensures the re-engagement of the lug with the groove when it is desired to return the antenna to the fixed, operative-position from the non-operative position.
A threaded opening 68 is formed inward from the outer end 69 of the rod 32 of the spindle 14 to receive the coaxial cable 70, and thereby connecting the antenna with the receiver and/or transmitter system (not shown). The cable 70 includes a center conductor 71 which comprises a plurality of strands 72 (FIG. 6). A metal sleeve 74 is positioned around the strands 72 at the inner end of the cable 70 prior to spreading the strands apart. Just slightly outward from the sleeve 74 is a threaded sleeve 76 for engaging the threaded opening 68 in the spindle rod 32. The spread apart strands 72 are tightly sandwiched between the sleeve 74 and inner surface of the opening 68. The flexibility of the center conductor 71 enables the spindle 14 to be pivoted although connected to stationary electrical terminals.
The metal sleeve 74 may be heated first and then slid over the insulation encasing the central conductor 71. The heated sleeve 74 causes the insulation to melt, which forms a securing collar or lip for retaining the sleeve 74 in place. Alternatively, the sleeve 74 may be press fitted or crimped on to the insulation. Thus, the cooperation of the strands 72, metal sleeve 74 and insulation distributes the forces transferred to the cable, as the pivoting of the spindle 16 causes the cable to twist in response thereto.
The outer conductor 78 of the cable 70 provides electrical ground, and is dis-associated from the part of the central conductor inside the rod 32.
The blocks 40 and 58 are rigidly secured, such as by welding or other suitable means, to the top surface 80 of a base plate 82. Base plate 82 includes a bent end portion 84 which is opposed and spaced from the bottom surface 86 of the base plate 82. The space 87 between the bent portion and the bottom surface 86 is dimensioned to permit the mounting device 10 to be positioned on a door, post, trunk lip etc.. In FIG. 1, the base plate 82 is positioned on the lip 90 of the rear car window, and in FIG. 2 the base plate 82 is positioned on the luggage posts 92. A pair of screws 94 are used to fasten the bent end portion 84 to the selected area, in a secure attachment.
A ground screw 96 is positioned in the base plate 82 for mechanically securing the ground conductor 78 of the cable 70. The blocks 40, 58 and plate 82 are constructed of metal, and therefore, are also tied to electrical ground via the conductor 78.
To increase the adaptability of the mount 10, for securing the antenna in the optimum position, an elbow 97 may be used. As shown in FIG. 7, the elbow 97 shifts the antenna position ninety degrees from the position of the antenna 12 in FIG. 5. The elbow 97 is secured to the spindle 14 with the screw member 98, and the antenna 12 is secured to the elbow 97 via the threaded opening 99 receiving the threaded antenna bottom end 22.
As shown in FIG. 6, the base plate 82 includes a rectangular cutout 102 formed therein, which affords greater flexibility for securing the mount 10, to different available mounting surfaces. For example, turn now to FIG. 9, the mount 10 is secured to a cylindrical body 104 having a diameter greater than the space 87 between the bottom surface 86 of the plate and the bent portion 84. A conventional type hose clamp 106 passes through the cutout 102 and tightly locks the cylindrical body 104 against the bottom surface 86 and the outer edge 108 of the base plate 82.
In FIG. 8, the mount 10 is secured to a rectangular bar 110 having a cross-sectional area less than the spacing 87 between the bottom surface 86 and the bent portion 84 of the base plate 82. The bar 110 is in abutting contact with the bottom surface 86 due to the force applied by the screws 94.
In FIG. 12 the strands 72, instead of being free at the tip 112 of the conductor 71 are soldered to the sleeve 74. Preferably, the sleeve 74 is heated with solder, and the conductor strands 72 absorb the heated solder as it is passed through the sleeve 74. The heated sleeve 74 melts the insulation 77 and is thereby securely retained on the insulation of the conductor 71. The tip 112 now tightly fits inside the tapered inner end 114 of the opening 68, and thus affords a positive electrical connection and also functions to distribute forces due to the cable 70 being rotated with the antenna 12. Thus, a fixed electrical connection is maintained, although the cable 70 may be frequently moved and twisted.
In FIG. 13 the groove identified by the reference 30a and the lug identified by the reference 28a, are shown tapered at the same angle. The complementary taper of the lug 28a and the groove 30a enables the spindle 14 to dis-engage when an extraordinary force is applied against the antenna 12, as when the car in FIG. 1 is driven into the garage with the antenna still extending vertically. The spring 52 maintains the antenna in the fixed position, and the applied force would cause the spring 52 to compress and the lug 28a would slide outward, to permit the antenna to pivot downward. If the force were sufficient the lug would slip completely out of the groove 30a and the spindle would freely rotate the antenna out of the path of the obstruction.
The description of the preferred embodiment of this invention is intended merely as illustrative of this invention, the scope and limits of which are set forth in the following claims. | A device for mounting an antenna on a surface or object, and is particularly suitable for use on a motive vehicle. The device is rotatable to a fixed operative-position for the antenna, which may have the antenna projecting in an upright or vertical direction, eventhough the surface on which the device is mounted, is inclined with respect to ground. The fixed operative-position for the antenna may be incrementally varied. Upon the application of an external force, the antenna may be released from the fixed position and rotated to a non-operative position for protecting the antenna, in the event the over head space is limited; and thereafter, the antenna may be returned to the precise operative-position. | 7 |
RELATED APPLICATION
The related application entitled "Control Device for the Actuation of Switchgears according to a Time Program" to J. Lelle and filed concurrently herewith is hereby incorporated by reference.
1. Field of the Invention
The invention relates to a control device having a timing and control logic unit for the actuation of several switch gears.
2. Background of the Invention
Such control devices are used, for example, for the control and monitoring of the burner and the igniting device of oil and gas furnaces, as well as to monitor switches of actuators, such as fuel valves and aeration throttles. A microprocessor evaluates the information transmitted over call circuits carrying the mains voltage and issues appropriate control commands. In particular, because of the safety required when switching on and when operating oil and gas furnaces, the switch-off capability of the switchgears for the loads as, for example, a fuel valve which are critical concerning safety regulations must be checked frequently so that a malfunction of the switchgear can be recognized early, before a dangerous situation may develop.
German patents DE-PS 30 44 047 C2 and DE-PS 30 41 521 C2 disclose a switchgear for oil burners in which information on switching states of relay and sensor contacts are transmitted by means of amplifiers to a microprocessor. The switching states of the relay contacts are transmitted via supply voltage carrying call circuits to respective amplifiers which are connected at the output to an input of the microprocessor. The microprocessor must be provided with a number of inputs at least equal to the number of amplifiers. For the galvanic separation of the call circuit and the microprocessor, separative elements, such as optocouplers or transmitters, are used. Here one separative element per signal voltage is present. The microprocessor is programmed to carry out a number of tests in order to ascertain whether the system having connected sinks actually and correctly goes through a switching-on phase. For this purpose, signals are memorized by the microprocessor and are compared with desired values. In the case of a defective sink state, the microprocessor switches off the sinks.
Furthermore, in an arrangement for the monitoring of alternative-current switches known from DE-OS 41 37 204, call circuits carrying mains voltage are connected via optocouplers to the scanning unit of an alternative-current detector. Each call circuit is connected to the optocoupler via a low pass consisting of a resistance and a capacitor connected in series to the optocoupler. The switching states of the A.C. switches are scanned and stored via the call circuits. In an evaluation unit downstream of the scanning unit, the switching states are compared with a desired state (open or closed) and a switching state signal containing at least one information item (error or no error) for all the existing A.C. switches is formed. It is not possible to know, from the switching state signal, which A.C. switch can no longer be switched off. Therefore, a simple display for diagnosis is not possible.
Optocouplers have been used, for example, as separative elements for the galvanic separation of the monitored system from the microprocessor. Optocoupler applications of this type are known from the specialized literature (TI Opto Kochbuch of 1975, ISBN 3 88078 000 5).
However, the optocouplers are disadvantageous because they are not error-proof and have a higher failure rate than other electronic components. Therefore, they must be checked for false signals also in active operation when used in applications where safety is critical. Furthermore, as the number of optocouplers increases, the electromagnetic compatibility and, thereby, the reliability of the control unit decrease. In systems with many call circuits carrying mains voltage this could involve great costs for as long as an expensive separative element, such as an optocoupler or transmitter and an input pin on the microprocessor, must be provided for each call circuit.
SUMMARY OF THE INVENTION
It is an object of the present invention to design a control device with a control logic unit in such a manner that it easily and reliably acquires information on the state of switchgears switching loads on or off ,where the information is available in the form of low-voltage signals, and transmits it to the control logic unit.
In one embodiment of the invention a control device for controlling a system a burner, for example, is provided. The control device comprises a timing and control logic unit and a plurality of switchgears which are actuated by the timing and control logic unit. A plurality of loads are provided. Each of the plurality of loads is connected in series to one of the plurality of switchgears in a mains voltage network of low tension between a phase and a zero-point. The loads receive current supply from the switchgears. A plurality of call circuits is provided. Each of the plurality of call circuits has an input connected to the series connections of one of the loads and one of the switchgears. A circuit block has a plurality of parallel inputs. Each parallel input is connected to one of the call circuits. The circuit block detects the state of each of the switchgears. The circuit block has a serial data output which is electrically connected to an input of the control logic unit via a serial data line. Each of the call circuits comprises a coupling element having an input connected on the series connection of a load and a switchgear and an output connected to the circuit block. Voltage signals are transmitted from the coupling elements to the circuit block. The voltages have a level of the zero-point when one of the plurality of switchgears is in an open state. The voltages are A.C. or D.C. voltages when one of the plurality of switchgears is in a closed state. The voltages are dependent on a timely voltage course of the phase relative to the zero-point.
The control logic unit causes the detection of the states of the switchgears by the circuit block by carrying out a test cycle. During the test cycle, the voltage signals are detected at the inputs of the circuit block as binary numbers as a function of a predetermined voltage level. Each binary number represents one state of said switchgears. The voltage signals are transmitted via the serial output and the serial data line to the control logic unit.
In another embodiment, the circuit block comprises at least one shift register connected in cascade.
In yet another embodiment, a synchronization device which synchronizes the detection of the voltages at the inputs of the circuit block with the mains voltage is provided.
In yet another embodiment, the detection of the state of the switchgears is made on the basis of state values obtained during a period of one to two half-waves of the mains voltage by multiple scanning.
In still another embodiment, separative elements which galvanically separate the circuit block and the control logic unit are provided.
In another embodiment, the testing cycle is carried out at given points in time to detect the state of the switchgears so as to recognize errors in continuous operation of the system.
In another embodiment, a testing module having one serial data input and a plurality of parallel outputs is provided. The testing module is connected to said control logic unit. The parallel outputs are connected to the inputs of the circuit block. The parallel outputs can be switched into either a conductive or a high-impedance tristate state. The testing module can comprise at least one shift register connected in cascade.
In yet another embodiment, the control device carries out a test cycle to detect input coupling errors or hardware errors of the circuit block at predetermined points in time by entering a test pattern via a serial data line into the testing module, putting the testing module in the conductive state, causing the voltage levels appearing at the inputs of the circuit block to be detected and transmitted to the control logic unit, comparing the returned test pattern with the entered test pattern and putting the testing module back into the tristate state. The test pattern comprises binary values.
BRIEF DESCRIPTION OF THE DRAWINGS
An example of the invention is explained in further detail through the drawings.
FIG. 1 shows a control device for the actuation of several switchgears,
FIG. 2 shows a control device with shift registers and a synchronization device,
FIG. 3 shows voltage diagrams, and
FIG. 4 shows a control device with a testing module.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 shows a control device for a burner having a timer and control logic unit 1 in the form of a microprocessor. The control device comprises two switchgears 2.1 and 2.2, two coupling elements 3.1 and 3.2 and one circuit block 4. The output of the first switchgear 2.1, which switches a load L1 to a mains voltage U PG located between a phase P and a zero point G, is connected to the input of the first coupling element 3.1. The output of the second switchgear 2.2, by means of which an additional load L2 is supplied by the mains voltage U PG , is connected to the input of the second coupling element 3.2. The outputs of the coupling elements 3.1 and 3.2 are connected to parallel inputs 4.1 and 4.2 of the circuit block 4, so that the low-voltage signals V 1 or V 2 which appear at the taps between the switchgears 2.1 or 2.2 and the loads L1 or L2 are transmitted to the circuit block 4 for further processing via the coupling elements 3.1 or 3.2 representing a call circuit ML1 or ML2. The circuit block 4 is electrically connected to the zero-point G via a line 4a. Additionally, the circuit block 4 is connected via two control lines 5a and 5b, as well as a serial output DA and a serial data line 6, to the microprocessor 1 for transmission of the voltage levels U 1 or U 2 present at the inputs 4.1 and 4.2 to the microprocessor 1. The control device can also be designed to control more than two loads, e.g., n=32 loads. Additional loads may also be controlled by the microprocessor 1 without monitoring of the state of the appertaining switchgear and, therefore, they are not connected to the circuit block 4 as the described loads L1 and L2.
The microprocessor 1 is programmed by a time program to switch the loads L1 and L2 on and off in a given sequence by means of the switchgears 2.1 and 2.2 during the switch-on phase of a gas burner, for example, and to monitor different processes, such as the formation of a flame and to switch off the entire system if necessary, so that the gas burner is at no time in danger of exploding. In addition, in continuous operation of the system to be controlled the microprocessor 1 executes a monitoring program for the recognition of error states. In order to determine the state (opened or closed) of the switchgears 2.1 or 2.2, the microprocessor 1 executes a testing cycle, as explained below. The frequency of the testing cycles depends on the application of the control device and the applicable legal provisions or standards. Thus for instance, automatic furnaces which meet the requirements of Standard EN 298 must recognize an error within a period of three seconds following its occurrence. A testing cycle is, therefore, executed typically every 200 milliseconds. In this manner, it is possible to reliably ascertain the state of each of the switchgears 2.1 or 2.2 within the required three seconds also if the state of one of the switchgears 2.1 or 2.2 has just changed during a testing cycle.
In the closed state of switchgear 2.1, as shown in FIG. 1, a current flows through this switchgear 2.1 and the appertaining load L1. Therefore, at the input of the coupling element 3.1, an A.C. voltage appears in the form of a low-tension signal V 1 which is substantially equal to the mains voltage U PG . In the open state of the switchgear 2.2, as shown in FIG. 1, a low-tension signal V 2 in the form of a D.C. voltage corresponding to the zero point G appears at the input of the coupling element 3.2. The coupling elements 3.1 and 3.2 serve in a known manner for the rectification of the low-voltage signals V 1 and V 2 and for the limitation of their level to the processable input levels of the circuit block 4. The coupling elements 3.1 and 3.2 also drain off overvoltages to the zero-point voltage G in order to prevent destruction of the circuit block 4 by voltage or current impulses. To this purpose the coupling elements are connected to the zero-point circuit G in a manner not shown here. A signal voltage U 1 thus appears at the input 4.1, its form and/or level being clearly different from the D.C. voltage U 2 with zero-point level G appearing at the input 4.2.
The testing cycle for the determination of the state of the switchgears 2.1 or 2.2 is as follows: at a suitable moment the microprocessor 1 causes the signal voltages U 1 and U 2 at the inputs 4.1 and 4.2 of the circuit block 4 to be detected according to a predetermined voltage level in the form of binary numbers "0" or "1" in parallel and to be transmitted thereupon to itself via the serial output DA of the circuit block 4 and the serial data line 6. A number "0" represents an open state and a number "1" a closed state.
The described control device makes it possible to use a control logic unit 1, particularly a microprocessor, with a number of inputs which may be substantially lower than the number m of the loads L1 to Lm whose appertaining switchgears 2.1 to 2.m must be monitored for their contact positions. In a control device or unit where the control logic unit 1 must be galvanically separated from the mains voltage U PG for reasons of safety, additional advantages with respect to reliability, electromagnetic compatibility and costs are achieved. These advantages are due to the fact that the control logic unit 1 can be separated from the circuit block 4, and thereby, also from the mains voltage U PG with only few galvanic separative elements. Therefore, the number of galvanic separative elements can also be considerably lower than the number m. A malfunction of one of the switchgears 2.1 or 2.2 is easy to indicate, since the information on the state of each of the switchgears 2.1 or 2.2 is available in the control logic unit 1 and can be displayed by simple means, e.g., luminous diodes or an LCD display.
Such a device can also be used as a signalling device to scan the position of switching contacts and to display them in process equipment.
Instead of the microprocessor 1, it is also possible to use a microcontroller, an application-specific integrated circuit (ASIC) or a programmable area logic (PAL). The control devices are suitable for operation in a D.C., as well as in an A.C. network, whereby the mains voltage U PG may also be in the range of low voltages, with a typical value of 24 V.
For the operation of the control unit in a D.C. network, synchronization for data collection is not required, while it is necessary for operation in an A.C. network. FIG. 2 shows a control device for operation in an A.C. network having n=16 switchgears, 2.1 to 2.16. FIG. 3 illustrates the time diagrams of the voltages U PG , U 1 , U 2 , U R and U SH/LD , as explained below. The control device is equipped with a circuit block 4 consisting of two shift registers 7.1 and 7.2 and of a synchronization device 8. For the sake of clarity, only the switchgears 2.1 and 2.2 and the coupling elements 3.1, 3.2, 3.8, 3.9 and 3.16 are drawn. The shift registers 7.1 and 7.2 have eight parallel inputs 4.1 to 4.8 or 4.9 to 4.16 as well as a serial data input DE and a serial data output DA. In the control lines 5a and 5b, as well as in the data line 6, optocouplers 9, 10 or 11 are installed and are used for galvanic voltage separation between the microprocessor 1 and the circuit block 4 under mains voltage. The optocouplers 9 and 10 are followed by a NAND element 9a or 10a for level reversal.
The modules MM74HC165 of National Semiconductor can be used as shift registers 7.1 and 7.2. They are provided with a clock input CL, a clock inhibit input INH and a shift/load input SH/LD for data collection and data output. Their operation is described in "MM47HC/47HC High-Speed CMOS Family Databooklet, National Semiconductor Corporation, 1981".
The synchronization device 8 has two inputs 8a and 8b and one output 8c. The input 8a is connected to the output of the NAND element 9a and to the control input INH of the shift registers 7.1 and 7.2. The mains voltage U PG appears at the input 8b. The output 8c is connected to the input SH/LD of the two shift registers 7.1 and 7.2. The serial output DA of the second shift register 7.2 is connected to the serial input DE of the first shift register 7.1, so that a cascade connection is created.
The switchgear 2.1 is in a closed state so that a sinusold alternative voltage appears at the input of the coupling element 3.1 in the form of a low-voltage signal V 1 . The coupling links 3.1 to 3.16 are known as a network of resistances, capacitors, diodes and a Z-diode, arranged so that a single-way rectified rectangular voltage U 1 appears at the output of the coupling element 3.1, with a level of a few volts, e.g., 5.7 V, relative to the zero point G.
The switchgear 2.2 is in the open state so that the low-voltage signal V 2 at the input of the coupling element 3.2 has the form of a D.C. voltage which appears at the output of the coupling element 3.2 as D.C. voltage U 2 with the zero-point level G.
The synchronization device 8 is provided with a coupling element 8d behind its input 8b, built up similarly to the coupling elements 3.1 to 3.16. A pulsating rectangular voltage U R appears at the output of the coupling element 8d. The phase of the rectangular voltage U R is synchronized with the rectangular voltage U 1 at the input 4.1 of the shift register 7.1. The output of the coupling element 8d is connected to the one input of a NAND element 8e and the control line 5a via input 8a to the other input of the NAND element 8e. The outputs of the NAND elements 9a, 10a and 8e are advantageously equipped with Schmitt-Trigger steps in order to obtain well-defined switching.
In normal operation of the control unit, the control lines 5a and 5b at the output of the microprocessor 1 are on low potential, so that the optocouplers 9 or 10 are in a dimmed state, while the control lines 5a and 5b, after the NAND elements 9a or 10a, carry a high potential because of the level reversal. Thus, a logically high state exists at the input INH while a pulsating rectangular voltage U SH/LD , which is complementary of the rectangular voltage U R , appears at the input SH/LD. Whenever the rectangular voltage U SH/LD changes from high to low potential, the voltage levels U 1 to U 16 , which are present at the inputs 4.1 to 4.16 of the shift registers 7.1 and 7.2, are detected as logic state value "0" or "1" and are stored in the registers. The phase of the rectangular voltage U SH/LD relative to the rectangular voltage U 1 is coordinated by means of the coupling element 8d so that the change-over of the rectangular voltage U SH/LD from high to low occurs whenever the voltage U 1 is already high, and a value "1" representing a logically high potential is memorized as state value of the switchgear 2.1 which is in the closed state. Since the switchgear 2.2 is open, the voltage U 2 is recognized according to a logically low potential as state value "0". In this manner, the parallel loading of the shift registers 7.1 and 7.2 always takes place at a point in time when a voltage level of a few volts appears at the inputs 4.1 to 4.16 in the closed state of a switchgear or a voltage level of zero volt relative to the zero-point level G in the open state of a switchgear. The constant data acquisition offers the advantage that the current states of the switchgears 2.1 to 2.16 are always available in the shift registers 7.1 and 7.2. To read the state values from the shift registers 7.1 and 7.2, the microprocessor 1 sets the control line 5a on high potential whereby a high potential also appears at the SH/LD inputs. In this manner, the data acquisition of the shift registers 7.1 and 7.2 is locked. With every shift impulse transmitted thereafter by the microprocessor 1 via the control line 5b, the detected state values are shifted by one place in the direction to the output DA of the shift registers 7.1 and 7.2. A value appearing at the output DA of the second shift register 7.2 is thus transmitted via the connection line to the serial input DE of the first shift register 7.1. A value appearing at the output DA of the first shift register 7.1 is transmitted over the serial data line 6 and the optocoupler 11 to the microprocessor 1. Following the first shift command the state value of the switchgear 2.1 thus arrives at the input of the microprocessor 1. Following the second shift command, it is the state value of switchgear 2.2, etc., until the state value of switchgear 2.16 arrives after the 16th shift command. The testing cycle to be carried out by the microprocessor 1 in order to detect the state of the switchgears 2.1 to 2.16 thus consists of the control commands required to lock the data acquisition and to read the shift registers 7.1 and 7.2.
The circuit arrangement with the shift registers 7.1 and 7.2 is advantageous because commercially available standard elements are used by means of which the control device can easily be expanded for any number of switchgears just by cascading. The utilization of the synchronization device 8 makes it possible to lay out the coupling elements 3.1 to 3.16, which only need to deliver a single-way rectified rectangular voltage at their output, in a simple manner. The memory requirements for the programming of the testing cycle are low because the testing cycle mainly comprises shift commands.
The synchronization device 8 is a hardware device used to ascertain that the state information of the switchgears 2.1 to 2.16, which is contained in the signal voltages U 1 to U 16 , is correctly acquired. This information could also be obtained by means of software, through multiple interrogation within a time period of one to two network half-waves, and an analysis of the values acquired in the time sequence, so that a synchronization device 8 would not be needed. Such examples of embodiments are described in the patent application "Controls for the Actuation of Switchgears according to a Time Program" by the inventor Josef Lelle which is subject to a parallel submission to the European Patent Office and filed concurrently herewith in the United States Patent Office. The text of which is an integral part of the instant application and is hereby incorporated by reference.
FIG. 4 illustrates a further development of a device for the control of up to n=8 switchgears 2.1 to 2.8 which are expanded by one testing module 12 to detect input coupling errors or hardware errors of the shift register 7. An input coupling error may occur, for example, if the state value read into the input 4.2 not only depends on the voltage level at input 4.2 but also on the voltage level which is present at another input, e.g., 4.5. A hardware error occurs when the read state value of an input always appears as logic "0" (stack at zero) or logic "1" (stack at one), whatever the appearing voltage level may be.
The testing module 12 is provided with a serial data input, a cycle input and an input which controls the state of its outputs 12.1 to 12.8. All of these inputs are connected via circuits 13, 14 or 15 to the microprocessor 1. Parallel outputs 12.1 to 12.8 are connected via circuits 16.1 to 16.8 to the corresponding inputs 4.1 to 4.8 of the shift register 7. The outputs 12.1 to 12.8 can be switched to a state which is known in the field as "tristate", in which they are high-impedance outputs and do not influence the state of the circuits 16.1 to 16.8 (see, e.g., U. Tietze and Ch. Schenk, "Semiconductor Switching Technology" (Halbleiterschaltungstechnik), 5th edition, Springer Verlag Berlin Heidelberg New York, ISBN 3-540-09848-8). The inputs 4.1 to 4.8 of the shift register 7 are also connected to the outputs of the coupling elements 3.1 to 3.8, but only the coupling element 3.1 is drawn for the sake of clarity. The testing module 12 as well as the shift register 7 are connected to the zero-point line G.
The control device illustrated in FIG. 4 functions as follows.
In normal operation the outputs 12.1 to 12.8 of the testing module 12 are in the tristate state and do not influence the voltages U 1 to U 8 at the inputs 4.1 to 4.8. To test the reliability of data acquisition by means of the circuit block 4 the microprocessor 1 carries out a test cycle at given points in time. During the test cycle, the microprocessor 1 transmits a test pattern consisting of eight binary values "0" or "1" via the serial circuit line 13 to the testing module 12. Following this transmission, these values are available as high or low voltages at the outputs 12.1 to 12.8 as soon as the microprocessor 1 puts the outputs 12.1 to 12.8, in a conductive state via control circuit line 15, so that voltage levels U 1 to U 8 with high or low voltage values, depending on the previously transmitted test pattern, appear at the inputs 4.1 to 4.8 of the shift register 7. The microprocessor 1 now transmits further commands to the shift register 7 in order to detect the voltage levels U 1 to U 8 at its inputs 4.1 to 4.8 as binary values and for their transmission to it. The microprocessor 1 then compares the reported binary values with the transmitted test pattern. The microprocessor 1 is programmed to transmit a number of selected test patterns to the testing module 12 and to read them again via shift register 7, so that input coupling errors, as well as hardware errors, can be detected. If necessary the control circuit lines 13, 14 and 15 can be provided with galvanic separative elements.
Finally, the above-described embodiments of the present invention are intended to be illustrative only. Numerous alternative embodiments may be devised by those skilled in the art without departing from the spirit and scope of the following claims. | Information appearing in the form of analog low-voltage signals (V 1 ;V 2 ) on call lines (ML1;ML2) which represents the states of switchgears (2.1;2.2) is conveyed in parallel to a circuit block (4). The information is digitalized at certain points in time and in accordance with a predetermined voltage level as binary values "0" or "1" and is transmitted in series to a control logic unit (1). The circuit block (4) is preferably a plurality of shift registers in cascade connection. Each call line is coupled via a coupling element (3.1;3.2) to the circuit block (4) so that the circuit block (4) is not destroyed even when overvoltages occur. In the closed state of a switchgear (2.1;2.2), a signal voltage (U 1 ;U 2 ) with changeable course appears at the corresponding input (4.1;4.2) of the circuit block (4). In the open state of a switchgear (2.1;2.2), the signal voltage (U 1 ; U 2 ) is a uniform signal (U 1 ;U 2 ). The digitalization is effected by means of a synchronization device (8) at points in time when the level of the changeable signal voltage (U 1 ;U 2 ) is clearly different from the level of the zero-point voltage (G). These controls are especially well suited to control an oil or gas burner in continuous operation. | 5 |
BACKGROUND OF THE INVENTION
The present invention is directed to an apparatus and method for manufacturing articles made of polyurethane. More specifically, the invention is directed to an apparatus having a mix chamber positioned below and in direct communication with a mold assembly.
Polyurethane foam has been used for many years for cushioning, insulation and other applications. Polyurethane foam is usually manufactured at atmospheric pressure from polyester or polyether based polyols combined with isocyanates, such as toluenediisocyanate (TDI), polymethylene polyphenylisocyanate (MDI), or mixtures thereof, and additives to form a finished product ranging from a very flexible to a very rigid product. The cell structure of the foam can range from completely open to completely closed. Examples of open cell, flexible polyurethane foam technology are disclosed in U.S. Pat. No. 4,451,583.
Expanded flexible polyurethane articles can be manufactured by the continuous conveyor method or by the molding method. Most expanded flexible polyurethane is currently produced by the continuous conveyor method for producing slabs or by molding articles in a noncontinuous process. The continuous conveyer method or "slab-stock" method is used to process the majority, by weight, of flexible polyurethane foam. In this method, the liquid chemicals are mixed together and poured on a carrier sheet of plastic or paper. The carrier sheet rests either on a conveyor flat floor with two vertical sides or on a conveyor with a round shape. As the chemicals proceed down the conveyor, they rise or expand in the form of closed cells. In the case of open cell foam, as the reacting chemicals reach full expansion, the cell walls open and flow into struts. These struts continue to solidify until an almost cured dry article is formed. At the end of the conveyor, a saw cuts off a length of the article, The article is then taken to a storage area for final curing, which usually takes about 24 hours. This process is continuous until the machine is stopped.
In the alternative molding method, the liquid chemicals are mixed and deposited in a mold, with or without a lid, and the chemicals expand to the shape of the mold. It is important that the chemicals in a mold be mixed in a short interval of time so that the chemicals react properly. One common prior art molding method for large parts is known as the "bucket method". In the bucket method, a mix chamber for mixing the liquid chemicals is located above the interior of a separate mold. The chamber is removed after the mixed chemicals are released in the mold. The chemicals expand and an article is formed in the mold. The bucket method has the disadvantage of being relatively complicated, difficult to clean, and produces foam full of blow holes. Further, the mix chamber in the bucket method is not in direct communication with the mold.
The present invention overcomes the disadvantages of the bucket method while retaining the major bucket method advantage of mixing the chemicals all at once. The mix chamber in the present invention is in direct communication with the mold. The present invention can be used alone to produce polyurethane articles with or without auxiliary blowing agents. It can also be used in a vacuum chamber to eliminate blowing agents as disclosed in my U.S. Pat. No. 5,182,313, the teachings of which are incorporated herein by reference, or a positive pressure chamber depending on the application.
SUMMARY OF THE INVENTION
The present invention is directed to an apparatus and method for manufacturing articles made of polyurethane. The apparatus includes a mold assembly in communication with a mix chamber. The mix chamber is positioned below the mold assembly. The mix chamber includes a propeller for mixing the liquid polyurethane chemicals. The mix chamber further includes a pneumatically actuated bladder that causes the mixed chemicals to move from the mix chamber to the mold assembly. The chemicals react in the mold assembly and expand to take on the shape of the mold. The method of the present invention comprises the steps of: (a) selecting polyurethane chemicals having certain specific weights; (b) placing the chemicals in a mix chamber wherein the chemicals stratify according to their specific weights to prevent detrimental reaction among the chemicals until final mixing; and (c) allowing said chemicals to expand to form an article.
It is the primary object of the present invention to provide an apparatus and method for manufacturing a variety of articles made of polyurethane.
It is an important object of the present invention to provide an apparatus having a mix chamber positioned below and in direct communication with a mold assembly.
Other objects and advantages of the invention will become apparent as the invention is described hereinafter in detail and with reference to the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side view of the apparatus of the present invention with the walls of the mold assembly and the mix chamber partially cut away to show the interior of the mold assembly and the mix chamber; and
FIG. 2 is a detailed side view of the mix chamber with the walls partially cut away.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to the drawings, the apparatus of the present invention is identified by reference numeral 10. The apparatus 10 includes a mold assembly 12. The mold assembly 12, which is preferably made of metal components, includes a top cover 14 and a body 16. In the present embodiment, the body 16 consists of a detachable wall 18 having a cylindrical shape. However, it should be understood that the body 16 can be formed in a variety of shapes and have any number of walls. The mold assembly includes a plastic liner 24 along the interior of the body 16. The liner 24 is fastened to the mold assembly 12 by upper and lower resilient elastic members 30 and 32, respectively, that extend around the exterior surface of the body 16. The plastic liner 24 can be made of a variety of materials with polyethylene, polypropylene and polyvinyl chloride plastics being preferred. The liner 24 has a thickness of approximately 0.025 to 0.25 mm with 0.125 mm being preferred.
The mold assembly includes a pump 34 that is in communication with the interior of the mold assembly body 16 by a conduit 36. The conduit 36 extends through the wall 18. When the pump 34 is actuated, air that is between the liner 24 and the interior of the body 16 is evacuated thereby creating a vacuum in this space. The vacuum forces the liner to adhere to the interior of the body 16. This results in a smooth molding surface within the mold assembly 12.
The mix chamber 50 is shown in FIGS. 1 and 2. The mix chamber 50 is positioned below the mold assembly 12. The chamber 50, which is preferably made of metal components, includes a shell 52 having a base 54 and an upwardly extending shell wall 56. The base 54 includes an insert plug 57 held in position by threaded studs 58 and nuts 59. The shell 52 is supported by a mix chamber frame 60 that includes a shell support member 62 and a propeller support member 64. The frame 60 also includes a mold assembly support member 66. A flexible mold bottom liner 68 is positioned between the support member 66 and the body 16. The liner 68 is constructed of a durable plastic material similar to the liner 24 of the mold assembly 12.
Referring to FIG. 2, the base 54 of shell 52 includes at least one opening for passage of polyurethane chemicals to the interior of the shell. In the present embodiment, the base includes a first opening 70 for the passage of polyol and additives and a second opening 72 for the passage of isocyanate. A conduit 74 extends through the first opening 70. The conduit is in communication with a manifold 76. The manifold 76 channels the flow of polyol and additives, such as water, amine, silicone and tin, from a polyol conduit 78 and additive conduits 80A-D. The conduits 78 and 80A-D are in communication with polyol and additive sources (not shown). The polyol and additives are moved by pumps 82 and 84A-D, respectively.
A conduit 88 extends through the second opening 72. The conduit 88 is in communication with a valve 90, The valve 90 is in communication with a conduit 92 that is connected to an isocyanate source (not shown). The movement of the isocyanate is caused by a pump 94.
It should be understood that the liquid chemicals can be introduced from the bottom, as shown in the drawings, or from the top of the mix chamber 50, or introduced from the top and bottom depending on the application. As described in detail below, the chemicals can be introduced to the mix chamber in various ways to stratify the individual chemicals to prevent a detrimental reaction.
In the present embodiment, slow speed pumps (82 and 84A-D) are used to place the chemicals in the mix chamber 50 through the base 54 of the shell 52. Slow speed pumps are relatively inexpensive and thus make the overall apparatus less expensive to manufacture. The chemicals are pumped into the mix chamber 50 in a manner and sequence that, due to the specific weight differences among the chemicals, they stratify such that chemicals that react aggressively with each other are separated from each other by chemicals with which they do not react aggressively. This stratification separates the chemicals in a manner such that within the time it takes to pump all the chemicals into the mix chamber using slow pumps no significant chemical reactions occur in the chemicals. The stratification also allows the chemicals to rest in the mix chamber for a period of time without significant reaction.
Still referring to FIG. 2, the insert plug 57 of the base 54 includes an opening 96 through which extends a propeller shaft 98 connected at one end to a motor 100 and at the other end to a propeller 102. An O-ring 104 maintains proper alignment of the shaft 98 within the opening 96 and provides a fluid-tight seal. The shaft 98 is connected to the motor 100 by a coupling pin 106. The propeller 102 can include any number of blades 108, with two being preferred. It should be understood that various mixing devices can be used to mix the chemicals.
A bladder 110 covers at least a portion of the interior of the shell 52. In the present embodiment, the bladder 110 extends from the top edge 112 of the shell wall 56 to a bottom edge 114 in the shell base 54. The bladder 110 is secured to the shell 52 so that the space between the bladder 110 and the shell wall 56 is substantially fluid-tight. The bladder 110 is constructed of a durable plastic material similar to the liner 24 of the mold assembly 12.
A passageway 120 extends through one of the shell walls 56. A conduit 122 is in communication with the passageway 120. The conduit 122 is in communication with a 3-way valve 124 that regulates the flow of a fluid, such as air, from pumps 126 and 128. The pump 126 causes air to flow through conduit 122 and into the space between the bladder 110 and the shell wall 56. The pump 128 creates a vacuum thereby evacuating air from the space. The movement of air into and out of the space causes the bladder 110 to expand and contract accordingly during the molding process. As it will be readily apparent to one skilled in the art, the expansion and contraction of the bladder 110 can also be done mechanically. Further, the flexible plastic bladder 110 as shown in the drawings can be replaced by a relatively inflexible member in communication with a mechanical device that could force the chemicals from the mix chamber 50 to the mold assembly 12.
During the apparatus assembly process, the insert plug 57 is positioned in the base 54 over the bladder 110 that has been placed along edge 114. The nuts 59 are then threaded to studs 58 to affix the plug 57 to the shell support member 62. This forms a fluid-tight seal in the bottom of the bladder 110. The top of the bladder 110 is then folded over the edge 112 of the shell wall 56. The pump 128 is activated to provide a vacuum to the space defined by the bladder 110 and the wall 56. The vacuum holds the bladder 110 tightly against the shell 52 and away from the blades 108 of the propeller 102 during the mixing of the chemicals.
The shaft 98 of the propeller 102 is inserted through opening 96 and attached to the motor 100. The polyol/additive conduit 74 and the isocyanate conduit 88 are then inserted in first opening 70 and second opening 72, respectively. The shaft and conduits fit tightly within their respective openings to prevent leakage.
The mold bottom liner 68 is positioned on the upper surface of the support member 66 to form a fluid-tight seal with the bladder 110 at the edge 112 of the wall 56. The liner 24 of the mold assembly is then positioned in the interior of the body 16. Top and bottom portions of the liner 24 are folded to the exterior of the body 16 and fastened to the exterior by elastic members 30 and 32, respectively. The mold assembly 12 is then positioned on top of and affixed to the mix chamber 50 providing a fluid-tight seal. When so positioned, the top of the shell 52 is in direct communication with the interior of the mold assembly 12. The top cover 14 is placed on the mold assembly 12. A vacuum is then applied through the conduit 36 by the pump 34 to draw the liner 24 against the mold body 16.
During the molding process, polyol and additives are pumped into the mix chamber 50 through conduit 74 by pumps 82 and 84A-D through valve 76. Isocyanate is then pumped into the mix chamber 50 through conduit 88 by a pump 92 through valve 90. When all of the liquid chemicals are in the chamber 50, the motor 100 is activated to cause propeller 102 to rotate. The chemicals are then mixed through agitation by the propeller blades 108. After the mixing is complete, the motor is deactivated. The chemicals begin to rise from the mix chamber 50 into the mold assembly 12. At the time the mixing cycle is complete, the valve 124 is switched from the vacuum pump 128 to the positive pressure pump 126 by valve 124. This causes air to pass through the conduit 122 and into the space defined by the bladder 110 and the shell 52. As shown in FIG. 1, the expansion of the bladder 110 forces the expanding chemicals out of the mix chamber 50 and into the mold assembly 12 for final forming. The electrical control system that operates the pumps, valves, motor and counters are not shown. The system is known in the art and is standard for an apparatus of the type disclosed herein.
After curing of the formed article, the mold assembly is disassembled and the article is removed. The apparatus is then cleaned and reassembled as described above for subsequent molding operations.
EXPERIMENTAL DATA
Test formulas, physical properties and experimental data are set forth below.
______________________________________TRIALChemical Proportion Specific weight______________________________________Polyol 4.94 kg 1.01Water .20 kg 1.00Amine catalyst .01 kg .87Silicone .10 kg 1.04Tin .01 kg 1.10Isocyanate 2.42 kg 1.22______________________________________
Polyol=3000 molecular weight polyether triol with a functionality of about 3.1.
Isocyanate=toluene diisocyanate (TDI) with an 80-20 ratio of 2,4 and 2,6 isomers.
All of the above proportions in the above chemical formula are by weight.
The specific weight listed for each chemical is the number that expresses the ratio between the weight of a given volume of listed substance and the weight of an equal volume of water.
EXAMPLE
The following example was produced in a cylindrically shaped mold that was 56 cm in diameter by 122 cm in height. The temperature of the mold was maintained at a constant 21° C.
About 1.36 kg of polyol listed in the formula of Trial is pumped into the mix chamber shell 52. All of the water, amine and silicone are then separately pumped into the shell 52. About 1.36 kg of polyol is then pumped into the shell 52. All of the tin is then pumped into the shell 52. The remaining polyol, about 2.22 kg, is then pumped into the shell 52. All of the isocyanate is then pumped into the shell 52. Due to the specific weights of the various chemicals, as stated above, they are stratified in layers in the mix chamber shell 52. This allowed the chemicals to be pumped into the shell 52 over a relatively long period of time. It also allowed the chemicals to rest within the shell 52 for a relatively long period of time without a detrimental reaction.
When the forming process began, the mix motor 100 was activated causing the propeller 102 to rotate at 600 rpm for approximately 15 seconds. The chemicals were completely mixed. The chemicals listed in the formula of Trial were selected and placed in the mix chamber 50 such that no detrimental reaction occurred among them before mixing and they were mixed in a manner that assured that the reaction age throughout the article was uniform as it was being formed.
After mixing, the chemicals expanded and rose through the top opening of the shell 52 and into the mold assembly 12. At the time the mixing stopped, the valve 124 applied approximately 1 kg/cm 2 positive pressure on the bladder 110. This caused the bladder 110 to expand and force the expanding chemicals out of the shell 52 and into the mold assembly 12. The expanding chemicals were formed into an article in the shape of the mold.
The chemicals were allowed to cure for 10 minutes in the mold assembly 12. The mold assembly was then disassembled and the finished article was removed. The apparatus 10 was then cleaned and reassembled for the next molding operation.
The above example produced an open cell flexible polyurethane article having a density of 0.68 kg/m 3 . The core density was determined after the outer surface was removed from the molded article. The weight of the chemicals placed into the apparatus was sufficient to compensate for the high density of the removed outer surface and to compensate for the off-gassing that occurred during the chemical reaction.
It should be understood that variations of the chemicals listed in Trial, with the exception of water, are available in other specific weights. Further, chemicals that perform substantially the same function are available that react in different ways.
The above detailed description of the present invention is given for explanatory purposes. It will be apparent to those skilled in the art that numerous changes and modifications can be made in the example of the invention described above without departing from the scope of the invention. Accordingly, the whole of the foregoing description is to construed in an illustrative and not a limitative sense, the scope of the invention being defined solely by the appended claims. | An apparatus for manufacturing articles made of polyurethane that includes a mold assembly in communication with a mix chamber. The mix chamber is positioned below the mold assembly. The mix chamber includes a propeller for mixing the liquid polyurethane chemicals. The mix chamber further includes a pneumatically actuated bladder that causes the mixed chemicals to move from the mix chamber to the mold assembly. The chemicals expand to take on the shape of the mold. The method of the present invention comprises the steps of: (a) selecting polyurethane chemicals having certain specific weights; (b) placing said chemicals in a mix chamber wherein chemicals stratify according to their specific weights to prevent detrimental reaction among the chemicals until final mixing; and (c) allowing the chemicals to expand to form an article. | 1 |
FIELD OF THE INVENTION
The present invention relates to a dental implant for the attachment of an artificial tooth.
BACKGROUND OF THE INVENTION
Dental treatments comprising implanting a dental implant at a site where a tooth or teeth are missing, and, with the dental implant as a root, attaching an artificial tooth onto the top of the dental implant as a substitute for a natural tooth, have been clinically applied, and are known in the art.
Such dental implants are conventionally made of metals such as titanium and a cobalt/chromium/molybdenum alloy. In recent years, alumina ceramics have received increasing attention because of the superior in vivo characteristics thereof, and are now in widespread use.
Various techniques for implanting a dental implant are known; a very popular technique is as follows:
Mucosa at a site where a tooth or teeth are missing is peeled apart, a grooved or tapped hole conforming to the shape of the root portion of the dental implant is formed in a jaw bone, and thereafter, the dental implant is placed in the hole and the mucosa is closed. In accordance with another method, a dental implant is implanted in a tooth extraction hole.
These methods, however, suffer from the following disadvantages:
(1) Although metal has sufficiently high mechanical strength, it has poor affinity for human bones because of their different properties. Moreover, the metal can be ionized and eluded, exerting adverse influences on the human body.
(2) Although alumina ceramics are not harmful to human body, they are very hard compared with human bones and have poor affinity therewith. Therefore, when a dental implant of such alumina ceramics is used for a long period of time, a clearance is formed, resulting in damage to the jaw bone at the adhesion site.
It is described in Japanese patent application (OPI) No. 50194/79 (the term "OPI" as used herein refers to a "published unexamined Japanese patent application") that the surface of stainless steel can be coated with calcium phosphate to alleviate the foregoing problems. However, this calcium phosphate is gradually replaced in vivo by bone tissue and, finally, the bone and stainless steel may come into contact with each other.
There is also a danger of stainless steel's corroding over a long time period of use, and exerting adverse influences on the human body.
SUMMARY OF THE INVENTION
The present invention relates to a dental implant for the attachment of a artificial tooth, comprising a root portion to be embedded in bone and a top portion to be projected in the mouth from the tooth mucosa, wherein the root portion comprises a high strength metal substrate, a ceramic or glass (i.e., a material selected from the group consisting of ceramics and glass) coating layer on the metal substrate, and a calcium phosphate coating layer on the ceramic or glass coating layer.
In a preferred embodiment of the present invention, in order to increase an adhesion area between the ceramic or glass coating layer and a bone tissue, thereby improving the adhesion strength, the ceramic or glass coating layer is fabricated so as to have an irregular surface, which is threaded or horizontally grooved at a pitch of about 0.1˜1 mm.
BRIEF DESCRIPTION OF THE DRAWING
The drawing is a cross-sectional view of a site wherein a dental implant in accordance with the present invention is implanted.
DETAILED DESCRIPTION OF THE INVENTION
The term "calcium phosphate" as used herein includes various types of calcium phosphate, e.g., from those compounds containing a large amount of calcium phosphate to those compounds called "apatite ceramics". Suitable examples include, e.g.: (1) high strength calcium phosphate as described in Japanese patent application (OPI) No. 56052/80 which is prepared by adding from 0.5 to 15% by weight of a calcium/phosphoric acid-based frit (Ca/P atomic ratio: 0.2/1 to 0.75/1) based on the weight of calcium phosphate component after calcined to powder composed mainly of calcium phosphate (Ca/P atomic ratio: 1.4/1 to 1.75/1) and, thereafter, melting the resulting mixture: (2) high strength calcium phosphate as described in Japanese patent application (OPI) No. 140756/80 (which corresponds to U.S. Pat. No. 4,376,168) which is prepared by adding from 0.5 to 15% by weight of alkali metal, zinc and/or alkaline earth metal oxide/phosphoric acid-based frit to the above-described calcium phosphate (Ca/P atomic ratio: 1.4/1 to 1.75/1), and thereafter calcining the resulting mixture; and high strength calcium phosphate as described in Japanese patent application (OPI) No. 80771/80 (which corresponds to U.S. Pat. No. 4,308,064), which is prepared by calcining a mixture of powder composed mainly of calcium phosphate and a calcium/phosphoric acid-based frit, and adding from 3 to 23% of Y 2 O 3 as a reinforcing agent to the above-formed product.
The present invention will hereinafter be explained in more detail by reference to various preferred features and to the accompanying drawing.
Referring to the FIGURE, a dental implant 1 of the present invention has a dental root portion 11 at the lower portion thereof. The dental root portion 11 comprises a high strength metal substrate 5 made, e.g., of a nickel-chromium alloy stainless steel, a cobalt-chromiummolybdenum alloy stainless steel, titanium or the like, and a ceramic coating layer 2 on the metal substrate 5. The ceramic coating layer 2 is made of alumina, zirconia, spinel, forsterite or the like and is provided by known techniques such as chemical vapor deposition, physical deposition, and flame spraying. In order to increase the adhesion strength between the ceramic coating layer 2 and jaw bone B, the surface of the ceramic coating layer 2 is fabricated so as to be irregular, e.g., the metal substrate or, if desired, the ceramic or glass coating layer is threaded, transversely grooved, horizontally grooved or any other suitable treatment is used to increase the surface area of the ceramic coating layer 2. The ceramic coating layer 2 is then coated with a calcium phosphate coating layer 3.
A typical example of a method for production of a dental implant in accordance with the present invention is as follows:
A mixture of 20 kg of CaCO 3 and 14 kg of P 2 O 5 was calcined at 1,300° C. for 2 hours to form a glass/crystal mixture of calcium phosphate which was in a half-molten state. The Ca/P atomic ratio of the mixture was about 1:1. The mixture was ground by means of a trommel (i.e., a ball mill) so that the proportion of particles having a size of 5μ or less was 40%. The thus-ground calcium phosphate was then added to water with 1% of methyl cellulose dissolved therein and stirred to form a calcium phosphate slurry. A 15 mm portion of a nickel chromium alloy stainless steel substrate (2.5 mm in diameter and 25 mm in length) was threaded at a pitch of 1 mm, and thereafter provided with a 10μ thick α-Al 2 O 3 coating layer by chemical vapor deposition. The substrate with the α-Al 2 O 3 coating layer provided thereon was then soaked in the above prepared calcium phosphate slurry, dried, and calcined in air at 700° C. to produce a dental implant with a calcium phosphate coating layer provided thereon.
Combustible powder having a particle size of from 20 to 500μ, such as carbon powder and an organic compound, for example, resin, polyethylene, foamed polyethylene, cellulose, vegatable fiber and grain powder, is incorporated into the calcium phosphate slurry in an amount of 5 to 60% by weight. The thus obtained mixture adheres to a ceramic or glass coating layer by means of dipping, brush coating or spraying, and then is sintered to provide a calcium phosphate coating layer having pores having an average diameter of from 20 to 500μ. Such a layer having pores has improved affinity for bones.
In implanting the dental implant of the present invention in a jaw bone, a mucosa A is cut and peeled away, a tapped hole conforming the shape of the dental implant is provided in a jaw bone B, and then, the dental root portion 11 of the dental implant is screwed in the tapped hole. A artificial tooth T is adhered onto the top portion of the implanted dental implant by means of an adhesive 4. The dental implant shows great affinity for the jaw bone because of the presence of the calcium phosphate coating layer. The calcium phosphate coating layer is gradually replaced by the bone. The replacement stops when the bone reaches the ceramic coating layer, and thus the bone does not come into contact with the stainless steel substrate. Therefore, even after a long period of time, the stainless steel does not exert adverse influences on human body. Moreover, since the ceramic coating layer has an irregular surface, the bone and the ceramic coating layer are bonded together over an increased surface area, and therefore the dental implant of the present invention can be used safely over a long period of time.
The surface of the ceramic coating layer may exist in a variety of forms, e.g., in the form of transverse grooves or horizontal grooves, or in a corrugated form, although it is threaded in the above-described embodiment. In addition, the close adhesion between the bone and the ceramic coating layer can be attained by producing a porous surface layer through proper adjustment of the particle size of, e.g., ceramic powder or glass powder, or of the flame temperature in flame spraying after deposition of ceramics. For example, ceramic bar or ceramic powder is molten at 2000° C. in case of alumina ceramic or at 1600° C. in case of zirconia ceramic with oxyacetylene flame and then the molten material is flame-coated at a pressure of 50 lb/inch 2 from the distance of 2 to 6 inches. Plasma jet flame can be used instead of the oxyacetylene flame.
While the invention has been described in detail and with reference to specific embodiments thereof, it will be apparent to one skilled in the art that various changes and modifications can be made therein without departing from the spirit and scope thereof. | A dental implant for the attachment of a artificial tooth is described. This dental implant comprises a root portion to be embedded in bone and a top portion to be projected in the mouth, wherein the root portion comprises a high strength metal substrate, a ceramic or glass coating layer on the substrate, and a calcium phosphate coating layer on the ceramic or glass coating layer. The dental implant can be secured to a jaw bone and overcomes the problems involved in using conventional art dental implants, e.g., adverse influences of stainless steel. | 0 |
RELATED APPLICATIONS
[0001] This application is the 35 U.S.C. § 371 National Application of International Application No. PCT/CN06/000107, filed on Jan. 23, 2006, which designated the United States, claiming priority to China Patent Application NO. 200510027795.6, filed on 15 Jul. 2005.
[0002] The invention is made under governmental grants of national science foundation of China (NSFC30470409) and Shanghai science and technology committee (STC03JC14020&0452nm085) that should be acknowledged.
TECHNICAL FIELD
[0003] This invention relates to preparation processes of enabling liquid pharmaceutical ingredients to be self-assembled into bi-stable vertical quantum wire arrays and potential uses in artificial polymer molecular quantum information material and clinical nano-diagnostic tools.
BACKGROUND
[0004] Vertical bi-stable quantum wires are the key component of developing high performance quantum calculation and ultra-fast or ultra-sensitive diagnostic implanted nano-devices and nano-biosensors, and become the hot point of bioelectronics, informatics and advanced functional material nanometer manufactures. A long-standing research interest is to develop biological molecules-based implanted medical devices with quantum bit memory and self-charged. It has been revealed that inelastic electron tunneling and intermolecular coordination along with hydrogen bonds enable single molecular level pharmaceutical verapamil, isoprenaline, superoxide dismutase and adenosine triphosphate to be self-assembled into bi-stable nanometer vertical quantum wire arrays that possess quantum bit operator permutations and kondo effects at room temperature as well as multiple utilities of charge transports and target recognitions.
SUMMARY
[0005] In one aspect of the invention, nanomedicine self-assembling into vertical bi-stable quantum wire arrays are selected from liquid ingredients consisting of the unitary, binary, ternary, and quaternary ingredients of a β-adrenergic agonist, a P 2 -purinergic agonist, a phenylalkylamine calcium channel blocker, an antioxidase antioxidant and/or nuclear acids according to the L 16 (2) 15 and the L 9 (3) 4 orthogonal schemes. The bi-stable quantum wire arrays with quantum bits and kondo effects at room temperature are prepared from self-assembled nanomedicine ingredients at a low temperature of −4° C. and identified by an interaction of point contact image (PCI) scanning probe microscopy and mathematical analysis workstations through inelastic electron tunneling and intermolecular energy coordinates.
[0006] The self-assembled nanomedicine in said bi-stable quantum wire array of self-assembled nanomedicine contains liquid ingredients as follows. The liquid ingredient of a β-adrenergic agonist includes isoprenaline. The concentration of the isoprenaline is in a range of from about 210 zeptoMol to about 0.001 zeptoMol. The liquid ingredient of a P 2 -purinergic agonist includes adenosine triphosphate. The concentration of adenosine triphosphate is in a range of from about 260 zeptoMol to about 1 zeptoMol. The liquid ingredient of a phenylalkyl-amine calcium channel blocker includes verapamil. The concentration of verapamil is in a range of from about 20 zeptoMol to about 0.001 zeptoMol. The liquid ingredient of an antioxidase antioxidant includes superoxide dismutase. The concentration of superoxide dismutase is in a range of from about 1 zeptoMol to about 0.001 zeptoMol. The liquid ingredient of a nuclear acid includes xanthine. The concentration of xanthine is in a range of from about 50 μM to about 5 mM.
[0007] The unitary bi-stable quantum wire array of self-assembled nanomedicinecan be a xanthine-based unitary nanomedicine self-assembly system, wherein the xanthine-based unitary nanomedicine self-assembly system is respectively selected from four groups of the L 16 (2) 15 orthogonal design protocol at molar mixture ratios of (verapamil:isoprenaline:superoxide dismutase : adenosine triphosphate) according to (i) 1:0:0:0; (ii) 0:1:0:0; (iii) 0:0:1:0; (iv) 0:0:0:1, and combinations thereof. The binary bi-stable quantum wire array of self-assembled nanomedicinecan be a xanthine-based binary nanomedicine self-assembly system, wherein the xanthine-based binary nanomedicine self-assembly system is respectively selected from the six groups of the L 16 (2) 15 orthogonal design protocol at molar mixture ratios of (verapamil:isoprenaline:superoxide dismutase:adenosine triphosphate) according to (i) 1:1:0:0; (ii) 1:0:1:0; (iii) 1:0:0:1; (iv) 0:1:1:0; (v) 0:1:0:1; (vi) 0:0:1:1, and combinations thereof. The ternary bi-stable quantum wire array of self-assembled nanomedicine is a xanthine-based ternary nanomedicine self-assembly system, wherein the xanthine-based ternary nanomedicine self-assembly system is respectively selected from four groups of the L 16 (2) 15 orthogonal design protocol at molar mixture ratios of (verapamil:isoprenaline:superoxide dismutase:adenosine triphosphate) according to (i) 1:1:1:0; (ii) 1:0:1:1; (iii) 1:1:0:1; (iv) 0:1:1:1, and combinations thereof. The quaternary bi-stable quantum wire array of self-assembled nanomedicine is a xanthine-based quaternary nanomedicine self-assembly system, wherein the xanthine-based quaternary nanomedicine self-assembly system is respectively selected in nine groups of the L 16 (2) 15 and L 9 (3) 4 orthogonal design protocol at molar mixture ratio of (verapamil:isoprenaline:superoxide dismutase:adenosine triphosphate) according to (i) 1:1:1:1; (ii) 1:2:2:2; (iii) 1:3:3:3; (iv) 2:1:2:3; (v) 2:2:3:1; (vi) 2:3:1:2; (vii) 3:1:3:2; (viii) 3:2:1:3; (ix) 3:3:2:1, and combinations thereof, and wherein (i) in the L 9 (3) 4 orthogonal design protocol is overlapped with the quaternary molar ratio group in the L 16 (2) 15 orthogonal design protocol.
[0008] The bi-stable quantum wire arrays of self-assembled nanomedicine are prepared by xanthine-based unitary, binary, ternary, or quaternary nanomedicine self-assembly in a preparation process comprising the steps as follows: (a) preparing a pharmaceutical standard solution of verapamil hydrochloride, a pharmaceutical standard solution of isoprenaline hydrochloride, a physiological buffer solution of superoxide dismutase, and a physiological buffer solution of adenosine triphosphate, respectively; (b) respectively mixing the optimum molar ratio of the selected ingredient solutions as mentioned in [0006] in a physiological buffer solution and/or a pharmaceutical standard solution according to L 16 (2) 15 and L 9 (3) 4 orthogonal design protocols; (c) immersing the silicon substrate into the desired ingredient mixture solutions as mentioned in [0006] to form bi-stable quantum wire arrays on the substrate; and (d) cooling the above mixed ingredient liquids at −4° C. for 96 hours on the substrates to form size-controlled bi-stable quantum wire arrays with quantum bits (qubits) and kondo effects at room temperature, wherein 3 dimensional (3D) nanometer size-controlled topographic structures of bi-stable quantum wire arrays with room temperature qubits can be identified by a PCI scanning probe microscopy (conducting atomic force microscopy, C-AFM) images and C-AFM electronic feature measurements, namely, current vs. voltage (I-V) curves and its analysis to decipher kondo effects (a maximum differential conductance peak around zero bias potential) in the 1 st derivative of I-V curves, spin-up and spin-down qubits (±½πN electron spins at the z-axis orientation) and spin echo phenomena (no angular momentum at all at the z-axis orientation) in the energy-frequency-phase and the energy-time-phase spectra through the 1 st derivatives and fast Fourier transformation of I-V curves.
[0009] In another aspect of the invention, the bi-stable quantum wire arrays with room temperature kondo effects and qubits are crystallized at nanometers from one or more ingredients selected from liquid pharmaceutical groups consisting of (a) a β-adrenergic receptor agonist; (b) a P 2 -purinergic receptor agonist; (c) a phenylalkylamine calcium channel blocker; and (d) an antioxidase antioxidant.
[0010] The preparation process of self-assembled bi-stable quantum wire arrays includes the following features: (1) the optimum self-assembly process of a bi-stable quantum wire comprises a crystallized process of liquid pharmaceutical ingredients on a substrate; (2) the optimum self-assembly process of the unitary bi-stable quantum wires comprises a selection process of liquid unitary pharmaceutical ingredients in either a β-adrenergic receptor agonist that includes isoprenaline, a P 2 -purinergic receptor agonist that includes adenosine triphosphate, a phenylalkylamine calcium channel blocker that includes verapamil or an antioxidase antioxidant that includes superoxide dismutase, and/or a nuclear acid that includes xanthine; (3) the optimum self-assembly process of bi-stable quantum wires of unitary, binary, ternary, and quaternary nanomedicine comprises a crystallized process of xanthine-based unitary, binary, ternary, and quaternary pharmaceutical liquid ingredients on the substrates.
[0011] The unitary bi-stable quantum wire array is respectively crystallized from xanthine-based liquid ingredients at molar mixture ratios of (verapamil : isoprenaline: superoxide dismutase : adenosine triphosphate) according to(i) 1:0:0:0; (ii) 0:1:0:0; (iii) 0:0:1:0; and (iv) 0:0:0:1. The binary bi-stable quantum wire array is respectively crystallized from xanthine-based liquid ingredients at the molar mixture ratios of (verapamil : isoprenaline: superoxide dismutase : adenosine triphosphate) according to (i) 1:1:0:0; (ii) 1:0:1:0; (iii) 1:0:0:1; (iv) 0:1:1:0; (v) 0:1:0:1; and (vi) 0:0:1:1. The ternary bi-stable quantum wire array is respectively crystallized from xanthine-based liquid ingredients at the molar mixture ratios of (verapamil:isoprenaline:superoxide dismutase:adenosine triphosphate) according to (i) 1:1:1:0; (ii) 1:1:0:1; (iii) 1:0:1:1; and (iv) 0:1:1:1. The quaternary bi-stable quantum wire array is respectively crystallized from xanthine-based liquid ingredients at the molar ratios of (verapamil:isoprenaline:superoxide dismutase:adenosine triphosphate) according to (i) 1:1:1:1; (ii) 1:2:2:2; (iii) 1:3:3:3; (iv) 2:1:2:3; (v) 2:2:3:1; (vi) 2:3:1:2; (vii) 3:1:3:2; (viii) 3:2:1:3; and (ix) 3:3:2:1. All unitary, binary, ternary and quaternary nanomedicine are respectively combined with xanthine at a desired molar concentration.
[0012] In another aspect of the invention, a crystallized process of preparing a bi-stable quantum wire array includes the following steps: (a) respectively making a pharmaceutical standard solution comprising one or more ingredients selected from the group consisting of verapamil, isoprenaline, superoxide dismutase, and adenosine triphosphate and respectively immersing a substrate into a desired volume of an optimum pharmaceutical standard solution in combination with a desired molar concentration of xanthine solution at −4° C. for 96 hours according to the L 16 (2) 15 and L 9 (3) 4 optimum design protocols, wherein such a time period with a cooling process allows liquid ingredients to be crystallized onto the substrates; (b) cooling verapamil in a range of about 20 zeptoMol to about 0.001 zeptoMol, isoprenaline in a range of about 210 zeptoMol to about 0.001 zeptoMol, adenosine triphosphate in a range of about 260 zeptoMol to about 1 zeptoMol, superoxide dismutase in a range of about 1 zeptoMol to about 0.001 zeptoMol and xanthine in a range of about 50 μM to about 5 mM at −4° C. for 96 hours respectively, resulting in nanometer scale, size-controlled, well-distributed, vertical-patterned bi-stable quantum wire arrays with qubits and kondo effects.
[0013] The details of one or more embodiments of the invention are set forth in the accompanying drawings and the description below. Other features, objects, and advantages of the invention will be apparent from the description and drawings, and from the claims.
DESCRIPTION OF DRAWINGS
[0014] FIG. 1 . The PCI (conducting atomic force microscopy, C-AFM) images the self-assembled topographic structure of xanthine-based vertical binary bi-stable quantum wire arrays made from nano-medicine on the N-doped silicon chip, and its cigar-shaped spatial geometrical size covers a height 3 nm, a length 500 nm and wideness 500 nm space, as depicted in FIG. 1 .
[0015] FIG. 2 . The PCI (C-AFM) images the self-assembled topographic structure of xanthine-based vertical ternary nanomedicine quantum wires with the highest qubits up to 254½π and 127π electron spins on the N-doped silicon chip, and its cigar-shaped spatial geometrical size covers a height 16 nm, a length 1000 nm and wideness 1000 nm, as depicted in FIG. 2 .
[0016] FIG. 3 . The PCI (C-AFM) images the self-assembled topographic structure of xanthine-based vertical quinary nanomedicine quantum wires and thin films with non-volatile qubits on the P-doped silicon chip, and its cigar-shaped spatial geometrical size covers a height 10 nm, a length 1000 nm and wideness 1000 nm, as depicted in FIG. 3 .
[0017] FIG. 4 . The PCI (C-AFM) images the self-assembled topographic structure of xanthine-based vertical quinary nanomedicine quantum wires and thin films with the optimum qubits up to 906½π, 302π or 151(2π) electron spins on the P-doped silicon chip, and its cigar-shaped spatial geometrical size covers a height 4 nm, a length 400 nm and wideness 400 nm, as depicted in FIG. 4 .
[0018] FIG. 5 . The PCI (C-AFM) images the self-assembled topographic structure of xanthine-based vertical quinary nanomedicine quantum wires and thin films with the controllable qubits with the phases of initial zero, ½π, π and 2π electron spins on the P-doped silicon chip, and its cigar-shaped spatial geometrical size covers a height 3.5 nm, a length 1000 nm and wideness 1000 nm, as depicted in FIG. 5 .
[0019] FIG. 6 . The PCI (C-AFM) images the self-assembled topographic structure of xanthine-based vertical quinary nanomedicine quantum wires and thin films with the controllable qubits with the phases of initial zero, ½π, π and 1½π electron spins on the P-doped silicon chip, its cigar-shaped spatial geometrical size covers a height 6 nm, a length 500 nm and wideness 500 nm, as depicted in FIG. 6 .
[0020] FIG. 7 . The PCI (C-AFM) images the self-assembled topographic structure of xanthine-based vertical quinary nanomedicine quantum wires and thin films with the ±10V bias potential-initiated qubits on the P-doped silicon chip, and its cigar-shaped spatial geometrical size covers a height 8 nm, a length 1000 nm and wideness 1000 nm, as depicted in FIG. 7 .
[0021] FIG. 8 . The PCI (C-AFM) images the self-assembled topographic structure of xanthine-based vertical quinary nanomedicine quantum wires and thin films with the ±7V and ±9V bias potential-initiated zero −½π-π and zero-½π-2π electron spin phase transitions on the P-doped silicon chip, its cigar-shaped spatial geometrical size covers a height 4 nm, a length 400 nm and wideness 400 nm, as depicted in FIG. 8 .
[0022] FIG. 9 . The PCI (C-AFM) images the self-assembled topographic structure of xanthine-based vertical quinary nanomedicine quantum wires and thin films with the ±7V, ±8V and ±9V bias potential-initiated π-½π-2π and zero-½π-2π electron spin phase transitions on the P-doped silicon chip, and its cigar-shaped spatial geometrical size of a height 50 nm, a length 1600 nm and wideness 1600 nm, as depicted in FIG. 9 .
[0023] FIG. 10 . The PCI (C-AFM) measures the I-V curve of ±35 pA quantum tunneling hysteresis (a, X axis=Voltage, Y axis=Current), the kondo effect conductance spectrum of 140 pA/V maximum differential conductance peak at 0 bias potential (b, X axis=Voltage, Y axis=Conductance), the energy-frequency-phase spectrum (c, X axis=Frequency, Y axis=Phase, Z axis=Energy) and the energy-time-phase spectrum (d, X axis=Time, Y axis=Phase, Z axis=Energy) of ±2V bias potential-initiated electron spins for qubits, all of them correspond to FIG. 1 .
[0024] FIG. 11 . The PCI (C-AFM) measures the I-V curve of 2.5 pA˜−22.5 pA quantum tunneling hysteresis (a, X axis=Voltage, Y axis=Current), the kondo effect conductance spectrum of 325 pA/V maximum differential conductance peak at -IV bias potential (b, X axis=Voltage, Y axis=Conductance), the energy-frequency-phase spectrum (c, X axis=Frequency, Y axis=Phase, Z axis=Energy) and the energy-time-phase spectrum (d, X axis=Time, Y axis=Phase, Z axis=Energy) of ±9V bias potential-initiated 954½π and 477π electron spins for dynamics of qubits, all of them correspond to FIG. 2 .
[0025] FIG. 12 . The PCI (C-AFM) measures the I-V curve of 0 pA˜−20 pA quantum tunneling hysteresis and quantum Hall effect (a, X axis=Voltage, Y axis=Current), the kondo effect conductance spectrum of 13 pA/V maximum differential conductance peak at −4V bias potentials (b, X axis=Voltage, Y axis=Conductance), the energy- frequency-phase spectrum (c, X axis=Frequency, Y axis=Phase, Z axis=Energy) and the energy-time-phase spectrum (d, X axis=Time, Y axis=Phase, Z axis=Energy) of ±6V, ±8V, ±9V and ±10V bias potential-initiated non-volatile qubits, all of them correspond to FIG. 3 .
[0026] FIG. 13 . The PCI (C-AFM) measures the I-V curve of ±30 pA quantum tunneling hysteresis and 0 pA quantum Hall effect (a, X axis=Voltage, Y axis=Current), the kondo effect conductance spectrum of 100 pA/V maximum differential conductance peak at −2V bias potentials (b, X axis=Voltage, Y axis=Conductance), the energy-frequency-phase spectrum (c, X axis=Frequency, Y axis=Phase, Z axis=Energy) and the energy-time-phase spectrum (d, X axis=Time, Y axis=Phase, Z axis=Energy) of ±7V, ±8V, ±9V and ±10V bias potential-initiated ½π-π electron spin shuttling for qubits, all of them correspond to FIG. 4 .
[0027] FIG. 14 . The PCI (C-AFM) measures the I-V curve of 0 pA˜−25 pA quantum tunneling hysteresis and quantum Hall effect (a, X axis=Voltage, Y axis=Current), the kondo effect conductance spectrum of 70 pA/V˜−50 pA/V maximum differential conductance peak at −2V bias potentials (b, X axis=Voltage, Y axis=Conductance), the energy -frequency-phase spectrum (c, X axis=Frequency, Y axis=Phase, Z axis=Energy) and the energy-time-phase spectrum (d, X axis=Time, Y axis=Phase, Z axis=Energy) of ±6V, ±7V, ±8V, ±9V and ±10V bias potential-initiated zero-½π-2π electron spin shuttling for qubits, all of them correspond to FIG. 5 .
[0028] FIG. 15 . The PCI (C-AFM) measures the I-V curve of 5 pA˜−32.5 pA quantum tunneling hysteresis and 0 pA quantum Hall effect (a, X axis=Voltage, Y axis=Current), the kondo effect conductance spectrum of 40 pA/V˜55 pA/V maximum differential conductance peak at 0V and −2V bias potentials (b, X axis=Voltage, Y axis=Conductance), the energy-frequency-phase spectrum (c, X axis=Frequency, Y axis=Phase, Z axis=Energy) and the energy-time-phase spectrum (d, X axis=Time, Y axis=Phase, Z axis=Energy) of ±8V, ±9V and ±10V bias potential-initiated π-½π-π electron spin shuttling for qubits, all of them correspond to FIG. 6 .
[0029] FIG. 16 . The PCI (C-AFM) measures the I-V curve of 20 pA˜−30 pA quantum tunneling hysteresis and 0 pA quantum Hall effect (a, X axis=Voltage, Y axis=Current), the kondo effect conductance spectrum of 55 pA/V maximum differential conductance peak at 0V bias potential (b, X axis=Voltage, Y axis=Conductance), the energy-frequency-phase spectrum (c, X axis=Frequency, Y axis=Phase, Z axis=Energy) and the energy-time-phase spectrum (d, X axis=Time, Y axis=Phase, Z axis=Energy) of ±7V and ±9V bias potential-initiated zero-½π-2π electron spin shuttling for qubits, all of them correspond to FIG. 7 .
[0030] FIG. 17 . The PCI (C-AFM) measures the I-V curve of 25 pA˜30 pA quantum tunneling hysteresis and 0 pA quantum Hall effect at 0V bias potential (a, X axis=Voltage, Y axis=Current), the kondo effect conductance spectrum of 65 pA/V maximum differential conductance peak at 0V bias potential (b, X axis=Voltage, Y axis=Conductance), the energy-frequency-phase spectrum (c, X axis=Frequency, Y axis=Phase, Z axis=Energy) and the energy-time-phase spectrum (d, X axis=Time, Y axis=Phase, Z axis=Energy) of ±8V, ±9V and ±10V bias potential-initiated zero-½π-π and zero −½π-2π electron spin shuttling for qubits, all of them correspond to FIG. 8 .
[0031] FIG. 18 . The PCI (C-AFM) measures the I-V curve of 5 pA˜−25 pA quantum tunneling hysteresis (a, X axis=Voltage, Y axis=Current), the kondo effect conductance spectrum of 35 pA/V maximum differential conductance peak at -IV bias potential (b, X axis=Voltage, Y axis=Conductance), the energy-frequency-phase spectrum (c, X axis=Frequency, Y axis=Phase, Z axis=Energy) and the energy-time-phase spectrum (d, X axis=Time, Y axis=Phase, Z axis=Energy) of ±8V, ±9V and ±10V bias potential-initiated N zero-½π-2π and N π-½π-2π electron spin shuttling for qubits, all of them correspond to FIG. 9 .
DETAILED DESCRIPTION
[0032] Vertical bi-stable quantum wire arrays are prepared from liquid unitary, binary, ternary, and quaternary nanomedicine complexes described herein to co-crystallized patterns through an interaction of inelastic electron tunneling and intermolecular co-ordinations of an antioxidase antioxidant, agonists of β-adrenergic and P 2 purinergic receptors, and/or a phenylalkylamine (benzalkonium) calcium channel blocker.
[0033] Crystallized, nanometer scale, size-controllable, vertical bi-stable quantum wire arrays with well-aligned, discrete-distributed spatial geometrical order structure array patterns are prepared from advantageous liquid ingredients of isoprenaline in a range of about 210 zeptoMol to about 0.001 zeptoMol, adenosine triphosphate in a range of about 260 zeptoMol to about 1 zeptoMol, verapamil in a range of about 20 zeptoMol to about 0.001 zeptoMol, and/or superoxide dismutase in a range of about 1 zeptoMol to about 0.001 zeptoMol, all of above unitary, binary, ternary and/or quaternary ingredients are combined with 50 μM˜5 mM xanthine in a liquid phase.
[0034] A nanometer preparation process of vertical bi-stable quantum wire arrays employs an interaction of inelastic electron tunneling and intermolecular electrostatic co-ordination to self-assemble optimum xanthine-based unitary, binary, ternary, and quaternary pharmaceutical standard solutions of isoprenaline, verapamil, superoxide dismutase, and/or adenosine triphosphate according to the L 16 (2) 15 and the L 9 (3) 4 orthogonal design protocols. The nanometer scale spatial vertical geometrical architecture self-assembly approach is advantageous for developing mechanism-based multi-functional nano-devices, ultra-faster, ultra-sensitive, ultra-density qubit devices and nano-diagnostic tools towards clinical utilities.
[0035] The electronic feature of vertical bi-stable quantum wire arrays is bi-stable electrical hysteresis with qubits (a relatively higher current level and a relatively lower current level) in the current-voltage (I-V) curves and quantum resonance (kondo effects) in their first derivatives of I-V curves (the dI-dV conductance spectrum) at room temperature. Kondo effects can be identified by a maximum conductance peak around zero bias potential in the 1 st derivative of I-V curves at room temperature (a room temperature Kondo effect is a quantum resonance phenomenon), and a feature of qubits can be identified by the energy-frequency-phase and energy-time-phase spectra after the faster Fourier transformation of the dI-dV conductance spectrum in frequency and time domains respectively, wherein the velocity uncertain quantum phase transition wave is clearly visible at the absolute zero point in a zero-point motion manner. The symmetry bi-stable spin-up and spin-down qubits undergo ±½πN (N may be several hundreds) phase transitions at the central point, whereas non-symmetry spin-up and spin-down qubits undergo spin echo (π angular momentum) at an initial and an end phase transition in combination with a non-symmetry spin-up and spin-down phase transition at the central point (presence of several ½π phase transition difference) for qubits. Both of symmetry and non-symmetry phase transitions are in a lower power state around the sub-eV level.
[0036] The invention employs combined methods of L 16 (2) 15 and L 9 (3) 4 orthogonal optimization protocols, PCI scanning probe microscopy, i.e., conducting atomic force microscopy (C-AFM), and ORIGIN mathematical analyses (available from OriginLab Co., Northampton, Mass.) to prepare the crystallized patterns from liquid unitary, binary, ternary, quaternary and quinary elements of isoprenaline (β-adrenergic agonist), adenosine triphosphate (P 2 -purinergic agonist), verapamil (phenylalkylamine calcium channel blocker), superoxide dismutase (antioxidase antioxidant) and xanthine (a unclear acid) respectively, and identify the advantage feature of vertical bi-stable quantum wire arrays with qubits.
[0037] The vertical unitary bi-stable quantum wire arrays on the p-doped (8-12Ω cm) or the n-doped (0.01˜0.05Ω cm) silicon substrates comprises xanthine-based unitary liquid pharmaceutical ingredient selected from isoprenaline (β-adrenergic agonist), adenosine triphosphate (P 2 -purinergic agonist), verapamil (phenylalkylamine calcium channel blocker) or superoxide dismutase (antioxidase antioxidant) at a molar mixture ratio according to (i) 1:0:0:0; (ii) 0:1:0:0; (iii) 0:0:1:0; and/or (iv) 0:0:0:1.
[0038] The vertical binary bi-stable quantum wire arrays on the p-doped (8-12Ω cm) or the n-doped (0.01˜0.05Ω cm) silicon substrates comprises xanthine-based binary liquid pharmaceutical ingredient selected from isoprenaline (β-adrenergic agonist), adenosine triphosphate (P 2 -purinergic agonist), verapamil (phenylalkylamine calcium channel blocker) and superoxide dismutase (antioxidase antioxidant) at a molar mixture ratio according to (i) 1:1:0:0; (ii) 1:0:1:0; (iii) 1:0:0:1; (iv) 0:1:1:0; (v) 0:1:0:1 and (vi) 0:0:1:1.
[0039] The vertical ternary bi-stable quantum wire arrays on the p-doped (8-12Ω cm) or the n-doped (0.01˜0.05Ω cm) silicon substrates comprises xanthine-based ternary liquid pharmaceutical ingredient selection from isoprenaline (a β-adrenergic agonist), adenosine triphosphate (a P 2 -purinergic agonist), verapamil (a phenylalkylamine calcium channel blocker) and superoxide dismutase (an antioxidase antioxidant) at a molar mixture ratio according to (i) 1:1:1:0; (ii) 1:0:1:1; (iii) 1:1:0:1; and (iv) 0:1:1:1.
[0040] The vertical quaternary bi-stable quantum wire arrays on the p-doped (8-12Ω cm) or the n-doped (0.010˜0.05Ω cm) silicon substrates comprises xanthine-based quaternary liquid pharmaceutical ingredient selection from isoprenaline (a β-adrenergic agonist), adenosine triphosphate (a P 2 -purinergic agonist), verapamil (a phenylalkylamine calcium channel blocker) or superoxide dismutase (an antioxidase antioxidant) at a molar mixture ratio according to (i) 1:1:1:1; (ii) 1:2:2:2; (iii) 1:3:3:3; (iv) 2:1:2:3; (v) 2:2:3:1; (vi) 2:3:1:2; (vii) 3:1:3:2; (viii) 3:2:1:3; and (ix) 3:3:2:1.
[0041] This invention can generate 24 groups' nanometer scale topographic structure data of size-controlled, discrete-distributed, well-aligned patterns of vertical bi-stable quantum wire arrays and 24 groups' electrical parameters of self-assembled unitary, binary, ternary, quaternary and quinary vertical bi-stable quantum wire arrays with qubits, namely, I-V curves, their first derivatives (the dI-dV conductance spectra) and faster Fourier transformations in frequency and time domains (the energy-frequency-phase spectra and the energy-time-phase spectra) and the three-dimensional (3D) topographic structures of bi-stable vertical quantum wire arrays can be respectively identified by C-AFM images and C-AFM electrical property measurements as depicted in FIGS. 1-18 . The spatial sizes of vertical bi-stable quantum wire arrays may range from angstroms to nanometers of several tens. The shortest vertical bi-stable quantum wire array is in a range of 14 angstroms. The smallest spatial size of a vertical bi-stable quantum wire array pattern is a range of 2 angstroms.
[0042] The architecture feature of vertical bi-stable quantum wire arrays is geometrical regular shape, size-controllable intermolecular coordination patterns, as shown in FIGS. 1-9 . The electrical feature of bi-stable quantum wire arrays includes electrical hysteresis, quantum tunneling currents, kondo effects and symmetry or non-symmetry spin-up and spin-down qubits in a lower power state, as typically identified in FIGS. 10 a - d , 11 a - d , 12 a - d , 13 a - d , 14 a - d , 15 a - d , 16 a - d , 17 a - d and 18 a - d . The topographic structure and electrical features of vertical bi-stable quantum wire arrays may be advantageous for developing multi-functional nano-diagnosis device and qubit informatics devices.
[0043] The process of preparing vertical bi-stable vertical quantum wire arrays on the silicon substrates includes the following steps as: 1) respectively preparing liquid pharmaceutical ingredients according to pharmaceutical standard guidelines; 2) respectively preparing liquid pharmaceutical standard ingredients of verapamil hydrochloride, isoprenaline hydrochloride, superoxide dismutase, and adenosine triphosphate in the desired concentrations as mentioned in [0006]; and 3) respectively mixing the liquid pharmaceutical standard ingredients of verapamil hydrochloride, isoprenaline hydrochloride, superoxide dismutase, and adenosine triphosphate in combination with a given molar concentration of xanthine buffer solution as indicated in [0006] in the given volume of buffer solutions at room temperature; 4) respectively storing the above liquid ingredients at −4° C. for applications; 5) respectively immersing the p-doped (8-12Ω cm) or the n-doped (0.01˜0.05Ω cm) silicon chips into the above desired xanthine-based unitary, binary, ternary and quaternary pharmaceutical ingredient solutions according to L 16 (2) 15 and L 9 (3) 4 orthogonal design protocols as described in [0006]; and 6) respectively storing liquid ingredients onto the p-doped (8-12Ω cm) or the n-doped (0.01˜0.05Ω cm) silicon substratesat −4° C. for 96 hours to obtain a liquid-solid phase transition and result in well-aligned and uniformly distributed vertical bi-stable quantum wire arrays with qubits and kondo effects.
[0044] In the L 16 (2) 15 orthogonal design protocol, there are four independent unitary pharmaceutical ingredient groups, six independent binary pharmaceutical ingredient groups, four independent ternary pharmaceutical ingredient groups and one independent quaternary pharmaceutical ingredient group at two molar ratios plus a blank control group. In the L 9 (3) 4 orthogonal design protocol, there are nine quaternary pharmaceutical ingredient groups at three molar ratios. All of above pharmaceutical ingredients are respectively combined with xanthine at given molar concentrations as announced in [0006].
EXAMPLE 1
[0045] Liquids Pharmaceutical ingredients were respectively prepared according to the pharmaceutical standards. Reference may be made to pharmaceutical standard guideline issued by the Ministry of Health in China. Topographic structure and qubit features of the 1:1:1:1 molar mixture ratios obtained from Example 1 are depicted in FIGS. 3 and 12 a - d.
[0046] The following pharmaceutical solutions were prepared according to the pharmaceutical standards(reference may be made to pharmaceutics guideline of the ministry of health in China):
i. Preparing a verapamil hydrochloride pharmaceutical liquid at a concentration of 2.5 mg/5 mL. ii. Preparing an isoprenaline hydrochloride pharmaceutical liquid at a concentration of 2 mg/100 mL. iii. Preparing a physiological buffer solution of superoxide dismutase at a concentration of 1 mg/2 mL. iv. Preparing a physiological buffer solution of adenosine triphosphate at a concentration of 20 mg/3.3 mL. v. Respectively preparing and taking the optimum molecular numbers from each ingredients of verapmil in a range of about 20 zeptoMol to about 0.001 zeptoMol, isoprenaline in a range of about 210 zeptoMol to about 0.001 zeptoMol, superoxide dismutase in a range of about 1 zeptoMol to about 0.001 zeptoMol, adenosine triphosphate in a range of 260 zeptoMol to about 1 zeptoMol and xanthine in a range of about 50 μM to about 5 mM, respectively mixing them at room temperature and preparing xanthine-based quaternary pharmaceutical ingredient physiological buffer solutions at a molar mixture ratio of 1:1:1:1 (verapamil:isoprenaline:superoxide dismutase:adenosine triphosphate) according to the L 9 (3) 4 orthogonal design protocol at room temperature, respectively keeping the final volume of 1 mL xanthine-based quaternary pharmaceutical ingredient physiological buffer solutions at −4° C. for applications. vi. Immersing a p-doped silicon substrate (8-12Ω cm) ed into the above desired 1 mL xanthine-based 1:1:1:1 (verapamil:isoprenaline:superoxide dismutase:adenosine triphosphate) quaternary pharmaceutical ingredient physiological buffer solutions according to the L 9 (3) 4 orthogonal design protocol, and storing at −4° C. for 96 hours. vii. The results of this practice example showed that the height of a quantum wire array is 10 nm ( FIG. 3 ); the I-V curve presented a bi-stable current peaks of 0.813 pA and −19.95 pA within ±8V bias potentials ( FIG. 12 a ), the differential conductance spectrum (dI/dV) revealed the quantized kondo effect, i.e., the maximum conductance peak of 13.08854 pA/V at the −3.741V bias potential ( FIG. 12 b ), the phase transitions covered zero degrees to −1260 degrees within the frequency domain from ±50000 Hz to 7.2475E-12 Hz in the frequency-phase-energy spectrum (FPP), where 14(−½π) electron spins or 7(−π) spin echo occurred at the y axis with the central frequency of 7.2475E-12 Hz at the x-axis and the energy fluctuation of 0.00603 eV at the z axis ( FIG. 12 c ), the phase transitions swept from zero degree to 1260 degrees within the time domain from zero to 1000 μs in the time-phase-energy spectrum (TPP),where 14(½π) electron spins or 7(π) spin echo occurred at the y axis with the central time of 513 μs at the x-axis and the energy fluctuation of 0.00151 eV at the z axis( FIG. 12 d ); the parental data in the FIG. 12( c - d ) simultaneously revealed ±(½π)N electron spins-driven qubits.
EXAMPLE 2
[0052] Liquid pharmaceutical ingredients were prepared according to the pharmaceutical standards (reference may be made to pharmaceutical standard guideline issued by the Ministry of Health in China). Topographic structure and qubit features of the 1:2:2:2 molar mixture ratios obtained from Example 2 are depicted in FIGS. 4 and 13 a - d.
[0053] The following pharmaceutical solutions were prepared according to the pharmaceutical standards, which may refer to pharmaceutics guideline of the ministry of health in China:
i. Preparing a verapamil hydrochloride pharmaceutical liquid at a concentration of 2.5 mg/5 mL. ii. Preparing an isoprenaline hydrochloride pharmaceutical liquid at a concentration of 2 mg/100 mL. iii. Preparing a physiological buffer solution of superoxide dismutase at a concentration of 1 mg/2 mL. iv. Preparing a physiological buffer solution of adenosine triphosphate at a concentration of 20 mg/3.3 mL. v. Respectively preparing and taking the optimum molecular numbers from each ingredients of verapmil in a range of about 20 zeptoMol to about 0.001 zeptoMol, isoprenaline in a range of about 210 zeptoMol to about 0.001 zeptoMol, superoxide dismutase in a range of about 1 zeptoMol to about 0.001 zeptoMol, adenosine triphosphate in a range of 260 zeptoMol to about 1 zeptoMol and xanthine in a range of about 50 μM to about 5 mM, respectively mixing them at room temperature and preparing xanthine-based quaternary pharmaceutical ingredient physiological buffer solutions at molar mixture ratios of 1:2:2:2 (verapamil:isoprenaline:superoxide dismutase:adenosine triphosphate), mixing them at room temperature according to the L 9 (3) 4 orthogonal design protocol, respectively keeping the 1 mL final volume of xanthine-based quaternary pharmaceutical ingredient physiological buffer solutions at −4° C. for applications. vi. Immersing a p-doped silicon substrate (8-12Ω cm) into the above desired 1 mL xanthine-based 1:2:2:2 (verapamil:isoprenaline:superoxide dismutase:adenosine triphosphate) quaternary pharmaceutical ingredient physiological buffer solutions according to the L 9 (3) 4 orthogonal design protocol, and storing at −4° C. for 96 hours. vii. The results of this practice example profiled that the height of quantum wire array is 4 nm ( FIG. 4 ); the I-V curve presented a bi-stable electrical property, i.e., the higher current of 20.71 pA and the lower current of −27.053 pA occurred within the ±7V bias potentials ( FIG. 13 a ); the differential conductance spectrum (dI/dV) revealed the quantized kondo effect, i.e., the maximum conductance peak of 110.492 pA/V located at the −2.376V bias potential ( FIG. 13 b ); the frequency-phase-energy spectrum (FPP) showed phase transitions from 180 degrees to −18180 degrees within the frequency domain from ±50000 Hz to 7.2475E-12 Hz, where 99(−½π) or 33(−1½π) or 404(−¼π) typical electron spins occurred at the y axis with the central frequency of 7.2475E-12 Hz at the x axis and the energy fluctuation of 0.04216 eV( FIG. 13 c ); the time-phase-energy spectrum (TPP) presented phase transitions from zero degree to 18540 degrees within the time domain from 0 μs to 100 μs, where 906(½π) or 302(1½π) or 412(¼π) typical electron spins happened at the y axis with the central time of 513 μs at the x axis and the energy fluctuation of 0.010541 eV at the z axis ( FIG. 13 d ). The parental data in FIG. 13 c - d simultaneously revealed ±(½π) N, ±(¼π) N and ±(1½π) N typical electron spins-driven qubits.
EXAMPLE 3
[0061] Liquid pharmaceutical ingredients were prepared according to the pharmaceutical standards. Reference may be made to pharmaceutical standard guideline issued by the Ministry of Health in China. Topographic structure and qubit features of the 1:3:3:3 molar mixture ratios obtained in Example 3 are depicted in FIGS. 5 and 14 a - d.
[0062] The following pharmaceutical solutions were prepared according to the pharmaceutical standards, which may refer to pharmaceutics guideline of the ministry of health in China:
i. Preparing a verapamil hydrochloride pharmaceutical liquid at a concentration of 2.5 mg/5 mL. ii. Preparing an isoprenaline hydrochloride pharmaceutical liquid at a concentration of 2 mg/100 mL. iii. Preparing a physiological buffer solution of superoxide dismutase at a concentration of 1 mg/2 mL. iv. Preparing a physiological buffer solution of adenosine triphosphate at a concentration of 20 mg/3.3 mL. v. Respectively preparing and taking the optimum molecular numbers from each ingredients of verapmil in a range of about 20 zeptoMol to about 0.001 zeptoMol, isoprenaline in a range of about 210 zeptoMol to about 0.001 zeptoMol, superoxide dismutase in a range of about 1 zeptoMol to about 0.001 zeptoMol, adenosine triphosphate in a range of 260 zeptoMol to about 1 zeptoMol and xanthine in a range of about 50 μM to about 5 mM, respectively mixing them at room temperature and preparing xanthine-based quaternary pharmaceutical ingredient physiological buffer solutions at molar mixture ratios of 1:3:3:3 (verapamil:isoprenaline:superoxide dismutase:adenosine triphosphate), mixing them at room temperature according to the L 9 (3) 4 orthogonal design protocol, respectively keeping the 1 mL final volume of xanthine-based quaternary pharmaceutical ingredient physiological buffer solutions at −4° C. for applications. vi. Immersing a p-doped silicon substrate (8-12Ω cm) into the above desired 1 mL xanthine-based 1:3:3:3 (verapamil:isoprenaline:superoxide dismutase:adenosine triphosphate) pharmaceutical solutions according to the L 9 (3) 4 orthogonal design protocol, and storing at −4° C. for 96 hours. vii. The results of this practice example profiled that the height of quantum wire array is 3.5 nm ( FIG. 5 ); the I-V curve presented a bi-stable electrical property, i.e., the higher current of 1.021 pA and the lower current of −23.998 pA occurred within the ±6V bias potentials ( FIG. 14 a ); the differential conductance spectrum (dI/dV) revealed the quantized kondo effect, i.e., the maximum conductance peak of 67.2825 pA/V located at the −1.917V bias potential ( FIG. 14 b ); the frequency-phase-energy spectrum (FPP) showed phase transitions from 0 degrees to −11512 degrees within the frequency domain from ±50000 Hz to 7.2475E-12 Hz, where 128(−½π) or 64(−π) spin echo or 32(−2π) typical electron spins occurred at the y axis with the central frequency of 7.2475E-12 Hz at the x axis and the energy fluctuation of 0.01581 eV ( FIG. 14 c ); the time-phase-energy spectrum (TPP) presented phase transitions from zero degree to 11512 degrees within the time domain from 0 μs to 1000 μs, where 128(½π) or 64(π) spin echo or 32(2π) typical electron spins happened at the y axis with the central time of 513 μs at the x axis and the energy fluctuation of 0.00395 eV at the z axis ( FIG. 14 d ). The parental data in FIG. 14 c - d simultaneously revealed ±(½π) N, ±(π) N and ±(2π) N typical electron spins-driven qubits.
EXAMPLE 4
[0070] Liquid pharmaceutical ingredients were prepared according to the pharmaceutical standards. Reference may be made to pharmaceutical standard guideline issued by the Ministry of Health in China. Topographic structure and qubit features of the 2:1:2:3 molar mixture ratios obtained in Example 4 are depicted in FIGS. 6 and 15 a - d.
[0071] The following pharmaceutical solutions were prepared according to the pharmaceutical standards(see, for example, pharmaceutics guideline of the ministry of health in China):
i. Preparing a verapamil hydrochloride pharmaceutical liquid at a concentration of 2.5 mg/5 mL. ii. Preparing an isoprenaline hydrochloride pharmaceutical liquid at a concentration of 2 mg/100 mL. iii. Preparing a physiological buffer solution of superoxide dismutase at a concentration of 1 mg/2 mL. iv. Preparing a physiological buffer solution of adenosine triphosphate at a concentration of 20 mg/3.3 mL. v. Respectively preparing and taking the optimum molecular numbers from each ingredients of verapmil in a range of about 20 zeptoMol to about 0.001 zeptoMol, isoprenaline in a range of about 210 zeptoMol to about 0.001 zeptoMol, superoxide dismutase in a range of about 1 zeptoMol to about 0.001 zeptoMol, adenosine triphosphate in a range of 260 zeptoMol to about 1 zeptoMol and xanthine in a range of about 50 μM to about 5 mM, respectively mixing them at room temperature and preparing xanthine-based quaternary pharmaceutical ingredient physiological buffer solutions at molar mixture ratios of 2:1:2:3 (verapamil:isoprenaline:superoxide dismutase:adenosine triphosphate), mixing them at room temperature according to the L 9 (3) 4 orthogonal design protocol, keeping xanthine-based quaternary pharmaceutical ingredient physiological buffer solutions in the 1 mL final volume at −4° C. for applications. vi. Immersing a p-doped silicon substrate (8-12Ω cm) into the above desired 1 mL of xanthine-based 2:1:2:3 (verapamil:isoprenaline:superoxide dismutase:adenosine triphosphate) desired pharmaceutical solutions according to the L 9 (3) 4 orthogonal design protocol, and storing at −4° C. for 96 hours. vii. The results of this practice example profiled that the height of quantum wire array is 6 nm ( FIG. 6 ); the I-V curve presented a bi-stable electrical property, i.e., the higher current of 2.07 pA and the lower current of −32.834 pA occurred within the ±10V bias potentials ( FIG. 15 a ); the differential conductance spectrum (dI/dV) revealed the quantized kondo effect, i.e., the maximum conductance peak of 53.2375 pA/V located at the −0.96V bias potential ( FIG. 15 b ); the frequency-phase-energy spectrum (FPP) showed phase transitions from 180 degrees to −14580 degrees within the frequency domain from ±50000 Hz to 7.2475E-12 Hz, where 126(−½π) or 81(−π) spin echo typical electron spins occurred at the y axis with the central frequency of 7.2475E-12 Hz at the x axis and the energy fluctuation of 9.58648E-9 eV ( FIG. 15 c ); the time-phase-energy spectrum (TPP) presented phase transitions from 180 degrees to 14940 degrees within the time domain from 0 μs to 1000 μs, where 166(½π) or 63(π) spin echo typical electron spins happened at the y axis with the central time of 513 μs at the x axis and the energy fluctuation of 0.00298 eV at the z axis ( FIG. 15 d ). The parental data in FIG. 15 c - d simultaneously revealed ±(½π) N and ±(π) N typical electron spins-driven qubits.
EXAMPLE 5
[0079] Liquid pharmaceutical ingredients were prepared according to the pharmaceutical standards. Reference may be made to pharmaceutical standard guideline issued by the Ministry of Health in China. Topographic structure and qubit features of the 2:2:3:1 molar mixture ratios obtained in Example 5 are depicted in FIGS. 7 and 16 a - d.
[0080] The following pharmaceutical solutions were prepared according to the pharmaceutical standards (see, for example, pharmaceutics guideline of the ministry of health in China):
i. Preparing aA verapamil hydrochloride pharmaceutical liquid at a concentration of 2.5 mg/5 mL. ii. Preparing an isoprenaline hydrochloride pharmaceutical liquid at a concentration of 2 mg/100 mL. iii. Preparing aA physiological buffer solution of superoxide dismutase at a concentration of 1 mg/2 mL. iv. Preparing aA physiological buffer solution of adenosine triphosphate at a concentration of 20 mg/3.3 mL. v. Respectively preparing and taking the optimum molecular numbers from each ingredients of verapmil in a range of about 20 zeptoMol to about 0.001 zeptoMol, isoprenaline in a range of about 210 zeptoMol to about 0.001 zeptoMol, superoxide dismutase in a range of about 1 zeptoMol to about 0.001 zeptoMol, adenosine triphosphate in a range of 260 zeptoMol to about 1 zeptoMol and xanthine in a range of about 50 μM to about 5 mM, respectively mixing them at room temperature and preparing xanthine-based quaternary pharmaceutical ingredient physiological buffer solutions at molar mixture ratios of 2:2:3:1 (verapamil:isoprenaline:superoxide dismutase:adenosine triphosphate), mixing them at room temperature according to the L 9 (3) 4 orthogonal design protocol, keeping the 1 mL final volume of xanthine-based quaternary pharmaceutical ingredient physiological buffer solutions −4° C. for applications. vi. Immersing a p-doped silicon substrate (8-12Ω cm) into the above desired 1 mL 2:2:3:1 (verapamil:isoprenaline:superoxide dismutase:adenosine triphosphate) pharmaceutical ingredient solution according to the L 9 (3) 4 orthogonal design protocol, and storing at −4° C. for 96 hours. vii. The results of this practice example profiled that the height of quantum wire array is 8 nm (FIG. 7); the I-V curve presented a bi-stable electrical property, i.e., the higher current of 20.723 pA and the lower current of −27.549 pA occurred within the ±8V bias potentials ( FIG. 16 a ); the differential conductance spectrum (dI/dV) revealed the quantized kondo effect, i.e., the maximum conductance peak of 55.5468 pA/V located at the −0.223V bias potential ( FIG. 16 b ); the frequency-phase-energy spectrum (FPP) showed phase transitions from 0 degrees to −10800 degrees within the frequency domain from ±50000 Hz to 7.2475E-12 Hz, where 120(−½π) or 40(−1½π) or 240(−¼π) or 60(−π) spin echo typical electron spins occurred at the y axis with the central frequency of 7.2475E-12 Hz at the x axis and the energy fluctuation of 0.0332 eV ( FIG. 16 c ); the time-phase-energy spectrum (TPP) presented phase transitions from 0 degrees to 10800 degrees within the time domain from 0 μs to 1000 μs, where 120(½π) or 40(1½π) or 240(¼π) or 60(π) spin echo typical electron spins happened at the y axis with the central time of 513 μs at the x axis and the energy fluctuation of 0.00833 eV at the z axis ( FIG. 16 d ). The parental data in FIG. 16 c - d simultaneously revealed ±(½π) N, ±(1½π) N, ±(¼π) N and ±(π) N typical electron spins-driven qubits.
EXAMPLE 6
[0088] Liquid pharmaceutical ingredients were prepared according to the pharmaceutical standards. Reference may be made to pharmaceutical standard guideline issued by the Ministry of Health in China. Topographic structure and qubit features of the 3:1:3:2 molar mixture ratios obtained in Example 6 are depicted in FIGS. 8 and 17 a - d.
[0089] The following pharmaceutical solutions were prepared according to the pharmaceutical standards (see, for example, pharmaceutics guideline of the ministry of health in China):
i. Preparing a verapamil hydrochloride pharmaceutical liquid at a concentration of 2.5 mg/5 mL. ii. Preparing an isoprenaline hydrochloride pharmaceutical liquid at a concentration of 2 mg/100 mL. iii. Preparing a physiological buffer solution of superoxide dismutase at a concentration of 1 mg/2 mL. iv. Preparing a physiological buffer solution of adenosine triphosphate at a concentration of 20 mg/3.3 mL. v. Respectively preparing and taking the optimum molecular numbers from each ingredients of verapmil in a range of about 20 zeptoMol to about 0.001 zeptoMol, isoprenaline in a range of about 210 zeptoMol to about 0.001 zeptoMol, superoxide dismutase in a range of about 1 zeptoMol to about 0.001 zeptoMol, adenosine triphosphate in a range of 260 zeptoMol to about 1 zeptoMol and xanthine in a range of about 50 μM to about 5 mM, respectively mixing them at room temperature and preparing xanthine-based quaternary pharmaceutical ingredient physiological buffer solutions at molar mixture ratios of 3:1:3:2 (verapamil:isoprenaline:superoxide dismutase:adenosine triphosphate), mixing them at room temperature according to the L 9 (3) 4 orthogonal design protocol, keeping the 1 mL final volume of xanthine-based quaternary pharmaceutical ingredient physiological buffer solutions at −4° C. for applications. vi. Immersing a p-doped silicon substrate (8-12Ω cm) into the above desired 1 mL 3:1:3:2 (verapamil:isoprenaline:superoxide dismutase:adenosine triphosphate) xanthine-based quaternary pharmaceutical ingredient physiological buffer solutions according to the L 9 (3) 4 orthogonal design protocol, and storing at −4° C. for 96 hours. vii. The results of this practice example profiled that the height of quantum wire array is 4.5 nm ( FIG. 8 ); the I-V curve presented a bi-stable electrical property, i.e., the higher current of 21.576 pA and the lower current of −31.509 pA occurred within the ±7V bias potentials ( FIG. 17 a ); the differential conductance spectrum (dI/dV) reveals the quantized kondo effect, i.e., the maximum conductance peak of 63.5786 pA/V located at the −0.715V bias potential ( FIG. 17 b ); the frequency-phase-energy spectrum (FPP) showed phase transitions from 0 degrees to −15480 degrees within the frequency domain from ±50000 Hz to 7.2475E-12 Hz, where 172(½π) or 81(−π) spin echo typical electron spins occurred at the y axis with the central frequency of 7.2475E-12 Hz at the x axis and the energy fluctuation of 0.05289 eV ( FIG. 17 c ); the time-phase-energy spectrum (TPP) presented phase transitions from 0 degrees to 10800 degrees within the time domain from 0 μs to 1000 μs, where 172(½π) or 81(π) spin echo typical electron spins happened at the y axis with the central time of 513 μs at the x axis and the energy fluctuation of 0.01322 eV at the z axis ( FIG. 17 d ). The parental data in FIG. 17 c - d simultaneously revealed ±(½π) N and ±(π) N typical electron spins-driven qubits.
EXAMPLE 7
[0097] Liquid pharmaceutical ingredients were prepared according to the pharmaceutical standards. Reference may be made to pharmaceutical standard guideline issued by the Ministry of Health in China. Topographic structure and qubit features of the 3:2:1:3 molar mixture ratios obtained in Example 7 are depicted in FIGS. 9 and 18 a - d.
[0098] The following pharmaceutical solutions were prepared according to the pharmaceutical standards(see, for example, pharmaceutics guideline of the ministry of health in China):
i. Preparing a verapamil hydrochloride pharmaceutical liquid at a concentration of 2.5 mg/5 mL. ii. Preparing an isoprenaline hydrochloride pharmaceutical liquid at a concentration of 2 mg/100 mL. iii. Preparing a physiological buffer solution of superoxide dismutase at a concentration of 1 mg/2 mL. iv. Preparing a physiological buffer solution of adenosine triphosphate at a concentration of 20 mg/3.3 mL. v. Respectively preparing and taking the optimum molecular numbers from each ingredients of verapmil in a range of about 20 zeptoMol to about 0.001 zeptoMol, isoprenaline in a range of about 210 zeptoMol to about 0.001 zeptoMol, superoxide dismutase in a range of about 1 zeptoMol to about 0.001 zeptoMol, adenosine triphosphate in a range of 260 zeptoMol to about 1 zeptoMol and xanthine in a range of about 50 μM to about 5 mM, respectively mixing them at room temperature and preparing xanthine-based quaternary pharmaceutical ingredient physiological buffer solutions at molar mixture ratios of 3:2:1:3 (verapamil:isoprenaline:superoxide dismutase:adenosine triphosphate), mixing them at room temperature according to the L 9 (3) 4 orthogonal design protocol, keeping the 1 mL final volume of xanthine-based quaternary pharmaceutical ingredient physiological buffer solutions at −4° C. for applications. vi. Immersing a p-doped silicon substrate (8-12Ω cm) into the above desired 1 mL 3:2:1:3 (verapamil:isoprenaline:superoxide dismutase:adenosine triphosphate) pharmaceutical ingredient solution according to the L 9 (3) 4 orthogonal design protocol, and storing at −4° C. for 96 hours. vii. The results of this practice example profiled that the height of quantum wire array is 50 nm ( FIG. 9 ); the I-V curve presented a bi-stable electrical property, i.e., the higher current of 5.478 pA and the lower current of −25.614 pA occurred within the ±8V bias potentials ( FIG. 18 a ); the differential conductance spectrum (dI/dV) revealed the quantized kondo effect, i.e., the maximum conductance peak of 35.5468 pA/V located at the −1.096V bias potential ( FIG. 18 b ); the frequency-phase-energy spectrum (FPP) showed phase transitions from 180 degrees to 23580 degrees within the frequency domain from ±50000 Hz to 7.2475E-12 Hz, where 262(½π) or 32(2π) or 64(π) spin echo typical electron spins occurred at the y axis with the central frequency of 7.2475E-12 Hz at the x axis and the energy fluctuation of 0.01244 eV ( FIG. 18 c ); the time-phase-energy spectrum (TPP) presented phase transitions from 0 degrees to −23220 degrees within the time domain from 0 μs to 1000 μs, where 158(−½π) or 69(−2π) or 78(−π) spin echo typical electron spins happened at the y axis with the central time of 513 μs at the x axis and the energy fluctuation of 0.00311 eV at the z axis ( FIG. 18 d ). The parental data in FIG. 18 c - d simultaneously revealed ±(½π) N, ±(π) N and ±(2π) N typical electron spins-driven qubits.
EXAMPLE 8
[0104] Liquid pharmaceutical ingredients were prepared according to the pharmaceutical standards (reference may be made to pharmaceutical standard guideline issued by the Ministry of Health in China). Topographic structure and qubit features of the 1:2:2:1 molar mixture ratios obtained in Example 8 are depicted in FIGS. 1 and 10 a - d.
[0105] The following pharmaceutical solutions were prepared according to the pharmaceutical standards (see for example, pharmaceutics guideline of the ministry of health in China):
i. Preparing a verapamil hydrochloride pharmaceutical liquid at a concentration of 2.5 mg/5 mL. ii. Preparing an isoprenaline hydrochloride pharmaceutical liquid at a concentration of 2 mg/100 mL. iii. Preparing a physiological buffer solution of superoxide dismutase at a concentration of 1 mg/2 mL. iv. Preparing a physiological buffer solution of adenosine triphosphate at a concentration of 20 mg/3.3 mL. v. Respectively preparing and taking the optimum molecular numbers from each ingredients of verapmil in a range of about 20 zeptoMol to about 0.001 zeptoMol, isoprenaline in a range of about 210 zeptoMol to about 0.001 zeptoMol, superoxide dismutase in a range of about 1 zeptoMol to about 0.001 zeptoMol, adenosine triphosphate in a range of 260 zeptoMol to about 1 zeptoMol and xanthine in a range of about 50 μM to about 5 mM, respectively mixing them at room temperature and preparing xanthine-based quaternary pharmaceutical ingredient physiological buffer solutions at molar mixture ratios of 1:2:2:1 (verapamil:isoprenaline:superoxide dismutase:adenosine triphosphate), mixing them at room temperature according to the L 9 (3) 4 orthogonal design protocol, keeping the 1 mL final volume of xanthine-based quaternary pharmaceutical ingredient physiological buffer solutions at −4° C. for applications. vi. Immersing a p-doped silicon substrate (8-12Ω cm) into the above desired 1 mL 1:2:2:1 (verapamil:isoprenaline:superoxide dismutase:adenosine triphosphate) pharmaceutical ingredient solutions according to the L 9 (3) 4 orthogonal design protocol, and storing at −4° C. for 96 hours. vii. The results of this practice example profiled that the height of quantum wire array is 3 nm ( FIG. 1 ); the I-V curve presented a bi-stable electrical property, i.e., the higher current and the lower current of ±34.581 pA occur within the ±9V bias potentials ( FIG. 10 a ); the differential conductance spectrum (dI/dV) revealed the quantized kondo effect, i.e., the maximum conductance peak of 140.51389 pA/V located at the −3.25V bias potential ( FIG. 10 b ); the frequency-phase-energy spectrum (FPP) showed phase transitions from 0 degrees to −19080 degrees within the frequency domain of ±50000 Hz˜7.2475E-12 Hz, where 254(−½π) or 127(−π) spin echo typical electron spins occurred at the y axis with the central frequency of 7.2475E-12 Hz at the x axis and the energy fluctuation of 0.05027 eV ( FIG. 10 c ); the time-phase-energy spectrum (TPP) presented phase transitions from 0 degrees to 19080 degrees within the time domain from 0 μs to 1000 μs, where 254(½π) or 127(π) spin echo typical electron spins happened at the y axis with the central time of 513 μs at the x axis and the energy fluctuation of 0.0124 eV at the z axis ( FIG. 10 d ). The parental data in FIG. 10 c - d simultaneously revealed ±(½π) N typical electron spins-driven qubits.
EXAMPLE 9
[0113] Liquid pharmaceutical ingredients were prepared according to the pharmaceutical standards(see for example, pharmaceutical standard guideline issued by the Ministry of Health in China). Topographic structure and qubit features of the 2:2:1:2 molar mixture ratios obtained in Example 9 are depicted in FIGS. 1 and 11 a - d.
[0114] The following pharmaceutical solutions were prepared according to the pharmaceutical standards(see, for example, pharmaceutics guideline of the ministry of health in China):
i. Preparing a verapamil hydrochloride pharmaceutical liquid at a concentration of 2.5 mg/5 mL. ii. Preparing an isoprenaline hydrochloride pharmaceutical liquid at a concentration of 2 mg/100 mL. iii. Preparing a physiological buffer solution of superoxide dismutase at a concentration of 1 mg/2 mL. iv. Preparing a physiological buffer solution of adenosine triphosphate at a concentration of 20 mg/3.3 mL. v. Respectively preparing and taking the optimum molecular numbers from each ingredients of verapmil in a range of about 20 zeptoMol to about 0.001 zeptoMol, isoprenaline in a range of about 210 zeptoMol to about 0.001 zeptoMol, superoxide dismutase in a range of about 1 zeptoMol to about 0.001 zeptoMol, adenosine triphosphate in a range of 260 zeptoMol to about 1 zeptoMol and xanthine in a range of about 50 μM to about 5 mM, respectively mixing them at room temperature and preparing xanthine-based quaternary pharmaceutical ingredient physiological buffer solutions at molar mixture ratios of 2:2:1:2 (verapamil:isoprenaline:superoxide dismutase:adenosine triphosphate), mixing them at room temperature according to the L 9 (3) 4 orthogonal design protocol, keeping the 1 mL final volume of xanthine-based quaternary pharmaceutical ingredient solutions at −4° C. for applications. vi. Immersing a p-doped silicon substrate (8-12Ω cm) into the above desired 1 mL 2:2:1:2 (verapamil:isoprenaline:superoxide dismutase:adenosine triphosphate) pharmaceutical ingredient solutions according to the L 9 (3) 4 orthogonal design protocol, and storing at −4° C. for 96 hours. vii. The results of this practice example profiled that the height of quantum wire array is 16 nm ( FIG. 2 ); the I-V curve presented a bi-stable electrical property, i.e., the higher current of 3.568 pA and the lower current of −22.19 pA occurred within the ±2V bias potentials ( FIG. 11 a ); the differential conductance spectrum (dI/dV) revealed the quantized kondo effect, i.e., the maximum conductance peak of 315.62 pA/V located at the −0.874V bias potential ( FIG. 11 b ); the frequency-phase-energy spectrum (FPP) showed phase transitions from 0 degrees to 18540 degrees within the ±50000 Hz-7.2475E-12 Hz frequency domain, where 206(½π) or 103(π) spin echo typical electron spins occurred at the y axis with the central frequency of 7.2475E-12 Hz at the x axis and the energy fluctuation of 0.14939 eV ( FIG. 11 c ); the time-phase-energy spectrum (TPP) presented phase transitions from 0 degrees to −181800 degrees within the 0 μs to 1000 μs time domain, where 202(±½π) or 101(−π) spin echo typical electron spins happened at the y axis with the central time of 513 μs at the x axis and the energy fluctuation of 0.01116 eV at the z axis ( FIG. 11 d ). The parental data in FIG. 11 c - d simultaneously revealed ±(½π) N and ±(π) N typical electron spins-driven qubits. | ABSTRACT A bi-stable quantum wire array of self-assembled nano-medicine and its process present in the invention. The bi-stable quantum wire array with quantum bit and kondo effect is prepared by self-assembling an oxygen radical antagonist of antioxidase, a β-receptor agonist, a P2 receptor agonist, a calcium antagonist of phenyl alkyl amines, and/or a nucleotide monomer of purines and its binary, ternary, quaternary or quinary compounds and using the interaction of inelastic electron tunneling. The invention not only benefits mechanisms-targeted multifunctional device discoveries, but also profits inventions of nanometer structures, novel materials, quantum calculation devices, biosensors and quantum bit magnetic random access memories (MRAM). | 0 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a remote meter reading arrangement and particularly to such an arrangement that uses an optical fibre local transmission system.
2. Description of Related Art
The concept of remote meter reading has been considered for a number of years. However, most of the plans and designs to date have concerned individual utilities, involved new and incompatible designs for meters, have failed to take account of the installed base of mechanical meters and have failed to take the concept to its ultimate and logical conclusion, which is for an integrated meter reading scheme where all utilities share the same transmission system and a central billing authority which collates the data and presents its accounts for payment to users at a greater frequency than the utilities have done to date individually.
The Technology may conveniently be split into three sections.
METER READING
DATA COUNTING
AND TRANSMISSION.
It is an inconvenient fact that Domestic meters for Gas, Electricity and Water each in their own way occupy inhospitable environments for electronic devices.
Electricity meters suffer from power surges and electrical interference.
Gas meters should, ideally, be kept separate from electrical devices because of the risk of leakage and explosion.
Water meters are usually found in damp conditions and frequently become submerged.
While the technology exists to keep electronics working in the most evil of environments, it is usually at a cost. It is important for each section of the automated meter reader to be cheap and trouble free.
The simplest method of reading any existing mechanical meter is to exploit the dials which rotate as the utilities product is consumed. If a light is focussed on a section of the fastest rotating dial and a light sensitive transducer is similarly focussed on the same point, as the dial rotates, the light level returned to the transducer will vary.
The counters may not necessarily be rotating discs but may take any other convenient form such as a flap display or electronically designed L.E.D.
SUMMARY OF THE INVENTION
It is an object of the present invention to improve and clarify the previous proposals for remote optical meter reading and is particularly concerned with the means for transmitting the light and for processing it when received in reflected form.
According to the present invention a meter reading arrangement comprises means for directing light at a meter having at least one moving indicator, wherein light is directed at the fastest moving indicator on the meter and an optical fibre transmission path links the meter to a remotely located meter interface unit, one end of the said fibre optical transmission path being directed at the said fastest moving indicator and the other onto transducer means at the interface unit, whereby each variation in light level reflected from the meter is transmitted to the interface unit for processing.
There may also be provided a second fibre optical transmission path over which light is directed from a remote source onto the meter for reflection to the interface unit. Focusing means may be provided adjacent the meter for focusing transmitted and/or reflected light.
The interface unit conveniently includes optical transducer means for sensing sequential variation changes in the amplitude of reflected transmitted light.
The meter interface unit may connect optically to a plurality of meters remotely situated from the interface unit and from each other, each meter being monitored over a separate optical path, and may integrate all the information provided by the variation counts for further onward transmission to another location where it can be interpreted for accounting, managerial and monitoring purposes.
The onward transmission means may be any suitable form which may include further optical fibre transmission cables, coaxial cables (such as used by cable TV), telephone lines, radio or mains carrier transmission over power cables.
Modulated light may be used to enhance the signal from the reflected light, to remove interference by ambient light and for the detection of fraud and rupture of the fibre optic cable or removal of the reading head. The modulated light may be mono-chromatic.
The light which is transmitted from the meter interface unit to the meter is reflected by varying amounts dependent upon the marking on the surface of the indicating means on the meter or when it is intercepted by a pointer which may rotate on the face or dial of the meter. Preferably the indicator means is a rotary means such as a ferraris disk which may have markings on its edge or face which will variably reflect the light from the optical fibre cable which may be directed to the edge or surface or both, a test dial where a pointer will rotate and intercept the light source and a barrel counter where the light source is directed at the least significant digit.
It will be appreciated that special precautions will be necessary for water meters that may become submerged. Where this condition is anticipated, special sealants and gaskets may be required. However, in the domestic environment, most water meters will be new, can be placed where they do not get easily submerged and the optical head could be designed into them.
On installation, an optical fibre device at the end of a transmission path could be attached to the glass or plastic of the meter with a transparent but slightly sticky glue which hardens by UV light when the correct position for focus and direction on to the relevant dial has been found. The same glue will attach Light Pipes to an optical fibre device.
The light pipes do not need to be of high optical quality nor do they need to convey a coherent image. Thus they can be relatively cheap and clad by a simple but tough plastic cover. Because the prism and lens of the device could be symmetrical, there is no requirement to ensure that the Light Pipe of a pair is handed. (It would appear similar to a length of twin core plastic flex).
BRIEF DESCRIPTION OF THE DRAWINGS
An example of a meter reading arrangement in accordance with the invention will now be described with reference to the four sheets of the accompanying drawing.
In the figures:
FIG. 1 is schematic diagram of an optical meter reader embodying the basic principles of the arrangement,
FIG. 2 shows a cross section of the arrangement of a pair of optical fibre transmission paths,
FIG. 3 shows the termination of one of the paths of FIG. 2 to illustrate the focussing of the light transmitted,
FIG. 4 shows detail of the functional components of the meter interface unit,
FIGS. 5a and 5b show different types of rotating members which can be used to originate incremental counts,
FIG. 6 is a trace of the output from a meter indicating how the transmitted output can be analysed.
FIGS. 7(a), 7(b) and 7(c) show three waveforms typically obtained from each an electricity, water and gas meter.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to the drawings and particularly to FIG. 1 thereof, this shows a rotating meter dial 1 having a pointer 2. An optical fibre cable 3 comprising a pair of optical fibre light pipes terminates in an optical fibre device comprising a focusing head 4 adjacent the meter dial 1, and at its other end the optical fibre cable terminates one pipe in an optical transducer such as the photodiode 5 and the other pipe in a light emitting source such as an L.E.D 6, both located in an interface unit 51.
As the dial 1 rotates light from the light source 6 is transmitted through the cable 3 and the focusing head 4 onto the edge of the dial 1 and as the pointer 2 passes the focusing head the light which is being reflected from the optical fibre cable 3 onto the dial is interrupted and for a brief period less light is reflected back from the dial along the optical fibre cable to the transducer 5. This gives a light variation effect. It is not always essential to use focusing in the head although this may be convenient.
If reference is now made to FIG. 2 this shows the details of the optical fibre transmission paths making up the light pipe 3. In cross section the pipe comprises two cores of optical fibre 31, surrounded by a respective plastics shielding 33. One of the paths 34 is used to transmit light to the meter at the other 35 to transmit reflective light from the meter.
Referring also to FIG. 3 here the light path 34 is shown terminating in a prism 41, which with a lens 42 is part of the focusing head 4 of FIG. 1. Light is deflected by prism 41 and focused by lens 42 onto the point 2 of the wheel 1 and reflected light is converted by a similar prism and lens arrangement (not shown). The lens 42 and the prism 41 can be replaced by a (convex) mirror.
Reference is now made to FIG. 4 this shows the set-up of a meter interface unit for monitoring a plurality of meters at a remote location. These meters may well for example be an electricity meter 11, a water meter 12 and a gas meter 13. The essential feature of each meter is that it has a moving marked member which can reflect the light and give a pulsed reflection. Each meter is connected by a respective optical fibre cable 3 to a respective optical transmit and receive module 8 containing the element 6 and 5 as indicated in FIG. 1. Outputs 9 from the modules 8 are connected to a microprocessor 10 which in turn is connected to a memory and storage register 14 and a communications interface 15. Further connections to the microprocessor 10 are a pulsed output meter 16 and a digital output meter 17 as well as possibly a home automation system 18.
Indications of movement from the meters 11, 12 and 13 are transmitted to the respective modules 8 where a signal is generated depending on the number of movements made in the meters over lines 9 to microprocessor 10. This carries out programs on an analogue/digital basis which recognise the patterns produced by the optical transducer in the units 8 and counts the units of consumption and stores them in the registers 14. It will also count and store units of consumption from meters such as 16 which have pulsed output systems and store data from meters such as 17 which have digital outputs. Thus the whole arrangement is not limited to merely one type of meter but can integrate all types of meter.
The microprocessor 10 is able to be programmed to provide active line testing for a telephone network on demand and to be able to communicate with home automation devices 18 such as those attached to an established Creda Net (RTM) or a similar system. The unit should also be able to interface with a number of standard networks to increase its applicability.
In operation light from a light source 6 such as an L.E.D is transmitted over an optical light pipe as shown in FIG. 2, although a single fibre could be used if a beam splitter was fitted at the meter interface unit end. The choice of fibre depends greatly on the type of installation and the length of the transmission path involved. In certain applications single fibres may be preferable. The light transmitted may come from a modulated source since this enhances the sensitivity of the arrangement and provides an indication of any break in the fibre which may have occurred for any reason. If modulated light is included then the optical transducer 5 receiving the reflected light will have to take account and sense this (such an arrangement would use phase lock loop circuitry).
If reference is now made to FIG. 5 the light level outputs which will be received by the optical transducer 5 will be appreciated for the different types of rotating indicator.
In FIG. 5a a barrel counter is shown with the barrels having the most significant bit (MSB) on the left and the least significant bit (LSB) on the right. The light from the light source 6 will be focused on the least significant bit barrel and this is engraved and marked with normal arabic numerals. Because of the shape of the numerals a different light level will be produced and reflected back down the cable 3 to the transducer 5 every time that a number passes a focusing head. The output light level for the various numerals is shown to the right of FIG. 5a and this is shown both from the analogue light output and the converted digitised output. It will be seen that each figure has a characteristic light level. This light level is not significant in the present application although with sophisticated circuitry a recognition could be established to determine which number is being observed and reflected. The idea of the invention is to count the revolutions of the least significant digit of the barrel remotely, using optical means.
The disc shown in FIG. 5b is the Ferraris wheel of the type used commonly in electricity meters where a pointer overlaps on the edge to give a mark on the edge and observation is made of the edge of the disc as it rotates. In this case the light is focused on the edge of the disc and each time the mark on the Ferraris wheel passes the light path the reflection is interrupted and this gives a single pulse of narrow width as is indicated in FIG. 5b. The output from a dial with a pointer will be similar.
FIG. 6 shows a typical trace from an electricity meter where it can be seen that the pattern output is regular and indications are given of light level changes where a long stripe occurs at 20 where a short stripe occurs at 21 and where this is a notch in the disc at 22. The sequence of light levels are able to be counted in the microprocessor 10 and stored in the registers 14 and 17 where they can be later abstracted and used for filing and accounting purposes. There is no need for the registers to be actually inspected but they ,can be interrogated by the telephone interface unit and the information passed over telephone lines 10 to a remote recording unit.
FIGS. 7(a), (b) and (c) show respectively outputs may be obtained from the Electricity, Water and Gas meters 11, 12 and 13. It will be noted that whereas each waveform is substantially different they are cyclic and repeat the same set of sequential output levels. It is this repetition which is important in the digital conversion. The time period taken by each sequence is unimportant.
The arrangement provides a simple and inexpensive way of reading a plurality of meters in a domestic installation and from time to time assessing the information gathered so that utility billing can take place. Most types of meters are able to be interrogated and recorded and since optical fibre cables are used there is no risk of danger from having separate electric light sources in areas such as gas meters where incendive sparking might occur and cause explosions or with water meters where the ingress of water can cause electronics to fail.
The whole installation is cheap and easy to install and can run for many years without any maintenance or servicing as it is basically a passive arrangement. | A meter reading arrangement has an optical fiber transmission path made up of a pair of optical fibers connecting between a meter to be read and a meter interface unit. Light is transmitted over one of the fibers to an indicator on the meter and reflected light is transmitted by the second fiber to a transducer in the interface unit. | 8 |
[0001] The present invention relates to a method for the preparation of 1,2-diaminocyclohexane-platinum (II) complexes, in particular cis-oxalato-(trans-l-1,2-cyclohexanediamine)-platinum (II) complexes such as oxaliplatin. Furthermore, the invention relates to an oxaliplatin substance of high purity and its use as pharmacologically active compound in pharmaceutical compositions (e.g. for the treatment of cancer).
[0002] “Oxaliplatin”, CAS Number [61825-94-3] is the generally used name for a Pt(II)-complex with the chemical name (SP-4-2)-[(1R,2R))-1,2-cyclohexandiamine-N,N′]-[oxalato-O,O′]-platinum(II). The conventional name is “cis-oxalato-(trans-l-1,2-cyclohexanediamine)-platinum (II)”. Oxaliplatin is a cytostatic drug against metastatic colorectal carcinoma. Basically, the oxaliplatin complex is a mixture of 3 isomers: a cis-isomer, which is a geometrical isomer and two trans-isomers (trans-d and trans-l), which are optical isomers (enantiomers). Oxaliplatin is the pure trans-l enantiomer having the following formula:
[0000]
[0003] While the anti-tumor activity of cis-platinum (II) compounds was generally known, the specific Pt compound was discovered in 1976 at Nagoya University (Japan) by Professor Yoshinori Kidani (ref to U.S. Pat. No. 4,169,846). Oxaliplatin is now frequently used in cancer therapy.
[0004] The process described in U.S. Pat. No. 4,169,846 is based on the reaction of the (SP-4-2)-dichloro-[(1R,2R))-1,2-cyclohexandiamine-N,N′]-platinum(II) complex, in the following abbreviated as (DACH)PtCl 2 , in water with two equivalents of silver nitrate (AgNO 3 ), an elimination of the obtained solid phase and a subsequent reaction of the obtained [(1R,2R)-1,2-cyclohexandiamine-N,N′]-platinum(II) diaquo-dinitrate (hereinafter abbreviated as (DACH)Pt(aquo)-2-dinitrate) with oxalic acid and/or its alkali metal salts. The product must be purified by recrystallisation; the final yield of the obtained oxaliplatin is usually quite low. Therefore, this general procedure is not suitable for industrial application.
[0005] Various methods for the preparation of oxaliplatin were later disclosed in the patent literature.
[0006] A major focus was on the reduction of the silver content of the oxaliplatin product to fulfil the requirements of the pharmaceutical specifications. According to the European Pharmacopeia April 2003, Annex 4.4, the silver content must be less than 5 ppm (as detected by AAS). Purification steps, which use alkaline iodides for the elimination of silver ions and other impurities from the (DACH)Pt(II) diaquo complexes were frequently reported in the state of the art.
[0007] U.S. Pat. No. 5,290,961 (and the corresponding EP 61704381) disclose a process for oxaliplatin manufacture, in which in a first step not less than two equivalents of silver are added to the compound (DACH)PtCl 2 . Thereafter, the precipitated AgCl is removed and sodium iodide and/or potassium iodide is added to convert the unreacted (DACH)PtCl 2 , its by-products and unreacted silver ions into their iodine compounds followed by the removal thereof. After this step, oxalic acid is added to form the oxaliplatin complex.
[0008] In WO 03/004505 A1, a similar purification step based on the addition of iodide ions is reported.
[0009] EP 1680434B1 discloses the addition of quarternary ammonium iodide compounds of the type (NR 4 )N I for removal of trace contaminants.
[0010] EP 1561754B1 describes a preparation process for oxaliplatin using the tetra-iodo complex K 2 PtI 4 as starting material for preparing the compound (DACH)PtI 2 . This intermediate is reacted with a silver salt such as AgNO 3 , the precipitated AgI is removed and the remaining (DACH)Pt-(aquo)-2-dinitrate complex is converted to oxaliplatin by addition of an oxalate compound.
[0011] A similar preparation method, also starting from K 2 PtI 4 , is disclosed in ES 2183714A1.
[0012] A drawback of the methods employing the iodide compound K 2 PtI 4 as starting material is that an additional step is coming to the process (due to the preparation of the K 2 PtI 4 complex from the dichloro compound K 2 PtCl 4 ), Thus, the resulting overall procedure is time-consuming and costly.
[0013] Furthermore, the preparation methods employing iodides lead to discoloration of the product due to the formation of platinum(II) mono- and diiodo complexes. The crude oxaliplatin product must therefore be recrystallized from water.
[0014] WO 2007/140804 discloses a method for manufacture of oxaliplatin, in which a solid inert material and a solid polymeric material containing cationic exchange groups is added in the various reaction steps.
[0015] EP 881226 teaches the use of deoxygenated water and a low oxygen environment for the production of oxaliplatin. Such processes are too time-consuming and costly to employ in industrial production scale.
[0016] In summary, the presently disclosed processes for manufacture of oxaliplatin are suffering from various drawbacks and are time-consuming, lengthy and costly.
[0017] Therefore it was an objective of the present invention to provide a manufacturing process for oxaliplatin, which is quick, simple, straightforward, economical and applicable to industrial production. The process should deliver the oxaliplatin product in high yield and high purity, suitable for pharmaceutical use. Furthermore, it was an objective to provide a process, in which the individual steps employed should not require deoxygenated water or low oxygen atmosphere.
[0018] These objectives are met by the preparation method according to the claims of the present invention.
[0019] The present invention provides a process for preparing oxaliplatin (cisoxalato-(trans-l-1,2-cyclohexanediamine)-platinum-II) of the structural formula I:
[0000]
[0000] comprising the following steps:
a) reacting potassium tetrachloroplatinate (II) [K 2 PtCl 4 ] with trans-l-1,2-cyclohexanediamine to obtain the dichloro-[(trans-l-1,2-cyclohexanediamine-N,N′]-platinum(II) complex, b) reacting the dichloro-[(trans-l-1,2-cyclohexandiamine-N,N′]-platinum(II) complex with silver sulfate (Ag 2 SO 4 ) to obtain [(trans-l-1,2-cyclohexandiamine-N,N′]-platinum(II)-diaquo-sulfate and silver chloride (AgCl), c) reacting the [(trans-l-1,2-cyclohexandiamine-N,N′]-platinum(II)diaquo sulfate with barium oxalate (BaC 2 O 4 ) to obtain oxaliplatin (cis-oxalato-(trans-l-1,2-cyclohexane-diamine)-platinum-II) and barium sulfate (BaSO 4 ).
[0023] The reaction steps a)-c) of the process of the present invention can be depicted in the following equations (1)-(3) (wherein “DACH” is the abbreviation for trans-l-1,2-cyclohexanediamine and “aq” denotes a H 2 O ligand in the Pt sulfate complex):
[0000] Step a): K 2 PtCl 4 +trans-l-DACH==>(DACH)PtCl 2 (1)
[0000] Step b): (DACH)PtCl 2 +Ag 2 SO 4 ==>(DACH)Pt(aq) 2 SO 4 +2AgCl (2)
[0000] Step c): (DACH)Pt(aq) 2 SO 4 + BaC 2 O 4 ==>(DACH)Pt(C 2 O 4 )+BaSO 4 (3)
[0024] In a preferred embodiment of the invention, the barium oxalate (BaC 2 O 4 ) employed in step c) is added in the form of separate components to the reaction mixture. Thus it can be formed “in situ” during the reaction. In this case, the two compounds oxalic acid (H 2 C 2 O 4 ) and barium hydroxide (Ba(OH) 2 ) are added successively or simultaneously in stoichiometric portions (i.e. equimolar) to the reaction mixture under stirring:
[0000] Step c1): (DACH)Pt(aq) 2 SO 4 +H 2 C 2 O 4 +Ba(OH) 2 ==>(DACH)Pt(C 2 O 4 )+BaSO 4 (3′)
[0025] Thus, in a preferred embodiment, the method of the present invention provides a process for preparing oxaliplatin (cis-oxalato-(trans-l-1,2-cyclohexanediamine)-platinum-II) of the structural formula I comprising the following steps:
a) reacting potassium tetrachloroplatinate (II) [K 2 PtCl 4 ] with trans-l-1,2-cyclohexanediamine to obtain the dichloro-[(trans-l-1,2-cyclohexanediamine-N,N′]-platinum(II) complex, b) reacting the dichloro-[(trans-l-1,2-cyclohexandiamine-N,N′]-platinum(II) complex with silver sulfate (Ag 2 SO 4 ) to obtain [(trans-l-1,2-cyclohexandiamine-N,N′]-platinum(II)-diaquo-sulfate and silver chloride (AgCl), c1) reacting the [(trans-l-1,2-cyclohexandiamine-N,N′]-platinum(II)diaquo-sulfate with equimolar portions of barium hydroxide Ba(OH) 2 ) and oxalic acid (H 2 C 2 O 4 ) to obtain oxaliplatin (cis-oxalato(trans-l-1,2-cyclohexane-diamine)-platinum-II) and barium sulfate (BaSO 4 ).
[0029] In this preferred embodiment, inexpensive starting materials can be used, which are readily available on the market.
[0030] The preparation processes of the invention may further comprise a step b′) of removal of the precipitated silver chloride (AgCl) after step b) and a step c′) of removal of the precipitated barium sulfate (BaSO 4 ) after steps c)/c1). In addition to these steps, further steps for removal of impurities and/or isolation and/or purification of the oxaliplatin product may be added to the process. As an example, the preparation process of the present invention may comprise the following steps:
a) reacting potassium tetrachloroplatinate (II) [K 2 PtCl 4 ] with trans-l-1,2-cyclohexanediamine to obtain the dichloro-[(trans-l-1,2-cyclohexanediamine-N,N′]-platinum(II) complex, b) reacting the dichloro-[(trans-l-1,2-cyclohexandiamine-N,N′]-platinum(II) complex with silver sulfate (Ag 2 SO 4 ) to obtain [(trans-l-1,2-cyclohexandiamine-N,N′]-platinum(II)-diaquo-sulfate and silver chloride (AgCl), b′) removal of the precipitated silver chloride (AgCl), c)/c1) reacting the [(trans-l-1,2-cyclohexandiamine-N,N′]-platinum(II)diaquo-sulfate with barium oxalate (BaC 2 O 4 ) (=step c)) or with equimolar portions of barium hydroxide (Ba(OH) 2 ) and oxalic acid (H 2 C 2 O 4 ) (=step c1)) to obtain oxaliplatin (cis-oxalato-(trans-l-1,2-cyclohexane-diamine)-platinum-II) and barium sulfate (BaSO 4 ), c′) removal of the precipitated barium sulfate (BaSO 4 ) and d) isolating and/or purification of the oxaliplatin product.
[0037] The present invention provides a manufacturing process for oxaliplatin, which is quick, straightforward, economical and applicable to industrial production. The process provides the oxaliplatin product in high yield and in high purity, in particular with a low silver content (<5 ppm). Compared to prior art manufacturing methods, the present process does not employ purification steps based on the addition of iodine compounds. Furthermore, the compound K 2 PtI 4 is not used as a starting material.
[0038] In general, the present process differs in two important features from the manufacturing methods of the prior art. At first, it uses silver sulfate (instead of silver nitrate) for the preparation of the intermediate (DACH)Pt(aq) 2 complex in step b). Secondly, the process employs barium oxalate (BaC 2 O 4 )—or alternatively an equimolar mixture of barium hydroxide (Ba(OH) 2 ) and oxalic acid (H 2 C 2 O 4 )—for the preparation of the oxaliplatin product (DACH)Pt(C 2 O 4 ) in step c).
[0039] The combination of these measures results in a very effective manufacturing process, allowing the removal of the ionic contaminants (barium ions and sulfate ions) from the mother liquor in the form of the practically water-insoluble BaSO 4 . It was surprisingly found that, after the removal of the BaSO 4 precipitate, the oxaliplatin product can be isolated in high purity from the mother liquor by simple solvent evaporation and crystallisation.
[0040] As there are a reduced number of processing steps and washing/purification procedures employed in the process, the product yields are quite high, reaching up to 80%.
[0041] In summary, the method according to the present invention provides very pure oxaliplatin product in high yield, which can be used as a pharmacologically active compound in pharmaceutical compositions.
DETAILED DESCRIPTION OF THE INVENTION
[0042] As already mentioned, the oxaliplatin compound is a mixture of 3 isomers. Oxaliplatin consists of the pure trans-l enantiomer. In order to achieve a high optical purity of the final oxaliplatin product, a trans-l-1,2-cyclohexane-diamine [=(1R,2R)-Diaminocyclohexane (DACH)] ligand with high optical purity should be employed in the process.
[0043] Step a:
[0044] Potassium tetrachloroplatinate (II) [K 2 PtCl 4 ], the starting material for step a), is readily available on the market. Typically, the Pt content should be in the range of 46.0 to 47.5 wt.-% and the water content should be <1 wt. %.
[0045] The (1R,2R)-diaminocyclohexane enantiomer suitable as starting material of the present invention should have a minimum optical purity of 99.5%, the content of the trans-d (=1S,2S) isomer should be <0.1%. Suitable DACH materials are manufactured by newly developed enantiomer separation technologies and are available from several vendors. The mixture of potassium chloroplatinate (K 2 PtCl 4 ) and DACH is stirred at room temperature for a time in the range of 2 to 10 hours, preferably in the range of 4 to 8 hours. The yellow (DACH)PtCl 2 precipitates and can be isolated e.g. by filtration with a filter unit. This intermediate (DACH)PtCl 2 is washed with purified water and organic solvents such as methanol and/or acetone. Drying is performed preferably in vacuum for a period of 1 to 6 hours.
[0046] Step b):
[0047] Generally, the silver sulfate employed in step b) is used in stoichiometric amounts in relation to the starting (DACH)PtCl 2 complex, e.g. per molar equivalent of the starting Pt complex one molar equivalent of silver sulfate is employed. The components are stirred in aqueous solution at room temperature (20° C.); the typical reaction time is in the range of 10 to 30 hours. Slightly increased reaction temperatures in the range of 30-50° C. may be used to avoid prolonged reaction times. The silver sulfate suitable for the present process should have a silver content of about 68.0 to 69.5 wt.-% Ag and a water content of <1 wt. %. Suitable products are available from different vendors.
[0048] Step c)/c1):
[0049] The barium oxalate (BaC 2 O 4 ) employed in step c) is commercially available or can be prepared separately prior to use in a simple reaction between equimolar amounts of barium hydroxide (Ba(OH) 2 ) and oxalic acid (H 2 C 2 O 4 ) in water. In case step c1) is employed, the components barium hydroxide (Ba(OH) 2 ) and oxalic acid (H 2 C 2 O 4 ) are added successively or simultaneously to the reaction mixture. Hereby, barium oxalate (BaC 2 O 4 ) is formed “in situ” in the reaction mixture. Barium hydroxide (Ba(OH) 2 ) may be employed in its mono-hydrate or its octa-hydrate form; oxalic acid can be used pure or in its di-hydrate form. All of these starting compounds are readily available on the market.
[0050] Generally, in step c) the pH is adjusted to the range of pH=4-7, preferably to the range of pH=5-6.5 after addition of the barium oxalate (BaC 2 O 4 ). In step c1), i.e. in case barium hydroxide (Ba(OH) 2 ) and oxalic acid (H 2 C 2 O 4 ) are added as separate compounds to the mixture, the pH is adjusted to the same pH range. Typically, steps c) and c1) are conducted at room temperature or at slightly increased reaction temperatures in the range of 30-50° C.
[0000] Steps b′) and c′):
[0051] The removal of the precipitated silver chloride (step b′)) is performed after step b) and the removal of the precipitated barium sulfate (step c′)) is conducted after step c) or step c1). These steps can be performed by use of standard separation and filtration operations known in the art. Separation and filtering equipment such as suction funnels, filter paper, filter presses, centrifuges etc. may be used. For improvement of the filtration process, aqueous suspensions of activated carbon (activated charcoal) may be spread over the filter paper prior to the start of the filtration processes. The filter cakes of precipitated AgCl (obtained in step b′)) and barium sulfate (obtained in step c′)) are generally analyzed by XRF (X-ray fluorescence) for platinum residues. If Pt residues are visible as defined peaks in the XRF spectrum, the corresponding filter cakes may be resuspended in purified water, stirred and filtered again. Finally the filter cakes may be collected for Pt recovery. If necessary, the filtration process may be repeated and the filtered solution containing the product (DACH)Pt(C 2 O 4 ) may be filtered again.
[0052] Step d):
[0053] For product isolation and/or purification, the resulting aqueous solution obtained in step c) or step c1) are concentrated in a rotation evaporator (e.g. “Rotavapor”) using a water-jet vacuum (10-20 Torr) at temperatures in the range of 25 to 50° C. Generally, the water is removed to almost dryness. Hereby, the oxaliplatin product crystallizes and precipitates. The resulting precipitate is isolated from the mother liquor by filtration and washed with cold, highly purified water and thereafter with acetone. Finally, the product is dried under vacuum for 1 to 5 hours.
[0054] Product Purity:
[0055] Typically, in the oxaliplatin product prepared according to the present invention, the Ag content is <5 ppm, preferably <3.5 ppm (as detected by atomic absorption spectroscopy, AAS). Thus, the product fulfils the specification of the European Pharmacopeia Apr. 2003, Annex 4.4. If necessary, suitable recrystallisation steps in purified water may be added. A general advantage of the present process is that no nitrate ions (NO 3 − ions) are employed. Thus, the contamination of the resulting oxaliplatin product with this ion is very low; the content of NO 3 − typically is <5 ppm, preferably <1 ppm (as detected by ion chromatography). Similarly, the content of Na + and K + typically is <5 ppm, preferably <1 ppm (as detected by ion chromatography). The final oxaliplatin product prepared according to the present invention reveals a very high optical purity. The concentration of the trans-d (=1S,2S) isomer is generally <0.1%. The product fulfils the requirements of the specification of the European Pharmacopeia Apr. 2003, Annex 4.4.
[0056] As a rule, the total yield of pure product is in range of 60 to 80%, more specifically in the range of 65 to 80% (based on Pt employed in the starting material K 2 PtCl 4 ). Product lumps may be de-agglomerated in a mortar. For protection against light, the product is stored in dark plastic bottles.
[0057] The following examples may illustrate the invention without narrowing its scope.
EXAMPLES
[0058] General Remarks:
[0059] Deionized water is used for all steps except for the stage of washing/rinsing of the final product. Here, highly purified water having a limited bacteria content (according to European Pharmacopoeia 4) is used.
[0060] Analytical Procedures:
[0061] Silver concentration is detected by AAS (Atomic absorption spectroscopy); XRF (X-ray fluorescence spectroscopy) is used for detection of residual platinum and silver contents. The alkali ions (Na + , K + etc) as well as the NO 3 − content are determined by ion chromatography (IC).
Example 1
Step a): Preparation of (DACH)PtCl 2
[0062] 106.4 g of potassium chloroplatinate K 2 PtCl 4 (0.256 mol; Pt-content 47.0 wt.-%; corresponding to 50.0 g Pt, supplier Umicore) are placed into a 5 l polypropylene tank and dissolved in 5 l of deionized water. Thereafter, 30 g of trans-l-1,2-cyclohexane-diamine [(R,R)-1,2-Diaminocyclohexane, CAS No. 20439-47-8], optical purity 99.5%) is added and the mixture is stirred at room temperature for 6 hours. The yellow product (DACH)PtCl 2 precipitates and is isolated by filtration over a filter unit. The filter cake is washed with deionized water, methanol and acetone and dried by vacuum for 4 hours. Yield >95%.
Step b): Reaction of (DACH)PtCl 2 with Silver Sulfate
[0063] 8 l of deionized water are charged into a 20 l polypropylene tank and 81.6 g silver sulfate Ag 2 SO 4 (0.26 mol; supplier Umicore) are added under stirring. Then, the Pt complex (DACH)PtCl 2 as prepared in step a), is added and the resulting suspension is stirred at room temperature for 20 hours. The precipitated AgCl is removed by filtration (step b′)). Before start of filtration, a suspension of activated carbon is applied over the filter paper. The filter cake is washed with deionized water and collected for Pt recovery. The filtrate contains the (DACH)Pt(aquo) 2 -(II)-sulfate complex, which is used in step c).
Step c1): Reaction of (DACH)Pt(aquo) 2 (II)-Sulfate with Barium Hydroxide and Oxalic Acid
[0064] The filtrate obtained from step b) (approx. 10-12 l), containing the (DACH)Pt(aquo) 2 -(II)-sulfate complex, is placed in a 20 l polypropylene tank. Thereafter, 32.4 g of oxalic acid dihydrate (H 2 C 2 O 4 ×2 H 2 O; 0.26 mol) and 81.6 g barium hydroxide octahydrate (Ba(OH) 2 .×8 H 2 O; 0.26 mol) are added under stirring. The reaction mixture is stirred for 20 hours at room temperature. The pH of the suspension is maintained at about pH=6. Then the filtration of the precipitated BaSO 4 is conducted through a filter unit (step c′)). Before start of filtration, a suspension of activated carbon is applied over the filter paper. The filter cake is washed with 1.5 l of deionized water and collected for Pt recovery.
[0065] The resulting solution is evaporated in a Rotavapor at 40° C. to almost dryness, whereby the oxaliplatin precipitates. The resulting precipitate is washed with 0.2-0.3 l of cold highly purified water (free of bacteria) and then with acetone. To protect the product against light, these operations are conducted under low intensity light. Finally, the product is dried under vacuum for 2 hours. The total yield of pure product is 65%.
[0066] The product is thereafter analyzed for impurities. Typically, the Ag content as detected by atomic absorption spectroscopy (AAS) is <5 ppm, preferably <3.5 ppm. If necessary, a recrystallisation step in purified water is added. In this example, the nitrate content is <1 ppm as detected by ion chromatography.
Example 2
[0067] This Example is conducted according to Example 1, however, barium oxalate (BaC 2 O 4 ) is used instead of barium hydroxide and oxalic acid (i.e. step c) is employed).
[0068] Barium oxalate is prepared separately by reacting equimolar portions of oxalic acid dihydrate (H 2 C 2 O 4 ×2H 2 O) and barium hydroxide octahydrate (Ba(OH) 2 .×8H 2 O) in deionized water. After reaction, the precipitated barium oxalate is isolated by filtration and dried prior to use.
[0069] The filtrate obtained in Example 1, step b) containing the (DACH)Pt(aquo) 2 -(II)-sulfate complex (approx. 10-12 l), is placed in a 20 l polypropylene tank. Thereafter 58.8 g of barium oxalate (BaC 2 O 4 , 0.26 mol) are added under stirring. The reaction mixture is stirred for 20 hours at room temperature. The pH of the suspension is maintained at about pH=6.
[0070] The further isolation of the product is conducted as described in Example 1. | The present invention is directed to a manufacturing process for 1,2-diamino-cyclohexane-platinum(II) complexes, specifically to a manufacturing process for oxaliplatin.
The process is straightforward, economical and applicable to industrial production. It comprises the reaction of (DACH)PtCl 2 with silver sulfate (Ag 2 SO 4 ) and the subsequent reaction of the resulting Pt sulfate complex (DACH)Pt(aq) 2 SO 4 with barium oxalate (BaC 2 O 4 ) or an equimolar mixture of barium hydroxide and oxalic acid to yield oxaliplatin in high purity with a low silver and low nitrate content. | 2 |
FIELD OF THE INVENTION
[0001] The present disclosure relates to micro-structure particles for bone growth and, in particular, for load bearing bone growth, wherein the micro-structure particles may include features which may align along a given axis.
BACKGROUND
[0002] Bone defects, such as the breakage or fracture of bones, may require the use of various fixation devices to align the bone pieces in a manner which may facilitate healing. For example, a variety of plates, screws, pins and/or wires, may be utilized to fix or stabilize bone fragments. However, in some cases, the use of such devices may cause additional fractures, infection or necrosis. Furthermore, additional procedures may be necessary to further the healing process, such as to elongate the bone or to remove plates, screws, or other devices.
SUMMARY OF THE INVENTION
[0003] An aspect of the present disclosure relates to a method of facilitating bone growth. The method may include positioning a device around at least a portion of a bone exhibiting a defect, the device capable of retaining bone segments and micro-structured particles. The method may also include applying micro-structure particles within the device to the defect, wherein each of the micro-structure particles include at least one pore therein. In addition, the method may include aligning at least a portion of the micro-structure particles and applying a polymer to the particles and solidifying the polymer.
[0004] Another aspect of the present disclosure relates to a method of facilitating bone growth. The method may include positioning a device substrate, including micro-structure particles and a polymer disposed thereon, around at least a portion of a bone exhibiting a defect, wherein the device may be capable of retaining bone segments and the micro-structured particles, wherein each of the micro-structure particles may include at least one pore therein. The method may also include aligning at least a portion of the micro-structure particles.
[0005] A further aspect of the present disclosure related to a method for facilitating bone growth, wherein the method may include applying a first polymer including micro-structure particles within a defect, wherein each of the micro-structure particles may include at least one pore therein and the first polymer may exhibit a viscosity of 50,000 centipoise to 500,000 centipoise. The method may also include aligning at least a portion of the micro-structure particles and applying a second polymer to the first polymer and solidifying a portion of the first polymer, forming a shell around at least a portion of a defect in a bone segment. The shell may be capable of retaining the bone segment and micro-structured particles.
BRIEF DESCRIPTION OF THE DRAWINGS
[0006] The above-mentioned and other features of this disclosure, and the manner of attaining them, will become more apparent and better understood by reference to the following description of embodiments described herein taken in conjunction with the accompanying drawings, wherein:
[0007] FIG. 1 is an example of a tubular device positioned over a bone fracture;
[0008] FIG. 2 is an example of a flexible sheet that may be utilized as a tubular device;
[0009] FIG. 3 is an example of a tubular device including an injection port;
[0010] FIG. 4 illustrates an example of a microstructure particle;
[0011] FIG. 5 a illustrates unaligned microstructure particles injected into a bone defect;
[0012] FIG. 5 b illustrates the microstructure particles of FIG. 5 a in an aligned arrangement;
[0013] FIG. 6 a illustrates unaligned microstructure particles disposed on a sheet in a polymer matrix, wherein the resin sheet may be formed into a tubular device over a bone segment;
[0014] FIG. 6 b illustrates aligned microstructure particles disposed on a sheet in a polymer matrix, wherein the resin sheet may be formed into a tubular device over a bone segment;
[0015] FIG. 7 a illustrates microstructure particles in a polymer material; and
[0016] FIG. 7 b illustrates the microstructure particle/polymer material composition positioned within a bone defect between two bone segments.
DETAILED DESCRIPTION
[0017] The present disclosure relates to a method and system for treatment. The method and system may include the implantation of a material or series of materials that may provide load bearing strength within a relatively short period of time, a day to a few weeks, and provide for the promotion of growth of new bone tissue.
[0018] The system may include a relatively tubular device, which may be positioned around a fracture, breakage or other defect in a bone. FIG. 1 illustrates an example of a tubular device 102 positioned over a bone fracture 104 in a bone 106 . The tubular material may be formed of a polymer material. The polymer material may be bioresobable, which may be understood as the ability of the material to be hydrolyzed or enzymatically degraded, such as enzymatic degradation within a given patient (human or animal). Examples of bioresobable materials may include polyurethanes, polycaprolactones, poly(lactic acid), poly(glycolic acid), etc.
[0019] The tubular device may be provided as a relatively flexible sheet and curved around the bone segment or, as illustrated in FIG. 2 , the tubular device 200 may be provided in an arcuate form having a longitudinal slit 202 allowing the passage of the bone segment therethrough. In one example, the tubular device may fit around the bone and seal onto itself via mechanical or chemical means. For example, one may utilize a bioresorbable adhesive. In another example, the tubular device may be attached to one or more bone segments also via mechanical or chemical means, such as through the use of screws, pins or other retention devices, or by an adhesive, such as bone cement.
[0020] As illustrated in FIG. 3 , the tubular device 300 may include an injection port 302 . The injection port may be an opening defined through the wall of the tubular device. In some examples, the opening may include a self sealing membrane 304 , such as one formed from silicone, polybutadiene, etc. Furthermore, in some examples, the injection port may be raised from the tubular device.
[0021] Once affixed, the tubular device may be filled with micro-structure particles. The micro-structure particles may include cylindrical, spherical, elliptical or other multifaceted particles, including those which may be hexagonal, octagonal, etc. The particles may have a length of 50 to 5000 μm, including all values and increments therein in 1.0 μm increments. The particles may also have a diameter (largest cross-sectional length) of 60 μm to 2000 μm, including all values and increments therein, in 1.0 μm increments. The particles may be formed from a relatively rigid bone-like material, such as calcium-phosphate, including amorphous calcium phosphate, dicalcium phosphate, α-tricalcium phosphate, β-tricalcium phosphate, pentacalcium hydroxyl apatite, and/or tetracalcium phosphate monoxide. In addition, the particles may be formed from a material that may be resorbable, inert or active (i.e., capable of actively taking part in physiological processes). The particles may be coated with a growth factor material, such as vascular endothelial growth factor (VEGF), statins, bone morphogenic proteins such as BMP-2 or with a relatively quickly resorbable polymer, inorganic or composite material such as collagen, poly(lactic-glycolic acid), poly(caprolactone), calcium phosphate, as well as polymer-inorganic composites such as biomineralized collagen-calcium phosphate.
[0022] The micro-structure particles may include one or more pores. It may be appreciated that the pores may allow for the growth of tissue therein. The pores may have a diameter in the range of 50 μm to 1,000 μm, including all values and increments therein, such as 100 μm to 500 μm. In some examples, the pores may be channels extending through the micro-structure particles, which extend along an axis of the particle. It may be appreciated that when the micro-particles align, the pores may align as well, forming a channel that spans across the micro-structure particles.
[0023] The pores may also be filled with one or more growth factors material, such those which may be osteogenic or angiogenic. Osteogenic growth factors may be understood as growth factors (compounds) that promote bone growth. Angiogenic growth factors may be understood as factors (compounds) that promote blood vessel growth. Such growth factors may include as vascular endothelial growth factor (VEGF), statins, bone morphogenic proteins such as BMP-2 or the pores may be filled with a relatively quickly resorbable polymer, inorganic or composite material such as collagen, poly(lactic-glycolic acid), poly(caprolactone), calcium phosphate, as well as polymer-inorganic composites such as biomineralizes collagen-calcium phosphate.
[0024] A contemplated example of a micro-structured particle is illustrated in FIG. 4 . The particle 400 may be formed of calcium phosphate or a biopolymer composite cement and may include an osteogenic growth factor 402 coated within a pore 404 , on the pore surface 406 , of the particle. In addition, an angiogenic growth factor 408 may be provided within the pore 404 . It may be appreciated that the growth factors employed within the pore may be arranged in any desired configuration. For example, at 408 one may incorporate osteogenic growth factor and at 402 one may incorporate angiogenic growth factor. Furthermore, the surface of the particle 410 may be coated with coating 412 including a functionalized polymer (such as poly(lactic acid), poly(glycolic acid), poly(caprolactone), an iron oxide or other ferrous composite, etc. The use of iron oxide or other ferrous composite materials may be selected to provide magnetic characteristics, as explained more fully below.
[0025] That is, the micro-structure particles may include self-alignment features, wherein the micro-structure particles may align in a relatively uniform manner when at a targeted location in a patient, such as at a bone fracture site. For example, the particles may include magnetic polarization, electrically conducting or chemical alignment features. The particles may be aligned by vibration, magnetic fields, electrical fields or flotation. Furthermore, alignment of the micro-particles may form an interconnected pore structure. Alignment may also provide for compaction of the particles. FIG. 5 a illustrates an example of relatively random particle alignment upon injecting or placing the micro-structure particles 502 proximate to or into the bone defect 504 in a bone 506 . FIG. 5 b illustrates and example of the particles 502 once at least a portion or all of the particles are aligned in the bone defect 504 within the bone 506 . As illustrated in FIG. 5 b , the particles may align along a given axis (A-A) of the bone, which may in some examples include alignment with a given bone length dimension.
[0026] Prior to or after the alignment of the micro-structure particles, other secondary particles including growth factors or calcium-phosphate may be added to the tubular device to fill in any voids. In addition, a polymer may be added to adhere the micro-structure particles and secondary particles (if present) together, within the tubular device. The polymer may include, but is not limited to, gelatin, collagen, poly(caprolactone), etc. The polymer may be provided as a liquid, or in liquid form, i.e., the polymer may exhibit a relatively low viscosity. That is, the viscosity may be less than or equal to 500,000 centipoise, e.g. in the range of 50,000 centipoise to 500,000 centipoise, including all values and increments therein.
[0027] The polymer may then be cured or at least partially solidified by the addition of a cross-linking agent, exposure to light, including UV light exhibiting at least one wavelength in the range of 400 nm to 10 nm, heat curing or a combination thereof. At least partially solidified may be understood as a state wherein the liquid polymer may resist, to some degree, deformation and/or changes in volume, and exhibit an increase in viscosity.
[0028] The tubular device may be sealed before or after adding the various particles or, in some examples, the tubular device may be removed. Referring back to FIG. 3 , the tubular device may be sealed at an edge 306 or along the length of adjoining surfaces 308 of the device. Sealing may occur by the use of mechanical or chemical means, such as bending the tubular device or the addition of an adhesive or cement. For example, as alluded to, the tubular device may be bent into a cylinder and secured utilizing the mechanical means described above. A cement or adhesive, such as bone cement or cyanoacrylate may be applied to seal the edges as well.
[0029] In other examples, a tubular device may be provided as a substrate in the form of, for example, a sheet, as illustrated in FIG. 6 a . The substrate 600 may include a biocompatible material or a reinforcing composite, such as those described above. The micro-structure particles 602 may be placed on a tubular device substrate 600 and a polymer 604 may be added to the particles spread on the sheet. The polymer may include, but is not limited to, gelatin, collagen, poly(caprolactone), or other polymers or polymer-precursors. The sheet may then be cut or otherwise adjusted to size, wrapped around the fracture, break or defect point of the bone, supported by viable bone segments and secured in place, forming a tubular device in which the micro-structure porous network may be contained. If not already polymerized prior to application of the sheet to the bone, the polymer may then be polymerized or cross-linked. Furthermore, the tubular device may be removed from the bone once polymerization or cross-linking begins. It may be appreciated that the micro-structure particles 602 may be aligned before, as illustrated in FIG. 6 b , or after placement of the sheet around the viable bone segments and formed into a tubular structure.
[0030] In a further example, illustrated in FIG. 7 a , micro-structural particles 702 may be encapsulated or otherwise compounded with a polymer material or polymer pre-cursor 704 . The mixture may exhibit a semi-solid viscosity, i.e., the material may be substantially solid but plastically deformable upon the application of pressure. As alluded to above, the viscosity of the polymers utilized for the mixture may be in the range of 50,000 centipoise to 500,000 centipoise. As illustrated in FIG. 7 b , the mixture of the micro-structural particles 702 and the polymer material 704 may then be implanted between viable bone segments 708 , 710 . A liquid polymer may then be added around the mixture of the micro-structural particles and encapsulating material, which may then be cross-linked providing a relatively rigid shell around a relatively soft core of the mixture of the micro-structural particles and encapsulating material. The liquid polymer may include, for example, functionalized acrylate monomers. The micro-structure particles may be aligned and the core may be polymerized as well.
[0031] The tubular devices formed herein may provide a degree of mechanical support for the bone. In addition, the micro-structure particles may also form some degree of stability and support for the bone. It may be appreciated that the microstructure particles may also form support for the growth of tissue, which may grow around the particles and/or within any pores. More specifically, it can be appreciated that alignment of particles along the length of a given bone, as illustrated in FIG. 5 b , when contained within tubular device 102 illustrated in FIG. 1 , will provide stability and support for the underlying bone during a given healing period.
[0032] The foregoing description of several methods and embodiments has been presented for purposes of illustration. It is not intended to be exhaustive or to limit the claims to the precise steps and/or forms disclosed, and obviously many modifications and variations are possible in light of the above teaching. It is intended that the scope of the invention be defined by the claims appended hereto. | The present disclosure relates to methods of facilitating bone growth. The method may include positioning a device around at least a portion of a bone exhibiting a defect, the device capable of retaining bone segments and micro-structured particles. The method may also include applying micro-structure particles within the device to the defect, wherein each of the micro-structure particles include at least one pore therein. In addition, the method may include aligning at least a portion of the micro-structure particles and applying a polymer to the particles and solidifying the polymer. | 0 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a continuation-in-part of International Patent Application No. PCT/CN2015/000655 with an international filing date of Sep. 21, 2015, designating the United States, now pending, and further claims foreign priority benefits to Chinese Patent Application No. 201510459642.2 filed Jul. 30, 2015. The contents of all of the aforementioned applications, including any intervening amendments thereto, are incorporated herein by reference. Inquiries from the public to applicants or assignees concerning this document or the related applications should be directed to: Matthias Scholl P.C., Attn.: Dr. Matthias Scholl Esq., 245 First Street, 18th Floor, Cambridge, Mass. 02142.
BACKGROUND OF THE INVENTION
Field of the Invention
The invention relates to a method for preparing 2,3,3,3-tetrafluoropropene.
Description of the Related Art
A conventional method for preparing 2,3,3,3-tetrafluoropropene utilizes hexafluoropropylene (HFP) and hydrogen as raw materials and involves a four-step process, including a two-step hydrogenation and a two-step dehydrofluorination. Thus, the conventional method is long, inefficient, and costly.
SUMMARY OF THE INVENTION
In view of the above-described problems, it is one objective of the invention to provide a method for preparing 2,3,3,3-tetrafluoropropene that is shorter, more efficient, and less expensive, and produces the desired material with more selectivity and in greater yield.
To achieve the above objective, in accordance with one embodiment of the invention, there is provided a method for preparing 2,3,3,3-tetrafluoropropene. The method comprises:
a) introducing hexafluoropropylene and hydrogen to a first reactor to allow hexafluoropropylene to react with hydrogen in the presence of a catalyst to obtain a first mixture comprising 1,1,1,2,3-pentafluoropropene, 1,1,1,2,3,3-hexafluoropropane, hydrogen fluoride, and hexafluoropropylene, in which, a molar ratio of hexafluoropropylene to hydrogen is between 1:0.95 and 1:0.99, a space velocity is between 200 and 1000 h −1 , a reaction temperature is between 50 and 400° C.; b) washing and drying the first mixture obtained from a), and introducing the treated first mixture to a first distillation column to obtain 1,1,1,2,3,3-hexafluoropropane in a bottom of the first distillation column and 1,1,1,2,3-pentafluoropropene and hexafluoropropylene at a top thereof; recycling 1,1,1,2,3,3-hexafluoropropane to the first reactor, and introducing 1,1,1,2,3-pentafluoropropene and hexafluoropropylene to a second distillation column to yield hexafluoropropylene at a top of the second distillation column and 1,1,1,2,3-pentafluoropropene at a bottom thereof; recycling hexafluoropropylene to the first reactor; c) introducing 1,1,1,2,3-pentafluoropropene obtained from b) and hydrogen to a second reactor and allowing 1,1,1,2,3-pentafluoropropene to react with hydrogen in the presence of a catalyst, to obtain a second mixture comprising 1,1,1,2,3-pentafluoropropane, 2,3,3,3-tetrafluoropropene, HF, and H 2 , in which a molar ratio of hydrogen to 1,1,1,2,3-pentafluoropropene is between 1:0.95 and 1:0.99, a space velocity is between 300 and 2000 h −1 , and a reaction temperature is between 80 and 500° C.; and d) washing and drying the second mixture obtained from c), and introducing the second mixture to a third distillation column to yield 1,1,1,2,3-pentafluoropropane at a bottom thereof; and recycling 1,1,1,2,3-pentafluoropropane to the second reactor, to yield 2,3,3,3-tetrafluoropropene at a top thereof.
In a class of this embodiment, the space velocity in a) is between 400 and 800 h −1 , and the reaction temperature is between 100 and 300° C.
In a class of this embodiment, the space velocity in c) is between 600 and 1500 h −1 , and the reaction temperature is between 120 and 400° C.
In a class of this embodiment, the catalyst in the first reactor is respectively filled in an upper section and a lower section of the first reactor. The catalyst in the upper section of the first reactor is Pd/C, and Pd accounts for between 0.1 and 1 wt. %. The catalyst in the lower section of the first reactor is chromium oxide.
In a class of this embodiment, the catalyst in the second reactor is respectively filled in an upper section and a lower section of the second reactor. The catalyst in the upper section of the second reactor is Pd/Al 2 O 3 , and Pd accounts for between 0.2 and 1.5 wt. %. The catalyst in the lower section of the second reactor comprise between 80 and 90 wt. % of chromium oxide and between 10 and 20 wt. % of zinc oxide.
In a class of this embodiment, both the first reactor and the second reactor are adiabatic reactors.
Both the first reactor and the second reactor can be divided into two sections with each section filled with different catalysts. The raw materials hexafluoropropylene and H 2 after being heated by a preheater enter the first reactor for reaction under the action of the catalysts in the upper section and the lower section. The dose of hexafluoropropylene is slightly excessive while H 2 is completely converted, thus, an obtained mixture includes 1,1,1,2,3,3-hexafluoropropane produced from the reaction, and a small amount of non-reacted hexafluoropropylene. The mixture then enters the lower section of the reactor where dehydrofluorination of 1,1,1,2,3,3-hexafluoropropane in a gas phase is performed to yield a mixture including 1,1,1,2,3,3-hexafluoropropane, 1,1,1,2,3-pentafluoropropene, HF, and a small amount of hexafluoropropylene. The mixture is then separated, the non-reacted 1,1,1,2,3,3-hexafluoropropane and hexafluoropropylene are returned to the first reactor, and 1,1,1,2,3-pentafluoropropene and the fresh H 2 are preheated by a preheater and introduced to the second reactor for reaction under the action of the catalysts of the upper and the lower sections, during which, the dose of H 2 is slightly excessive and 1,1,1,2,3-pentafluoropropene is completely converted, a resulting mixture includes 2,3,3,3-tetrafluoropropene, 1,1,1,2,3-pentafluoropropane, HF, and a small amount of H 2 . The mixture is then separated to yield the product 2,3,3,3-tetrafluoropropene, while the non-reacted 1,1,1,2,3-pentafluoropropane is returned to the second reactor and the small amount of H 2 is discharged.
Hydrogenation of hexafluoropropylene and dehydrofluorination of 1,1,1,2,3,3-hexafluoropropane are performed in the first reactor. The hydrogenation of hexafluoropropylene is a strong exothermic reaction. The activity of the catalyst and the selectivity of the products are greatly influenced by the reaction temperature, and too high the temperature may result in coking and deactivation of the catalyst for hydrogenation. The temperature of the hydrogenation is lower than the temperature of dehydrofluorination, the heat quantity of the lower section is partially supply of heat quantity produced by the hydrogenation of the upper section, and the heat quantity of the hydrogenation of the upper section is carried away by the excessive 1,1,1,2,3,3-hexafluoropropane. The temperature of the upper section of the first reactor is controlled between 50 and 150° C., and preferably between 80 and 120° C., and the temperature of the lower section is between 250 and 400° C. The higher the space velocity is, the more the materials that the unit catalyst surface contacts are, and the higher the loading of the reaction is. Thus, based on comprehensive consideration, the selected space velocity is between 200 and 1000 h −1 , preferably between 400 and 800 h −1 . To make H 2 totally converted for avoiding subsequent separation problem of H 2 , the dose of hexafluoropropylene is slightly excessive and the excessive hexafluoropropylene can be returned to the first reactor; and the molar ratio of hexafluoropropylene to hydrogen is between 1:0.95 and 1:0.99.
Hydrogenation of 1,1,1,2,3-pentafluoropropene and dehydrofluorination of 1,1,1,2,3-pentafluoropropane are performed in the second reactor. Similar to the reactions in the first reactor, a part of the heat quantity of the lower section is also supplied by the heat quantity produced in the hydrogenation in the upper section. 1,1,1,2,3-pentafluoropropene is made completely converted, thus avoiding the subsequent problems of difficult separation of 1,1,1,2,3-pentafluoropropene and 2,3,3,3-tetrafluoropropene. The temperature of the upper section of the second first reactors controlled between 80 and 200° C., preferably between 100 and 150° C., and the temperature of the lower section is controlled at between 300 and 500° C., and the space velocity is controlled between 300 and 2000 h −1 , preferably between 600 and 1500 h −1 , and a molar ratio of H 2 to 1,1,1,2,3-pentafluoropropene is between 1:0.95 and 1:0.99.
The upper sections of the first reactor and the second reactor are filled with the precious metal Pd catalyst. As the loading amount of the precious metal is too low, the catalytic activity is not enough, and a best balance point exists among the amount of Pd and the catalytic activity. The selection of the carrier is critical for the catalyst. The hydrogenation of HFP is easily carried out, the activated carbon is selected as the catalyst because of its high specific area, which is beneficial to load catalytic substance with small amount but high dispersion degree and to prepare catalyst of high catalytic activity. The hydrogenation of 1,1,1,2,3-pentafluoropropene is difficult, the Al 2 O 3 carrier has relatively strong acidity, the active component Pd is well dispersed on the carrier. Al 2 O 3 carrier has high mechanical strength, and the catalyst has long service life. It is found from the experiment that the upper section of the first reactor is filled with the Pd/C catalyst and Pd accounts for between 0.1 and 1 wt. %, and the lower section of the second first reactors filled with the Pd/Al 2 O 3 catalyst and Pd accounts for between 0.2 and 1.5 wt. %. Pretreatment of the catalyst can be conducted in other reactors.
The catalysts in the lower sections of the first reactor and the second reactor are those including chromium oxide as the active component. The catalyst of the lower section of the first reactor is the pure chromium oxide, and the catalyst of the lower section of the second reactor comprises between 80 and 90 wt. % of chromium oxide and between 10 and 20 wt. % of zinc oxide and is prepared as follows: mixing nitrates of chromium and zinc according to a certain ratio to prepare a diluted solution of a certain concentration, adding a precipitant for reaction, performing filtration, washing by water, desiccation, calcination, granulation, and tablet pressing to prepare a precursor, fluorinating the precursor to yield the catalyst. The pretreatment of the catalyst can be conducted in other reactors.
Both the first reactor and the second reactor adopt the adiabatic type or the isothermal type, preferably adopting the adiabatic type. And the material of the reactors can adopt the carbon steel or the stainless steel.
Advantages of a method for preparing 2,3,3,3-tetrafluoropropene according to embodiments of the invention are summarized as follows:
1. The two-step gas phase route is adopted, the procedure is simple, and there are few byproducts produced. 2. The conversion rate and the selectivity are high, the conversion rate of hexafluoropropylene is higher than 99%, and the conversion rate of 1,1,1,2,3-pentafluoropropene is 100%. Both the selectivity of 1,1,1,2,3,3-hexafluoropropane and 1,1,1,2,3-pentafluoropropane are 100%. 3. H 2 of the first reactor is totally converted and 1,1,1,2,3-pentafluoropropene of the second first reactors totally converted, so that the separation problems of the non-reacted H 2 and 1,1,1,2,3-pentafluoropropene are solved. 4. The heat quantity produced in the hydrogenation is fully utilized by the dehydrofluorination, thus, the heat quantity is comprehensively utilized, and the energy consumption is reduced.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention is described hereinbelow with reference to accompanying drawings, in which the sole FIGURE is a flow chart illustrating a method for preparing 2,3,3,3-tetrafluoropropene according to one embodiment of the invention.
In the drawings, the following reference numbers are used: 1 . First reactor; 2 . First alkaline washing column; 3 . First drying column; 4 . First distillation column; 5 . Second distillation column; 6 . Second reactor; 7 . Second alkaline washing column; 8 . Second drying column; 9 . Third distillation column; and 10 - 21 . Pipelines.
DETAILED DESCRIPTION OF THE EMBODIMENTS
For further illustrating the invention, experiments detailing a method for preparing 2,3,3,3-tetrafluoropropene are described below. It should be noted that the following examples are intended to describe and not to limit the invention.
As shown in the sole figure, raw materials hexafluoropropylene and H 2 are introduced to a first reactor for reaction to yield a mixture comprising 1,1,1,2,3,3-hexafluoropropane, 1,1,1,2,3-pentafluoropropene, HF, and HFP at an outlet of the first reactor. The mixture is introduced via a pipeline 10 to a first alkaline washing column 2 for removing HF therefrom. A resulting mixture is introduced to a first drying tower 3 via a pipeline 11 for drying, then to a first distillation column 4 via a pipeline 12 . 1,1,1,2,3,3-hexafluoropropane is obtained at a bottom of the first distillation column 4 and cycled to the first reactor via a pipeline 13 , and 1,1,1,2,3-pentafluoropropene and HFP are obtained at a top of the first distillation column 4 and introduced to a second distillation column 5 via a pipeline 14 . HEP was obtained at a top of the second distillation column 5 and cycled to the first reactor via a pipeline 15 ; and 1,1,1,2,3-pentafluoropropene was obtained at a bottom of the second distillation column 5 and introduced to a second reactor via a pipe 16 . In the meanwhile, fresh H 2 is added to the second reactor for reaction to yield a mixture comprising 1,1,1,2,3-pentafluoropropane, 2,3,3,3-tetrafluoropropene, HF, and H 2 at an outlet of the second reactor. The mixture is than introduced to a second alkaline washing column 7 via a pipe 17 for removing HF therefrom. A resulting mixture is introduced to a second drying column 8 via a pipe 18 , and then to a third distillation column 9 via a pipe 19 . 1,1,1,2,3-pentafluoropropane is obtained at a bottom of the third distillation column 9 and cycled to the second reactor via a pipe 20 , product 2,3,3,3-tetrafluoropropene is obtained at a top of the third distillation column 9 , and H 2 is discharged as a non-condensed gas.
Example 1
200 mL of a Cr 2 O 3 catalyst was added with HF for fluorination at a temperature of 350° C. for 30 hrs to yield an activated Cr 2 O 3 catalyst, which was then added to a lower section of the first reactor (adiabatic reactor made of carbon steel). 150 mL of a Pd/C catalyst (Pd accounts for 0.1 wt. %) was pretreated with a mixed gas comprising H 2 and N 2 (a molar ratio of H 2 to N 2 is 1:19) at a space velocity of 1200 mL g −1 (catal.) h −1 at a temperature of 350° C. for 15 hrs, then the Pd/C catalyst after treatment was filled in an upper section of the first reactor. The upper section of the first reactor was heated to a temperature of 50° C., and the lower section thereof was heated to the temperature of 300° C. Thereafter, hexafluoropropylene and H 2 with a molar ratio of 1:0.95 was introduced to the first reactor at a space velocity of 300 h −1 for reaction, and products obtained from an outlet of the first reactor were washed by an alkaline and then samples were collected for analysis, results of which are listed in Table 1-1.
TABLE 1-1
Data analysis of organic substances at an outlet of a first reactor
1,1,1,2,3-
1,1,1,2,3,3-
Components
pentafluoropropene
hexafluoropropane
HFP
Contents (wt. %)
36.2
63.5
0.3
200 mL of a catalyst comprising Cr 2 O 3 and ZnO 2 (90 wt. % of Cr 2 O 3 and 10 wt. % of ZnO 2 ) was added with HF for fluorination at a temperature of 350° C. for 30 hrs to yield an activated catalyst comprising Cr 2 O 3 and ZnO 2 , which was then added to a lower section of the second reactor (adiabatic reactor made of carbon steel). 180 mL of a Pd/Al 2 O 3 catalyst (Pd accounts for 0.3 wt. %) was pretreated with a mixed gas comprising H 2 and N 2 (a molar ratio of H 2 to N 2 is 1:19) at a space velocity of 1200 mL g −1 (catal.) h at a temperature of 350° C. for 15 hrs, then the Pd/Al 2 O 3 catalyst after treatment was filled in an upper section of the second reactor. The upper section of the second reactor was heated to a temperature of 100° C., and the lower section thereof was heated to the temperature of 320° C. Thereafter, 1,1,1,2,3-pentafluoropropene and H 2 obtained from the first reactor were introduced to the second reactor for reaction with a molar ratio of H 2 to 1,1,1,2,3-pentafluoropropene of 1:0.96 and a space velocity of 300 h −1 , and products obtained from an outlet of the second reactor were washed by an alkaline and then samples were collected for analysis, results of which are listed in Table 1-2.
TABLE 1-2
Data analysis of organic substances at an outlet of a second reactor
2,3,3,3-
1,1,1,2,3-
Components
tetrafluoropropene
pentafluoropropane
Contents (wt. %)
28.3
71.7
Example 2
The activation of the Cr 2 O 3 catalyst and the pretreatment of the Pd/C catalyst were the same as Example 1. 200 mL of the activated Cr 2 O 3 catalyst was filled in a lower section of a first reactor (adiabatic reactor made of carbon steel), and 150 mL of the pretreated Pd/C catalyst (Pd accounts for 0.3 wt. %) was filled in an upper section of the first reactor. The upper section of the first reactor was heated to the temperature of 80° C., and the lower section of the first reactor was heated to the temperature of 280° C. Hexafluoropropylene and H 2 were introduced to the first reactor at a molar ratio of hexafluoropropylene to H 2 of 1:0.95 at a space velocity of 200 h −1 for reaction, and products obtained from an outlet of the first reactor were washed by an alkaline and then samples were collected for analysis, results of which are listed in Table 2-1.
TABLE 2-1
Data analysis of organic substances at an outlet of a first reactor
1,1,1,2,3-
1,1,1,2,3,3-
Components
pentafluoropropene
hexafluoropropane
HFP
Contents (wt. %)
42.5
57.3
0.2
The activation of the catalyst comprising Cr 2 O 3 and ZnO 2 and the pretreatment of the Pd/Al 2 O 3 catalyst were the same as Example 1. 200 mL of the activated catalyst comprising Cr 2 O 3 and ZnO 2 (88 wt. % of Cr 2 O 3 and 12 wt. % of ZnO 2 ) was filled in a lower section of the second reactor (adiabatic reactor made of carbon steel), and 180 mL of the pretreated Pd/Al 2 O 3 catalyst (containing 0.5 wt. % of Pd) was filled in an upper section of the second reactor. The upper section of the second reactor was heated to the temperature of 120° C., and the lower section thereof was heated to the temperature of 300° C. Thereafter, 1,1,1,2,3-pentafluoropropene and H 2 obtained from the first reactor were introduced to the second reactor for reaction with a molar ratio of H 2 to 1,1,1,2,3-pentafluoropropene of 1:0.95 and a space velocity of 800 h −1 , and products obtained from an outlet of the second reactor were washed by an alkaline and then samples were collected for analysis, results of which are listed in Table 2-2.
TABLE 2-2
Data analysis of organic substances at an outlet of a second reactor
2,3,3,3-
1,1,1,2,3-
Components
tetrafluoropropene
pentafluoropropane
Contents (wt. %)
31.7
68.3
Example 3
The activation of the Cr 2 O 3 catalyst and the pretreatment of the Pd/C catalyst were the same as Example 1. 200 mL of the activated Cr 2 O 3 catalyst was filled in a lower section of a first reactor (adiabatic reactor made of carbon steel), and 150 mL of the pretreated Pd/C catalyst (containing 0.5 wt. % of Pd) was filled in an upper section of the first reactor. The upper section of the first reactor was heated to the temperature of 100° C., and the lower section of the first reactor was heated to the temperature of 320° C. Hexafluoropropylene and H 2 were introduced to the first reactor at a molar ratio of hexafluoropropylene to H 2 of 1:0.97 at a space velocity of 800 h −1 for reaction, and products obtained from an outlet of the first reactor were washed by an alkaline and then samples were collected for analysis, results of which are listed in Table 3-1.
TABLE 3-1
Data analysis of organic substances at an outlet of a first reactor
1,1,1,2,3-
1,1,1,2,3,3-
Components
pentafluoropropene
hexafluoropropane
HFP
Contents (wt. %)
54.3
45.6
0.1
The activation of the catalyst comprising Cr 2 O 3 and ZnO 2 and the pretreatment of the Pd/Al 2 O 3 catalyst were the same as Example 1. 200 mL of the activated catalyst comprising Cr 2 O 3 and ZnO 2 (88 wt. % of Cr 2 O 3 and 12 wt. % of ZnO 2 ) was filled in a lower section of the second reactor (adiabatic reactor made of carbon steel), and 180 mL of the pretreated Pd/Al 2 O 3 catalyst (containing 0.8 wt. % of Pd) was filled in an upper section of the second reactor. The upper section of the second reactor was heated to the temperature of 150° C., and the lower section thereof was heated to the temperature of 400° C. Thereafter, 1,1,1,2,3-pentafluoropropene and H 2 obtained from the first reactor were introduced to the second reactor for reaction with a molar ratio of H 2 to 1,1,1,2,3-pentafluoropropene of 1:0.97 and a space velocity of 800 h −1 , and products obtained from an outlet of the second reactor were washed by an alkaline and then samples were collected for analysis, results of which are listed in Table 3-2.
TABLE 3-2
Data analysis of organic substances at an outlet of a second reactor
2,3,3,3-
1,1,1,2,3-
Components
tetrafluoropropene
pentafluoropropane
Contents (wt. %)
56.8
43.2
Example 4
The activation of the Cr 2 O 3 catalyst and the pretreatment of the Pd/C catalyst were the same as Example 1. 200 mL of the activated Cr 2 O 3 catalyst was filled in a lower section of a first reactor (adiabatic reactor made of carbon steel), and 150 mL of the pretreated Pd/C catalyst (containing 0.8 wt. % of Pd) was filled in an upper section of the first reactor. The upper section of the first reactor was heated to the temperature of 120° C., and the lower section of the first reactor was heated to the temperature of 310° C. Hexafluoropropylene and H 2 were introduced to the first reactor at a molar ratio of hexafluoropropylene to H 2 of 1:0.97 at a space velocity of 600 h −1 for reaction, and products obtained from an outlet of the first reactor were washed by an alkaline and then samples were collected for analysis, results of which are listed in Table 4-1.
TABLE 4-1
Data analysis of organic substances at an outlet of a first reactor
1,1,1,2,3-
1,1,1,2,3,3-
Components
pentafluoropropene
hexafluoropropane
HFP
Contents (wt. %)
57
42.8
0.2
The activation of the catalyst comprising Cr 2 O 3 and ZnO 2 and the pretreatment of the Pd/Al 2 O 3 catalyst were the same as Example 1. 200 mL of the activated catalyst comprising Cr 2 O 3 and ZnO 2 (88 wt. % of Cr 2 O 3 and 12 wt. % of ZnO 2 ) was filled in a lower section of the second reactor (adiabatic reactor made of stainless steel), and 180 mL of the pretreated Pd/Al 2 O 3 catalyst (containing 1.5 wt. % of Pd) was filled in an upper section of the second reactor. The upper section of the second reactor was heated to the temperature of 130° C., and the lower section thereof was heated to the temperature of 350° C. Thereafter, 1,1,1,2,3-pentafluoropropene and H 2 obtained from the first reactor were introduced to the second reactor for reaction with a molar ratio of H 2 to 1,1,1,2,3-pentafluoropropene of 1:0.97 and a space velocity of 1000 h −1 , and products obtained from an outlet of the second reactor were washed by an alkaline and then samples were collected for analysis, results of which are listed in Table 4-2.
TABLE 4-2
Data analysis of organic substances at an outlet of a second reactor
2,3,3,3-
1,1,1,2,3-
Components
tetrafluoropropene
pentafluoropropane
Contents (wt. %)
61.5
38.5
Example 5
The activation of the Cr 2 O 3 catalyst and the pretreatment of the Pd/C catalyst were the same as Example 1. 200 mL of the activated Cr 2 O 3 catalyst was filled in a lower section of a first reactor (adiabatic reactor made of carbon steel), and 150 mL of the pretreated Pd/C catalyst (containing 1.0 wt. % of Pd) was filled in an upper section of the first reactor. The upper section of the first reactor was heated to the temperature of 150° C., and the lower section of the first reactor was heated to the temperature of 330° C. Hexafluoropropylene and H 2 were introduced to the first reactor at a molar ratio of hexafluoropropylene to H 2 of 1:0.98 at a space velocity of 1000 h −1 for reaction, and products obtained from an outlet of the first reactor were washed by an alkaline and then samples were collected for analysis, results of which are listed in Table 5-1.
TABLE 5-1
Data analysis of organic substances at an outlet of a first reactor
1,1,1,2,3-
1,1,1,2,3,3-
Components
pentafluoropropene
hexafluoropropane
HFP
Contents (wt. %)
68.4
31.5
0.1
The activation of the catalyst comprising Cr 2 O 3 and ZnO 2 and the pretreatment of the Pd/Al 2 O 3 catalyst were the same as Example 1. 200 mL of the activated catalyst comprising Cr 2 O 3 and ZnO 2 (90 wt. % of Cr 2 O 3 and 10 wt. % of ZnO 2 ) was filled in a lower section of the second reactor (adiabatic reactor made of stainless steel), and 180 mL of the pretreated Pd/Al 2 O 3 catalyst (containing 0.5 wt. % of Pd) was filled in an upper section of the second reactor. The upper section of the second reactor was heated to the temperature of 100° C., and the lower section thereof was heated to the temperature of 450° C. Thereafter, 1,1,1,2,3-pentafluoropropene and H 2 obtained from the first reactor were introduced to the second reactor for reaction with a molar ratio of H 2 to 1,1,1,2,3-pentafluoropropene of 1:0.98 and a space velocity of 1500 h −1 , and products obtained from an outlet of the second reactor were washed by an alkaline and then samples were collected for analysis, results of which are listed in Table 5-2.
TABLE 5-2
Data analysis of organic substances at an outlet of a second reactor
2,3,3,3-
1,1,1,2,3-
Components
tetrafluoropropene
pentafluoropropane
Contents (wt. %)
79.7
20.3
Example 6
The activation of the Cr 2 O 3 catalyst and the pretreatment of the Pd/C catalyst were the same as Example 1. 200 mL of the activated Cr 2 O 3 catalyst was filled in a lower section of a first reactor (adiabatic reactor made of carbon steel), and 150 mL of the pretreated Pd/C catalyst (containing 1.0 wt. % of Pd) was filled in an upper section of the first reactor. The upper section of the first reactor was heated to the temperature of 130° C., and the lower section of the first reactor was heated to the temperature of 400° C. Hexafluoropropylene and H 2 were introduced to the first reactor at a molar ratio of hexafluoropropylene to H 2 of 1:0.98 at a space velocity of 500 h −1 for reaction, and products obtained from an outlet of the first reactor were washed by an alkaline and then samples were collected for analysis, results of which are listed in Table 6-1.
TABLE 6-1
Data analysis of organic substances at an outlet of a first reactor
1,1,1,2,3-
1,1,1,2,3,3-
Components
pentafluoropropene
hexafluoropropane
HFP
Contents (wt. %)
74.4
25.4
0.2
The activation of the catalyst comprising Cr 2 O 3 and ZnO 2 and the pretreatment of the Pd/Al 2 O 3 catalyst were the same as Example 1. 200 mL of the activated catalyst comprising Cr 2 O 3 and ZnO 2 (80 wt. % of Cr 2 O 3 and 20 wt. % of ZnO 2 ) was filled in a lower section of the second reactor (adiabatic reactor made of stainless steel), and 180 mL of the pretreated Pd/Al 2 O 3 catalyst (containing 0.3 wt. % of Pd) was filled in an upper section of the second reactor. The upper section of the second reactor was heated to the temperature of 100° C., and the lower section thereof was heated to the temperature of 500° C. Thereafter, 1,1,1,2,3-pentafluoropropene and H 2 obtained from the first reactor were introduced to the second reactor for reaction with a molar ratio of H 2 to 1,1,1,2,3-pentafluoropropene of 1:0.95 and a space velocity of 2000 h −1 , and products obtained from an outlet of the second reactor were washed by an alkaline and then samples were collected for analysis, results of which are listed in Table 6-2.
TABLE 6-2
Data analysis of organic substances at an outlet of a second reactor
2,3,3,3-
1,1,1,2,3-
Components
tetrafluoropropene
pentafluoropropane
Contents (wt. %)
84.6
15.4
Example 7
The activation of the Cr 2 O 3 catalyst and the pretreatment of the Pd/C catalyst were the same as Example 1. 200 mL of the activated Cr 2 O 3 catalyst was filled in a lower section of a first reactor (adiabatic reactor made of carbon steel), and 150 mL of the pretreated Pd/C catalyst (containing 0.3 wt. % of Pd) was filled in an upper section of the first reactor. The upper section of the first reactor was heated to the temperature of 100° C., and the lower section of the first reactor was heated to the temperature of 300° C. Hexafluoropropylene and H 2 were introduced to the first reactor at a molar ratio of hexafluoropropylene to H 2 of 1:0.99 at a space velocity of 300 h −1 for reaction, and products obtained from an outlet of the first reactor were washed by an alkaline and then samples were collected for analysis, results of which are listed in Table 7-1.
TABLE 7-1
Data analysis of organic substances at an outlet of a first reactor
1,1,1,2,3-
1,1,1,2,3,3-
Components
pentafluoropropene
hexafluoropropane
HFP
Contents (wt. %)
61.4
38.5
0.1
The activation of the catalyst comprising Cr 2 O 3 and ZnO 2 and the pretreatment of the Pd/Al 2 O 3 catalyst were the same as Example 1. 200 mL of the activated catalyst comprising Cr 2 O 3 and ZnO 2 (90 wt. % of Cr 2 O 3 and 10 wt. % of ZnO 2 ) was filled in a lower section of the second reactor (adiabatic reactor made of stainless steel), and 180 mL of the pretreated Pd/Al 2 O 3 catalyst (containing 0.5 wt. % of Pd) was filled in an upper section of the second reactor. The upper section of the second reactor was heated to the temperature of 150° C., and the lower section thereof was heated to the temperature of 300° C. Thereafter, 1,1,1,2,3-pentafluoropropene and H 2 obtained from the first reactor were introduced to the second reactor for reaction with a molar ratio of H 2 to 1,1,1,2,3-pentafluoropropene of 1:0.99 and a space velocity of 600 h −1 , and products obtained from an outlet of the second reactor were washed by an alkaline and then samples were collected for analysis, results of which are listed in Table 7-2.
TABLE 7-2
Data analysis of organic substances at an outlet of a second reactor
2,3,3,3-
1,1,1,2,3-
Components
tetrafluoropropene
pentafluoropropane
Contents (wt. %)
62.4
37.6
Example 8
The activation of the Cr 2 O 3 catalyst and the pretreatment of the Pd/C catalyst were the same as Example 1. 200 mL of the activated Cr 2 O 3 catalyst was filled in a lower section of a first reactor (adiabatic reactor made of carbon steel), and 150 mL of the pretreated Pd/C catalyst (containing 0.3 wt. % of Pd) was filled in an upper section of the first reactor. The upper section of the first reactor was heated to the temperature of 120° C., and the lower section of the first reactor was heated to the temperature of 250° C. Hexafluoropropylene and H 2 were introduced to the first reactor at a molar ratio of hexafluoropropylene to H 2 of 1:0.99 at a space velocity of 500 h −1 for reaction, and products obtained from an outlet of the first reactor were washed by an alkaline and then samples were collected for analysis, results of which are listed in Table 8-1.
TABLE 8-1
Data analysis of organic substances at an outlet of a first reactor
1,1,1,2,3-
1,1,1,2,3,3-
Components
pentafluoropropene
hexafluoropropane
HFP
Contents (wt. %)
52.7
47.2
0.1
The activation of the catalyst comprising Cr 2 O 3 and ZnO 2 and the pretreatment of the Pd/Al 2 O 3 catalyst were the same as Example 1. 200 mL of the activated catalyst comprising Cr 2 O 3 and ZnO 2 (90 wt. % of Cr 2 O 3 and 10 wt. % of ZnO 2 ) was filled in a lower section of the second reactor (adiabatic reactor made of stainless steel), and 180 mL of the pretreated Pd/Al 2 O 3 catalyst (containing 0.3 wt. % of Pd) was filled in an upper section of the second reactor. The upper section of the second reactor was heated to the temperature of 150° C., and the lower section thereof was heated to the temperature of 300° C. Thereafter, 1,1,1,2,3-pentafluoropropene and H 2 obtained from the first reactor were introduced to the second reactor for reaction with a molar ratio of H 2 to 1,1,1,2,3-pentafluoropropene of 1:0.95 and a space velocity of 600 h −1 , and products obtained from an outlet of the second reactor were washed by an alkaline and then samples were collected for analysis, results of which are listed in Table 8-2.
TABLE 8-2
Data analysis of organic substances at an outlet of a second reactor
2,3,3,3-
1,1,1,2,3-
Components
tetrafluoropropene
pentafluoropropane
Contents (wt. %)
56.7
43.3
Example 9
The activation of the Cr 2 O 3 catalyst and the pretreatment of the Pd/C catalyst were the same as Example 1. 200 mL of the activated Cr 2 O 3 catalyst was filled in a lower section of a first reactor (adiabatic reactor made of carbon steel), and 150 mL of the pretreated Pd/C catalyst (containing 0.3 wt. % of Pd) was filled in an upper section of the first reactor. The upper section of the first reactor was heated to the temperature of 80° C., and the lower section of the first reactor was heated to the temperature of 320° C. Hexafluoropropylene and H 2 were introduced to the first reactor at a molar ratio of hexafluoropropylene to H 2 of 1:0.99 at a space velocity of 500 h −1 for reaction, and products obtained from an outlet of the first reactor were washed by an alkaline and then samples were collected for analysis, results of which are listed in Table 9-1.
TABLE 9-1
Data analysis of organic substances at an outlet of a first reactor
1,1,1,2,3-
1,1,1,2,3,3-
Components
pentafluoropropene
hexafluoropropane
HFP
Contents (wt. %)
64.1
35.8
0.1
The activation of the catalyst comprising Cr 2 O 3 and ZnO 2 and the pretreatment of the Pd/Al 2 O 3 catalyst were the same as Example 1. 200 mL of the activated catalyst comprising Cr 2 O 3 and ZnO 2 (90 wt. % of Cr 2 O 3 and 10 wt. % of ZnO 2 ) was filled in a lower section of the second reactor (adiabatic reactor made of stainless steel), and 180 mL of the pretreated Pd/Al 2 O 3 catalyst (containing 0.5 wt. % of Pd) was filled in an upper section of the second reactor. The upper section of the second reactor was heated to the temperature of 100° C., and the lower section thereof was heated to the temperature of 350° C. Thereafter, 1,1,1,2,3-pentafluoropropene and H 2 obtained from the first reactor were introduced to the second reactor for reaction with a molar ratio of H 2 to 1,1,1,2,3-pentafluoropropene of 1:0.95 and a space velocity of 400 h −1 , and products obtained from an outlet of the second reactor were washed by an alkaline and then samples were collected for analysis, results of which are listed in Table 9-2.
TABLE 9-2
Data analysis of organic substances at an outlet of a second reactor
2,3,3,3-
1,1,1,2,3-
Components
tetrafluoropropene
pentafluoropropane
Contents (wt. %)
58.4
41.6
While particular embodiments of the invention have been shown and described, it will be obvious to those skilled in the art that changes and modifications may be made without departing from the invention in its broader aspects, and therefore, the aim in the appended claims is to cover all such changes and modifications as fall within the true spirit and scope of the invention. | A method for preparing 2,3,3,3-tetrafluoropropene, including: a) introducing hexafluoropropylene and hydrogen to a first reactor for reaction in the presence of a catalyst to obtain a first mixture; b) washing and drying the first mixture, and introducing the treated first mixture to a first distillation column to obtain 1,1,1,2,3,3-hexafluoropropane, 1,1,1,2,3-pentafluoropropene, and hexafluoropropylene; recycling the 1,1,1,2,3,3-hexafluoropropane to the first reactor, and introducing the 1,1,1,2,3-pentafluoropropene and the hexafluoropropylene to a second distillation column to yield hexafluoropropylene and 1,1,1,2,3-pentafluoropropene; and recycling the hexafluoropropylene to the first reactor; c) introducing the 1,1,1,2,3-pentafluoropropene and hydrogen to a second reactor in the presence of a catalyst to obtain a second mixture; and d) washing and drying the second mixture, and introducing the second mixture to a third distillation column to yield 1,1,1,2,3-pentafluoropropane; and recycling the 1,1,1,2,3-pentafluoropropane to the second reactor to yield 2,3,3,3-tetrafluoropropene. | 2 |
RELATED APPLICATIONS
This application relates to U.S. application Ser. No. 202,418, filed Oct. 30, 1980, and entitled "Liquid Dispensing Apparatus."
BACKGROUND OF THE INVENTION
This invention relates generally to an apparatus for applying sealant to the threads of articles, such as fasteners, pipes, particularly to such an apparatus capable of pressing the sealant into the thread roots of the coated articles to completely fill the area where most leaks occur when used in a wide variety of applications.
Sealants of various types are available as preapplied coatings for locking and sealing together threaded parts. One such family of sealants or adhesives is dry to the touch and contains microcapsules of liquid anaerobic (curing in the absence of air) adhesive. During installation of a threaded article coated with this structural adhesive, liquid resin is released from its protective capsule to quickly fill the voids between the mating threads. Upon curing, a tough adhesive bond is formed between the male and female elements. The assembly is thus securely locked and sealed, or "unitized." These and other types of adhesives can be preapplied to parts long before they are used. If properly applied, the particular sealant blocks leakages in threaded joints which can be loosened, tightened and retightened without affecting the seal, and the sealant and can be reused several times on joints without recoating.
Such preapplied sealant and adhesive coatings have been applied on-the-job by manually brushing, dipping, spraying, swabbing, or roll coating, all of which are time consuming, messy and ineffective in assuring that the coating material is sufficiently pressed into the thread roots to provide a consistent leak-proof coating of the threaded parts. If voids or bubbles occur at the thread roots during coating application, leakages are apt to occur through the locked and sealed joint.
SUMMARY OF THE INVENTION
It is therefore an object of the present invention to provide an apparatus for applying sealants to the threads of articles in a simple, economical and highly efficient manner which assures consistent leak-proof coatings of threadedly joined parts.
Another object of this invention is to provide such an apparatus which includes an article support for incrementally moving a plurality of articles along an arcuate path, rotatable article spindle assemblies on the support being spaced apart a predetermined distance and being stopped at a dispensing station and at a wiping station which are likewise spaced apart such predetermined distance. A dispensing nozzle adjacent the path at the dispensing station dispenses a coating of sealant onto the threads of each article stopped thereat, and a wiper wheel at the wiping station wipes the coated threads and presses the coated sealant into the thread roots, the wiper wheel being rotatable and including a peripheral wiper surface.
A further object of the present invention is to provide such an apparatus wherein each spindle assembly is rotated at the dispensing station to effect a coating of sealant along at least a portion of the thread circumference, and preferably along the entire circumference.
A still further object of this invention is to provide such an apparatus wherein each spindle assembly is rotated by a rotatable magnetic disc which transmits the rotation via magnetic atttraction with another magnetic disc associated with each spindle assembly.
A still further object of this invention is to provide such an apparatus wherein a dispensing pump is provided for feeding sealant to the nozzle, and a switch actuates the dispensing of sealant before each spindle assembly is stopped at the dispensing station. Such a switch may be in the form of a switch arm extending into the arcuate path for actuation by each article as it approaches the dispensing station.
Other objects, advantages and novel features of the invention will become more apparent from the following detailed description of the invention when taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic top plan view of the sealant applying apparatus according to the invention;
FIG. 2 is a sectional view, at a slightly enlarged scale, taken substantially along the line 2--2 of FIG. 1, showing the dispensing pump and the sealant supply container;
FIG. 3 is a cross-sectional view of the wiper assembly taken substantially along the line 3--3 of FIG. 1;
FIG. 4 is a side elevational view of the motor and support for the wiper assembly, taken along the line 4--4 of FIG. 3;
FIG. 5 is a sectional view of a portion of the rotatable worktable including a typical spindle assembly, taken substantially along the line of 5--5 of FIG. 1;
FIG. 6 is a sectional view showing the dispensing nozzle, taken substantially along the line 6--6 of FIG. 1; and
FIG. 7 is a sectional view of the rotary mechanism for rotating each spindle assembly at the dispensing station, taken substantially along the line 7--7 of FIG. 1.
DETAILED DESCRIPTION OF THE INVENTION
Turning now to the drawings wherein like reference characters refer to like and corresponding parts throughout the several views, the sealant applying apparatus is generally designated 10 in FIG. 1 and includes a base 11 (FIG. 2) adapted to rest on a table or the like, and a removable cover 12 attached thereto. A dispensing pump assembly 13, shown in detail in FIG. 2, is mounted on base 11 and is similar to the liquid dispensing apparatus of the aforementioned U.S. Ser. No. 202,418, the entire disclosure thereof being specifically incorporated herein by reference. Thus, the pump assembly comprises a piston and cylinder unit 14 which includes a housing 15 containing a cavity 16 having a product inlet bore 17 in communication with the outlet of a supply container 18 for the sealant or adhesive to be coated on to the threads of articles in a manner to be described in more detail hereinafter. Housing 15 also includes a pump cylinder defined by a bore 19 extending from the cavity and terminating in a pump outlet 21 controlled by a spring loaded ball check valve 22. A piston or plunger rod 23, shown in its retracted position in FIG. 2, extends rearwardly through a seal ring and an O-ring located at the central opening of a support element 24 containing a collar mounted on the piston rod which is guided along a longitudinal track to prevent piston rod rotation during its longitudinal adjustment, all as in the same manner set forth in the aforementioned application. The piston also extends rearwardly through connector element 25 and 26 attached to opposite ends of an air cylinder 27, the piston rod terminating in a threaded end 28. The stroke of the piston rod 23 is adjusted by a rotatable dispense knob 29 extending outwardly of the base and cover, the knob engaging a threaded sleeve 31 secured to the piston rod. This sleeve engages internal threads on the knob so that upon knob rotation, the piston rod displacement may be accordingly increased or decreased. A graduated scale 30 may be provided for indicating rod displacement, and thus the amount of sealant to be dispensed, by matching an indicator line on the knob with one of the graduations.
Air pressure lines (not shown) interconnect respectively with air ports 32,33 respectively connected as at 34,35 with a solenoid assembly 36 (FIG. 1). Thus, pressurized air admitted to port 32 extends the piston while at the same time exhausting pressurized air through port 33, and vice-versa for retracting the piston. During outward displacement of the piston sealant is discharged through outlet 21 and into a dispensing head assembly 37 (FIG. 6) via a tubing 38. This assembly, positioned at a dispensing station, comprises a dispense nozzle 39 overlying cover plate 12 and is mounted via a block 41 on a horizontal support 42 through an adjusting knob 43. Support 42 has an elongated opening 44 to facilitate longitudinal adjustment of the nozzle toward and away from the threaded article to be coated. And, support 42 is mounted on a sleeve 45 surrounding a vertical support rod 46 extending from base 11 through the cover. An adjustment knob 47 on the sleeve has its tip 48 in engagement with a vertical groove 49 on the support rod to facilitate adjustment of the nozzle along a vertical axis. And, the dispensing head assembly may be adjustable about the axis of rod 46 upon the movement of sleeve 45.
An article carrier in the form of an indexable worktable 51 (FIGS. 1 and 5) is removable mounted on base 11 by a table locking knob 52 threaded into a central axle 53 extending from a rotary actuator 54. A sleeve 55 frictionally engages axle 53 for rotation thereof, and a central hub 56 surrounds the sleeve. Lower and upper thrust bearing 57 and 58 are provided between the sleeve and the hub, as well as a combined bearing and over-running clutch 59. The entire worktable may thus be removed for maintenance and cleaning upon the removal of locking knob 52. Rotary actuator mechanism 54 comprised of a clevis mounted air cylinder operatively connected to a pivot arm on the worktable axle, is operatively connected with the solenoid assembly as is an actuator 89 having a positioning detent 61 at the upper end of a piston 62 movable between its solid outline and phantom outline positions of FIG. 5. The rotary actuator is designed to rotate its axle or driven shaft 53 counterclockwise (when viewed from the top in FIG. 5) through 60° whereupon rotation stops and is rotated clockwise through 60° whereupon it again stops and the cycle is repeated. Each such counterclockwise rotation is transmitted through over-running clutch 59 to the worktable to effect a rotary movement thereof through 60°. The worktable is retained and precisely located at its stopped position by the engagement between detent 61 and the inner surface of a tapered locating wall cavity 63 recessed into the underside of the worktable. Six of such wall cavities, radially spaced apart 60°, are provided (FIG. 1). Piston 62 is extended to its FIG. 5 position upon actuation of actuator 59 from the solenoid assembly, whereupon positioning detent 61 is moved into the depression formed by wall cavity 63. At the end of the article dispensing operation, to be described hereinafter, piston 62 is retracted upon a signal received from the solenoid assembly thereby shifting disc 61 out of engagement to its phantom outline position. In the meantime, shaft 53 returns to its initial position upon clockwise movement through 60° while the worktable is stopped. Bearings 57, 58 and 59 facilitate such return movement unimpeded by the worktable.
A plurality of spindle assemblies 65 (six shown in FIG. 1) are radially spaced apart 60° adjacent the periphery of the worktable. Each such assembly includes a vertical spindle 66 extending outwardly of a stud 67 and having a horizontal spindle disc 68 attached to the stud. A disc 69 of magnetic material is secured to the underside of the stud. And, the stud is rotatable about its central axis within a surrounding bearing 71.
Beneath the worktable and mounted on base 11 is a motor 72 (FIG. 7) operatively connected with the solenoid assembly and having a drive spindle 73 on which a drive magnetic disc 74 is securely mounted. As shown, discs 69 and 74 are spaced apart a slight distance when each spindle assembly is intermittently stopped at the dispensing station. Thus, rotation of the drive magnetic disc transmits that rotation to magnetic disc 69 via magnetic attraction for rotating the spindle assembly a predetermined amount during the dispensing of sealant on to the threads of an article A (FIG. 3) supported on spindle 66.
The pump plunger in assembly 13 is actuated by the movement of a switch arm 75 (FIGS. 1 and 6) pivotally mounted as at 76 on a block 77 made part of the dispensing head assembly. The switch is connected into the electrical system of the apparatus for operating the pump plunger via the solenoid assembly as the switch arm is tripped by the article to be coated during the movement along its path into the dispensing station. The switch arm therefore extends toward the worktable and into the path of travel of the articles to be coated.
In accordance with the invention the coated threads of each article are wiped and the applied coatings are pressed into the thread roots by the provision of a wiper assembly 78, shown in FIGS. 1 and 3, located at a wiping station radially spaced 60° from the dispensing station. A motor 79 is mounted on base 11 and its output drive spindle supports an externally threaded stud 81 for the rotation thereof upon motor actuation. This stud forms a part of the wiper assembly and extends outwardly of cover 12. A wiper wheel 82, having a resilient belt 83 mounted along the periphery, is threaded on to stud 81 and is locked into a predetermined position therealong by a lock nut 84. Belt 83 and dispensing nozzle 39 lie at substantially the same elevation to assure a wiping of all the coated threads and a pressing of the coated sealants into the thread roots to fill all the voids. Belt 83 may be of a plastic material or the like which becomes surface-saturated with sealant for effectively performing its wiping and pressing functions. And, depending on the size of the articles to be coated, wiper wheel assembly 78 may be adjusted toward and away from spindle 66 supporting article A by axially rotating motor 79 about the support rod which supports the wiper assembly. As shown in FIGS. 1 and 4, a spring bias upper set screw 85 mounted on a post 86 is provided for the adjustment together with a bottom set screw (FIG. 4) 87.
In setting up the present apparatus for dispensing, the proper tooling pieces (not shown) are selected for the parts to be coated and are press fitted over spindles 66 of the indexing table. Articles A to be coated are placed over the tooling pieces which are, of course, appropriately selected for fasteners, pipes, plugs, valves, fittings, etc.
The height of dispensing head assembly 37 is adjusted by loosening knob 47 at the back of the head, raising or lowering the head until nozzle 39 points approximately one thread above the center of the threads to be coated, and retightening the knob. Knob 43 on the top of the dispensing head is then loosened and the head is slid in or out until nozzle 39 is approximately 1/16 inch from the article to be coated at the dispensing station.
The appropriate wiping roller 82 is selected depending on the size of the article to be coated. This wiper wheel is then threaded down over threaded stud 81 until the bottom of the wheel lies at approximately the third thread of the article, after which the wiper wheel is locked in place by lock nut 84.
The dispense control knob 29 of pump assembly 13 is then turned to its minimum setting.
It should be pointed out that the articles to be coated may be either manually or automatically loaded and/or unloaded in place without departing from the invention. After setting up the apparatus as aforedescribed, an electrical power switch (not shown) is turned on whereupon the article to be coated at the dispensing station commences rotation as the magnetic disc 74 transmits its rotation via magnetic attraction to the overlying magnetic disc 69 associated with the spindle assembly. Also, the threaded article at the wiping station will begin to rotate as it is turned by the wiper wheel.
An indexing speed is chosen to comfortably allow the operator to load and unload the threaded articles or to permit some suitable automated loading and unloading equipment to function.
As each threaded article approaches the dispensing station, it trips switch arm 75 as it moves thereagainst for actuation of the pump plunger which dispenses a quantity of sealant through nozzle 39 after a predetermined electronic delay, on to the threads of the article which is being rotated. The amount of sealant to be dispensed may be adjusted at this time upon a turning of control knob 29. At the wiping station, the coated threads are wiped by belt 83 and the sealant is firmly pressed into the thread roots to fill any and all voids in the threads to provide consistently leak-proof coatings.
The table is indexed through 60° arcs in a continuous manner for the remaining articles supported thereon after the completion of the dispensing and wiping operations as aforedescribed. The six threaded articles may be coated more than once if necessary and, after they move beyond the wiping station, the coated articles are unloaded from the worktable and replaced with new articles to be coated.
Obviously, many other modifications and variations of the present invention are made possible in light of the above teachings. It is therefore to be understood that within the scope of the appended claims the invention may be practiced otherwise than specifically described. | An apparatus for coating the threads of articles such as fasteners, pipes, plugs, valves, fittings, etc., includes an indexing table for intermittently moving the articles along an arcuate path, rotatable article spindle assemblies on the table radially spaced apart an equal distance and being stopped at a dispensing station and at a wiping station spaced therefrom equal to such distance. A dispensing head at the dispensing station includes a nozzle for delivering a coating of the sealant onto the threads of a rotating articles, and a wiper wheel at the wiping station wipes the coated threads and presses the coated sealant into the thread roots during rotation of the wheel which likewise rotates the coated articles. | 1 |
This application is a continuation to U.S. patent application Ser. No. 09/293,636, filed Apr. 15, 1999 now U.S. Pat. No. 6,235,605.
FIELD OF THE INVENTION
This invention relates to semiconductor fabrication processing and, more particularly, to a method for forming polysilicon for semiconductor devices, such as dynamic random access memories (DRAMs).
BACKGROUND OF THE INVENTION
The continuing trend of scaling down integrated circuits has motivated the semiconductor industry to consider new techniques for fabricating precise components at sub-micron levels. Along with the need for smaller components, there has been a growing demand for devices consuming less power. In the manufacture of memory devices, these trends have led the industry to refine approaches to achieve thinner capacitor cell dielectric and surface enhanced storage capacitor electrodes.
In dynamic random access memory (DRAM) devices it is essential that storage node capacitor cell plates be large enough to exhibit sufficient capacitance in order to retain an adequate charge in spite of parasitic capacitance and noise that may be present during circuit operation. As is the case for most semiconductor integrated circuitry, circuit density is continuing to increase at a fairly constant rate. The issue of maintaining storage node capacitance is particularly important as the density of DRAM arrays continues to increase for future generations of memory devices. The ability to densely pack storage cells while maintaining required capacitance levels is a crucial requirement of semiconductor manufacturing technologies if future generations of expanded memory array devices are to be successfully manufactured.
One area of manufacturing technology that has emerged has been in the development of Hemi-Spherical Grain (HSG) silicon. HSG silicon enhances storage capacitance when used to form the storage node electrode without increasing the area required for the cell or the storage electrode height. The available methods include use of Low Pressure Chemical Vapor Deposition (LPCVD), engraving storage electrodes using polysilicon film followed by P-diffusion utilizing POCl 3 source gas, a mixture of spin-on-glass (SOG), coating the polysilicon with resist, and HSG formation. The size of the silicon grain formed by these processes may be somewhat random and uncontrolled.
SUMMARY OF THE INVENTION
The present invention comprises a method to selectively deposit HSG silicon at only desired locations. An exemplary implementation of the present invention comprises a process for selectively forming a silicon structure for a semiconductor assembly. The process first forms a silicon rich material on a semiconductor assembly substrate. Next, a silicon resistive material is formed on the silicon rich material and patterned to allow exposure of a portion of the silicon rich material. Next, a continuous silicon film is formed on the silicon rich material while avoiding the formation of a continuous silicon film on the silicon resistive material. This selective deposition of silicon may be accomplished by presenting a silicon source gas and a silicon stripping agent to the semiconductor assembly. The silicon source gas will readily deposit silicon onto the silicon rich material, while the silicon resistive material will not readily accept the formation of a silicon film thereon. To ensure no continuous silicon is formed on the silicon resistive material, a stripping agent is introduced during the silicon deposition step to remove any silicon nucleation on the silicon resistive film.
A second exemplary implementation of the present invention comprises a process for selectively forming a silicon structure for a semiconductor assembly. The process first forms a conductive silicon rich material on a semiconductor assembly substrate. Next, a nonconductive silicon rich material is formed on the conductive silicon rich material. Next, a silicon reactive material is formed on the nonconductive silicon rich material, where the silicon reactive material and the nonconductive silicon rich material are patterned to expose of a portion of the conductive silicon rich material. Next, a continuous silicon film is formed on the conductive silicon rich material and on the nonconductive silicon rich material while converting the silicon reactive film to a silicon reacted film by presenting a silicon source gas to the semiconductor assembly substrate.
BRIEF DESCRIPTION OF THE DRAWINGS
FIGS. 1A and 1B are cross-sectional views depicting semiconductor substrates after selective deposition of silicon, including amorphous silicon (FIG. 1A) and hemispherical grain silicon (FIG. 1 B).
FIGS. 2A and 2B are cross-sectional views depicting semiconductor substrates including a recessed feature after selective deposition of silicon, including amorphous silicon (FIG. 2A) and hemispherical grain silicon (FIG. 2 B).
FIG. 2C is a cross-sectional view of the structure of FIG. 2B taken after the formation of a capacitor.
DETAILED DESCRIPTION OF THE INVENTION
Exemplary implementations of the present invention are directed to processes for forming selectively deposited silicon in a semiconductor device as depicted in the embodiments of FIGS. 1A, 1 B, 2 A, 2 B and 2 C.
Referring to FIG. 1A, substrate 10 is prepared for the processing steps of the present invention. Substrate 10 must be a silicon rich material, such as a conductively doped silicon wafer, a consecutively doped polysilicon plug that connects to an underlying access device. Other examples of preferred silicon rich materials include conductively doped amorphous silicon and the like.
For purposes of the present invention, a silicon rich material is defined as a material that promotes the nucleation of silicon atoms on its surface during a silicon deposition process that presents a silicon source gas to the surface of an in-process semiconductor assembly (such as to substrate 10 ). A silicon resistive material 11 of a desired pattern is formed on substrate 10 . For purposes of the present invention, a silicon resistive material is a material that resists the formation of continuous silicon layer during a silicon deposition process that presents a silicon source gas to its surface. Examples of silicon resistive materials are oxides, boro-phospho-silicate glass (BPSG) and tetra-ethyl-ortho-silicate (TEOS).
Next, silicon rich material 10 and silicon resistive material 11 are subjected to a silicon deposition step. The silicon deposition step will selectively deposit silicon on the silicon rich material while depositing little or no silicon on silicon resistive material 11 . Any formation of silicon deposits that do occur on silicon resistive material 11 will simply amount to silicon nucleation deposits that do not form a continuous film, nor are the silicon nucleation deposits conductive.
The selective deposition of silicon is accomplished by selecting deposition gases that chemically respond differently to certain materials. The proper deposition gases will be selective to the chemical makeup of substrate 10 and material 11 , in that the chemical reactions between the deposition gases and the materials will cause silicon deposition to occur on the silicon rich material and be resistive to the deposition of silicon on the silicon resistive material. For example, one implementation of the present invention uses a silicon source gas, such as silane, in combination with a silicon-stripping agent, such as hydrochloric acid (HCl), in this deposition step. The HCl may be introduced insitu with silane gas or the HCl may be introduced in the middle of the silicon deposition step for a period of time. Another option is to present silane gas for a period of time, then turn off the silane gas, introduce HCl for a period of time, then turn off the HCl and turn on the silane gas again. These steps may be repeated as needed so that silicon is effectively deposited on the silicon rich material, while being effectively stripped from the silicon resistive material.
These implementations of the deposition source gas in combination with HCl will accomplish the desired results of the present invention. The silicon atoms (present in the silane) will nucleate and bond with the silicon rich material of substrate 10 to form a continuous silicon film thereon, while resisting bonding with silicon resistive material 11 . If silicon nucleation does begin to occur on the silicon resistive material 11 , the hydrochloric acid will provide insitu cleaning and effectively strip any silicon formation from material 11 . The selectively deposited silicon may also be an insitu conductively doped silicon. Any silicon deposits remaining on silicon resistive material 11 will not form a continuous silicon film.
Alternatively, the material selected for material 11 may be a silicon reactive material that reacts with silicon to form a silicon compound component. The makeup of this silicon compound component is such that by using a selective etching chemistry the selective etch will remove the reacted silicon compound component while leaving, any non-reacted silicon, as well as any underlying material, intact. Examples of a silicon reactive material include refractory metals, such as tungsten, which would react with silicon to form tungsten silicide (WSi x ).
When selecting a silicon reactive material for material 11 , the final process results in the formation of selective silicon by the use of several steps that differ from the first exemplary implementation of the present invention. First a silicon reactive material is substituted for a silicon resistive material. After silicon reactive material 11 is formed, silicon deposition follows whereby the silicon atoms present in the source gas will nucleate and form a continuous silicon film on silicon rich material 10 , while the silicon atoms will react with silicon reactive material 11 to form the reacted silicon compound component mentioned previously. It is important that the entire film of silicon reactive material 11 is converted to a reacted silicon compound so that a subsequent selective etch can remove the entire reacted silicon and at the same time leave the deposited silicon film on silicon rich material 10 . For example, to selectively remove WSi x a dry isotropic etch can be used that will remove the WSi x and stop on the deposited silicon film. Another method to selectively remove the WSi x would be to use a selective wet etch chemistry. For example, using NH 4 OH:H 2 :H 2 would remove WSi x at approximately 50 angstroms/minute and remove silicon at approximately 5 angstroms/minute.
Replacing silicon resistive material with a silicon reactive material and implementing the selective etch step described can be used in the following exemplary implementations of the present invention as discussed for FIGS. 1B-2C. Therefore, though only the embodiment of using silicon resistive material is discussed in the following embodiments, that is not to be construed as limiting these embodiments to use of only a silicon resistive material.
FIG. 1B depicts a second exemplary implementation of the present invention. The concepts demonstrated in FIG. 1A are used here as well, except in this embodiment the selectively deposited silicon material 13 is either amorphous silicon or hemispherical grain (HSG) silicon. If the material of choice is amorphous silicon, then the amorphous silicon can be subjected to an annealing step in order to convert the amorphous silicon to HSG silicon.
FIG. 2A depicts a third exemplary implementation of the present invention. The concepts demonstrated in FIG. 1A are used here as well, except in this embodiment a more complex structure is formed. In FIG. 2A, substrate 20 is prepared for the processing steps of the present invention. Again, substrate 20 must be a silicon rich material as defined previously. Next, a second silicon rich material 21 is formed on substrate 20 . Silicon rich material 21 must be an insulator and it is preferred that silicon rich material 21 be silicon nitride. After the formation of material 21 , a silicon resistive material 22 is formed on insulation material 21 . Materials 21 and 22 are then patterned and etched as shown to a desired width and depth preceding a subsequent deposition of selective silicon. Silicon rich materials 20 and 21 and silicon resistive material 22 are subjected to a silicon deposition step. The silicon deposition step will selectively deposit silicon layer 23 on the silicon rich materials 20 and 21 while depositing little or no silicon on silicon resistive material 22 . The selective deposition of silicon is accomplished by the selective deposition method described in the first exemplary implementation.
FIGS. 2B-2C depict a fourth exemplary implementation of the present invention. The concepts demonstrated in FIG. 2A are used here as well, except that in this embodiment the selectively deposited silicon material 24 is either amorphous silicon or hemispherical grain (HSG) silicon. If the material of choice is amorphous silicon, then the amorphous silicon can be subjected to an annealing step in order to convert the amorphous silicon to HSG silicon.
Referring now to FIG. 2C, HSG silicon 24 is conductively doped either during deposition or implanted with conductive dopants after deposition. Next, a capacitor dielectric layer 25 is formed over material 22 and silicon material 24 . Finally, conductive material 26 is formed over dielectric layer 25 to complete a process utilizing the present invention to form a storage capacitor. The structure is then completed in accordance with fabrication process known to those skilled in the art.
In any of the above exemplary implementations of the present innovation, when the desired final silicon layer is HSG silicon, a quality HSG silicon film can be a formed by several methods. One preferred method is to deposit amorphous silicon at a temperature range of approximately 550° C. to 560° C. and then subject the amorphous silicon film to an anneal at a temperature of 560° C. to 650° C. to convert the silicon film to HSG silicon. Another preferred method is to deposit amorphous silicon at a temperature of 560° C. to 650° C., while seeding with a silicon based gas (such as SiH 4 , SiH 6 , etc.) in combination with an inert gas (such as N 2 , He 2 , etc.). Afterwards, the deposited amorphous silicon film is subjected to an anneal at a temperature of 560° C. to 650° C. to convert the silicon film to HSG silicon.
It is to be understood that although the present invention has been described with reference to several preferred embodiments, various modifications, known to those skilled in the art, such as utilizing the disclosed methods to form programmable floating gate devices, may be made to the process steps presented herein without departing from the invention as recited in the several claims appended hereto.
U.S. Pat. Nos. 5,407,534, 5,418,180, 5,658,381 and 5,721,171 contain disclosure concerning HSG formation and are hereby incorporated by reference as if set forth in their entirety. | A process to selectively form silicon structures, such as a storage capacitor, by forming a conductive silicon, forming a silicon nitride layer on the conductive silicon substrate, forming a tungsten layer on the silicon nitride layer, patterning the tungsten layer and the silicon nitride layer to expose a underlying portion of the conductive silicon substrate, forming a continuous silicon film on the exposed portion of the conductive silicon substrate and on an adjacent portion of the silicon nitride layer while completely converting the tungsten layer to a tungsten silicide film by presenting a silicon source gas to the semiconductor memory assembly to form a continuous conductive silicon film used as a first capacitor electrode, forming a capacitor dielectric on the first capacitor electrode and the oxide layer, and forming a second capacitor electrode on the capacitor dielectric. | 8 |
BACKGROUND
[0001] The present disclosure relates generally to information handling systems, and more particularly to an enhanced unified extensible firmware interface (UEFI) framework layer that can be integrated into an independent basic input/output system (BIOS) vendor's (IBV's) BIOS.
[0002] As the value and use of information continues to increase, individuals and businesses seek additional ways to process and store information. One option is an information handling system (IHS). An IHS generally processes, compiles, stores, and/or communicates information or data for business, personal, or other purposes. Because technology and information handling needs and requirements may vary between different applications, IHSs may also vary regarding what information is handled, how the information is handled, how much information is processed, stored, or communicated, and how quickly and efficiently the information may be processed, stored, or communicated. The variations in IHSs allow for IHSs to be general or configured for a specific user or specific use such as financial transaction processing, airline reservations, enterprise data storage, or global communications. In addition, IHSs may include a variety of hardware and software components that may be configured to process, store, and communicate information and may include one or more computer systems, data storage systems, and networking systems.
[0003] To add new functionality, IHS manufacturers may develop new Uniform Extensible Firmware Interface (UEFI) based basic input/output system (BIOS) for both desktop and Portable devices. In order to support the functionality and capabilities that the manufacturer has had in its prior BIOS offerings, changes are required to the UEFI framework. These changes may provide enhancements to the UEFI framework. The other parts of the UEFI BIOS, Pre-memory/pre-EFI Initialization (e.g., PEI) Drivers, Driver execution Environment (e.g., DXE) Drivers & System Management Mode (SMM) BIOS code, may then use this enhanced set of framework interfaces (e.g., protocols) to access the IHS. This does not cause a problem as long as the code that is being developed is only going to be used internal to the IHS manufacturer's BIOS and hence have access to the new framework interfaces.
[0004] For ease of interchangeability of systems and to support manufacturability by different vendors, it is desirable that the IHS manufacturer provide some of the internally developed PEI, DXE and SMM functionality and that those code objects could then be plugged into Original Design Manufacturer (ODM) UEFI BIOSs or Independent BIOS Vendor (IBV) BIOSs to maintain the IHS manufacturer's BIOS behavior even when the BIOS being used is an ODM or IBV product that is not the IHS manufacturer's internally developed UEFI BIOS. This poses a problem, because the IHS manufacturer PEI, DXE and SMM functionality is dependent on the framework changes that were made in the IHS manufacturer's internally developed UEFI BIOS to provide additional capabilities. As such, these modules are presented as being personality modules that could be plugged in at will to another vendor's UEFI BIOS.
[0005] However, using these personality modules proposes a problem because the IHS manufacturer's UEFI personality modules are not traditionally designed to plug into an ODM's or IBV's UEFI BIOS with the standard UEFI Framework interfaces. In other words, personality modules are designed to use the IHS manufacturer's enhanced UEFI Framework interfaces and are not designed to be pluggable into a UEFI BIOS that is using the standard UEFI Framework interfaces. Without another solution, the IHS manufacturer may thus be required to provide its BIOS source code to ODMs or IBV BIOS providers in order for the IHS manufacturer's personality modules to work with these outside systems.
[0006] Accordingly, it would be desirable to provide an improved unified extensible firmware interface framework layer absent the disadvantages discussed above.
SUMMARY
[0007] According to one embodiment, a unified extensible firmware interface (UEFI) includes providing by a manufacturer, a basic input/output system (BIOS) personality module to initialize an information handling system (IHS) and receiving from an outside vendor, a BIOS initialization module to initialize the IHS. The UEFI also includes integrating operations of the personality module and the initialization module by translating communication between the personality module and the initialization module.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] FIG. 1 illustrates an embodiment of an information handling system (IHS).
[0009] FIG. 2 illustrates an embodiment of a software/hardware stack for the IHS of FIG. 1 .
[0010] FIG. 3 illustrates a block diagram of an embodiment of a UEFI personality module layer diagram.
DETAILED DESCRIPTION
[0011] For purposes of this disclosure, an IHS 100 includes any instrumentality or aggregate of instrumentalities operable to compute, classify, process, transmit, receive, retrieve, originate, switch, store, display, manifest, detect, record, reproduce, handle, or utilize any form of information, intelligence, or data for business, scientific, control, or other purposes. For example, an IHS 100 may be a personal computer, a network storage device, or any other suitable device and may vary in size, shape, performance, functionality, and price. The IHS 100 may include random access memory (RAM), one or more processing resources such as a central processing unit (CPU) or hardware or software control logic, read only memory (ROM), and/or other types of nonvolatile memory. Additional components of the IHS 100 may include one or more disk drives, one or more network ports for communicating with external devices as well as various input and output (I/O) devices, such as a keyboard, a mouse, and a video display. The IHS 100 may also include one or more buses operable to transmit communications between the various hardware components.
[0012] FIG. 1 is a block diagram of one IHS 100 . The IHS 100 includes a processor 102 such as an Intel Pentium™ series processor or any other processor available. A memory I/O hub chipset 104 (comprising one or more integrated circuits) connects to processor 102 over a front-side bus 106 . Memory I/O hub 104 provides the processor 102 with access to a variety of resources. Main memory 108 connects to memory I/O hub 104 over a memory or data bus. A graphics processor 110 also connects to memory I/O hub 104 , allowing the graphics processor to communicate, e.g., with processor 102 and main memory 108 . Graphics processor 110 , in turn, provides display signals to a display device 112 .
[0013] Other resources can also be coupled to the system through the memory I/O hub 104 using a data bus, including an optical drive 114 or other removable-media drive, one or more hard disk drives 116 , one or more network interfaces 118 , one or more Universal Serial Bus (USB) ports 120 , and a super I/O controller 122 to provide access to user input devices 124 , etc. The IHS 100 may also include a solid state drive (SSDs) 126 in place of, or in addition to main memory 108 , the optical drive 114 , and/or a hard disk drive 116 . It is understood that any or all of the drive devices 114 , 116 , and 126 may be located locally with the IHS 100 , located remotely from the IHS 100 , and/or they may be virtual with respect to the IHS 100 .
[0014] Not all IHSs 100 include each of the components shown in FIG. 1 , and other components not shown may exist. Furthermore, some components shown as separate may exist in an integrated package or be integrated in a common integrated circuit with other components, for example, the processor 102 and the memory I/O hub 104 can be combined together. As can be appreciated, many systems are expandable, and include or can include a variety of components, including redundant or parallel resources.
[0015] FIG. 2 illustrates an embodiment of a software/hardware stack 128 for an IHS 100 . The software/hardware stack 128 includes an operating system 130 , an unified extensible firmware interface (UEFI) 132 , UEFI framework BIOS firmware 134 and hardware 136 . The operating system 130 is a software program code that is responsible for the management and coordination of activities and the sharing of the resources of the IHS 100 . The operating system 130 acts as a host for application programs that are run on the IHS 100 . The operating system 130 also handles the details of the operation of the hardware 136 . The UEFI 132 is a specification that defines a software 130 interface between the operating system 130 and the platform firmware 134 . The firmware 134 is a computer program that is embedded in a hardware 136 device. Firmware is generally understood as something between hardware 136 and software. Like software, firmware 134 is a computer program that is executed by a processor 102 . However, firmware 134 is also linked to hardware 136 , and has little meaning outside of the hardware 136 . In an embodiment, the firmware 134 is the framework based BIOS code that executes and sets up the system prior to UEFI 132 setting up the interface for loading the operating system. The hardware 136 is the physical components of the IHS 100 , such as, the processor 102 , the memory I/O hub 104 , the memory 108 , and a variety of other components of the IHS 100 . Portions of the hardware 136 may be referred to as the chipset for the IHS 100 .
[0016] FIG. 3 illustrates a block diagram of an embodiment of a UEFI personality module layer diagram 138 . The layer diagram includes a BIOS framework 140 , including interfaces and infrastructure. It should be readily understood by a person having ordinary skill in the art that the BIOS framework 140 has an SMM/DXE phase 142 and an PEI phase 144 . The PEI phase 142 is generally considered a pre-memory (e.g., main memory 108 ) initialization and the SMM/DXE phase 142 is generally considered post-memory (e.g., main memory 108 ) initialization.
[0017] As should be readily understood, the SMM (system management mode)/DXE (driver execution environment) phase 142 is known in the art as the initialization of the IHS 100 where most of the system initialization takes place. Generally, the PEI (pre-EFI (UEFI) initialization) phase 144 initializes permanent memory (e.g., main memory 108 ) in the platform so that the DXE phase 142 may be loaded and executed. In an embodiment, the PEI phase 144 provides a standardized system for specific initial configuration routines for the processor 102 , and other components such as, the chipset and system board. The PEI phase 144 initializes enough of the system to allow instantiation of the DXE phase 142 . In an embodiment, the DXE phase 142 may include a DXE foundation (not shown), a DXE dispatcher 156 , and DXE drivers (not shown). A DXE foundation generally produces a set of boot services, runtime services and DXE services. The DXE dispatcher 156 generally discovers and executes DXE drivers in the proper order. The DXE drivers are also generally responsible for initializing the processor 102 , chipset (e.g., the memory I/O hub 104 and a variety of other components), platform components and software abstractions. The result of the DXE is generally a fully formed EFI/UEFI interface. In an embodiment, the SMM portion of the SMM/DXE phase 142 operates substantially the same as the DXE portion.
[0018] In an SMM portion of the SMM/DXE phase 142 , the phase 142 includes any number of SMM personality modules 146 , an SMM personality module interface layer 148 , any number of independent BIOS vendor (IBV) or vendor SMM modules 150 and an IBV or vendor SMM dispatcher 158 . In a DXE portion of the SMM/DXE phase 142 , the phase 142 includes any number of DXE personality modules 152 , a DXE personality module interface layer 154 , any number of IBV or vendor DXE modules 156 and an IBV or vendor DXE dispatcher 160 .
[0019] The PEI phase 144 includes any number of PEI personality modules 170 , a PEI personality module interface layer 172 , any number of IBV or vendor PEI modules 174 and a IBV or vendor PEI dispatcher 176 .
[0020] FIG. 3 discloses a system to allow an IHS manufacturer's UEFI modules 146 , 152 and/or 170 to be able to plug into other vendors BIOS systems. Thus, the present disclosure provides an IHS manufacturer's personality modules 146 , 152 and/or 170 without loosing the uniqueness (e.g., BIOS setup, initialization, and a variety of other functions). Traditional BIOS frameworks may be changed to get the functionality and behavior of the BIOS to provide the unique features or “feel” specific to a particular IHS manufacturer.
[0021] In an embodiment, the system creates one or more personality module interface layers 148 , 154 , and/or 172 that the IHS manufacturer provides along with any personality modules 146 , 152 , and/or 170 in order to allow the IHS manufacturer's personality modules 146 , 152 , and/or 170 to run. The personality module interface layers 148 , 154 , and/or 172 acts as a translator between the personality modules 146 , 152 and/or 170 and the standard Framework interfaces 140 along with interfaces from other standard drivers 150 , 156 and/or 174 as needed. Thus, the personality module interface layer 148 , 154 and/or 172 may be used rather than changing the personality modules 146 , 152 and/or 170 and possibly loosing functionality or capabilities. Additionally, the personality module interface layer 148 , 154 and/or 172 may be used rather than providing the IHS manufacturer's enhanced UEFI Framework to other BIOS vendors to use in their BIOSs. In an embodiment, the IHS manufacturer may provide the personality module interface layer 148 , 154 and/or 172 as a binary driver executable file to the generic BIOS vendors, rather than providing the source code to the generic BIOS vendors. Using the UEFI environment allows having the framework differences in a translator such as, the personality module interface layer 148 , 154 and/or 172 , and not in the framework 140 itself.
[0022] In an embodiment, the personality module interface layer 148 , 154 and/or 172 consumes as many standard UEFI protocols as necessary from a IBV BIOS. These interfaces and dependencies may be documented thoroughly to define to the IBV and ODM vendors the set of standard UEFI interfaces and protocols that may be required in order to be compatible with the personality modules 146 , 152 and/or 170 and their respective interface layers 148 , 154 and/or 172 .
[0023] The personality module interface layers 148 , 154 and/or 172 provide enhancements and changes along with any special functionality and protocols that the IHS manufacturer personality modules 146 , 152 and/or 170 are dependant on. In other words, The personality module layer may incorporate the IHS manufacturer's uniqueness and functionality associated with the UEFI Framework 140 . Because these personality module interface layers 148 , 154 and/or 172 may be provided as code objects that could then be linked into other IBV or ODM BIOSs, an IHS manufacturer does not risk loosing its unique code.
[0024] A feature of the present disclosure is that IBV and ODM BIOS providers (e.g., generic BIOS providers) would have very few, if any, changes to make to their BIOS systems, except for supporting the required standard UEFI Framework Interfaces. The ODM or IBV may then merge their UEFI BIOS with the IHS manufacturer personality module interface layers 148 , 154 and/or 172 along with the personality modules 146 , 152 and/or 170 for an IHS manufacturer specific product BIOS solution. This would make it easier for an ODM to use an IBV BIOS, but still be able to plug in the IHS manufacturer's functionality to provide to customers.
[0025] The systems and methods of this disclosure provide the personality module interface layers 148 , 154 and/or 172 allow the IHS manufacturer to provide specific configuration information to an IBV or ODM without breaking or changing the “standard” UEFI framework interfaces. The new personality module layers (e.g., 146 , 152 and/or 170 ) allow the IHS manufacturer to create new functionality and interfaces that the IHS manufacturer's BIOS group would have had to add to the framework. These separate and autonomous layer modules then provide the IHS manufacturer's unique services to the individual personality modules 146 , 152 and/or 170 that are being included in the ODM or IBV UEFI BIOS.
[0026] Without the solution proposed in this disclosure, an IHS manufacturer may have to either propagate the framework changes to other IBVs (e.g., possibly through lengthy standards committee changes), or by providing the IHS manufacturer's framework changes to the IBV or ODM BIOS providers.
[0027] Although illustrative embodiments have been shown and described, a wide range of modification, change and substitution is contemplated in the foregoing disclosure and in some instances, some features of the embodiments may be employed without a corresponding use of other features. Accordingly, it is appropriate that the appended claims be construed broadly and in a manner consistent with the scope of the embodiments disclosed herein. | A unified extensible firmware interface (UEFI) includes providing by a manufacturer, a basic input/output system (BIOS) personality module to initialize an information handling system (IHS) and receiving from an outside vendor, a BIOS initialization module to initialize the IHS. The UEFI also includes integrating operations of the personality module and the initialization module by translating communication between the personality module and the initialization module. | 6 |
FIELD OF THE INVENTION
This invention relates to an improved method for manufacturing paper and paperboard products and paper and paperboard products manufactured by the process. More particularly, this invention relates to method for manufacturing paper and paperboard products having.
BACKGROUND OF THE INVENTION
The brightness and whiteness of paper or paperboard can be improved by, among other ways, treating the surface of a paper or paperboard web with an optical whitener or optical brightening agent (OBA). The OBA works by absorbing UV light and re-emitting it at visible light wavelengths, measured in a specified reflective range.
SUMMARY OF THE INVENTION
One aspect of the present invention relates to a method of manufacturing paper and paperboard products comprising:
forming a composition comprising water, uncooked starch and powdered optical brightener;
cooking the composition to form a cooked composition comprising cooked or hydrated starch and powdered optical brightener;
applying the cooked composition to at least one surface of a paper or paperboard substrate at the size press in a paper or paperboard manufacturing process to form a sized paper or paperboard substrate; and
drying the sized paper or paperboard substrate to form a dried sized paper or paperboard substrate.
Another aspect of the present invention relates to a method of manufacturing sized paper and paperboard products comprising:
forming a sizing composition comprising water, cooked starch and powdered optical brightener;
applying the sizing composition to at least one surface of a paper or paperboard substrate at the size press in a paper or paperboard manufacturing process to form a sized paper or paperboard substrate; and
drying the sized paper or paperboard substrate to form a dried sized paper or paperboard substrate.
Still another aspect of the present invention relates to a dried sized paper or paperboard substrate formed by the process of this invention. The process of this invention and the dried sized paper or paperboard substrate formed by the process of this invention exhibit one or more beneficial properties. For example, the dried sized paper or paperboard substrate formed by the process of this invention exhibit higher brightness ceilings as compared to dried sized paper or paperboard substrate formed by conventional processes in which a liquid optical brightener is added to cooked starch to form the size press composition.
Yet another aspect of the present invention relates to the cooked composition comprising cooked starch and powdered optical brightener.
BRIEF DESCRIPTION OF THE DRAWINGS
A full understanding of the invention can be gained from the following description of the preferred embodiments when read in conjunction with the accompanying drawings in which:
FIG. 1 is a graph of Tappi Directional Brightness versus optical brightener pickup in grams based on Example 1;
FIG. 2 is a graph of CIE Whiteness versus optical brightener pickup in grams based on Example 1;
FIG. 3 is a graph of Tappi Directional Brightness versus optical brightener pickup in grams based on Example 2; and
FIG. 4 is a graph of CIE Whiteness versus optical brightener pickup in grams based on Example 2.
DETAILED DESCRIPTION OF THE INVENTION
While this invention is susceptible of embodiment in many different forms, there is shown and described in drawing, figures, and examples and will herein be described in detail preferred embodiments of the invention with the understanding that the present disclosure is to be considered as an exemplification of the principles of the invention and is not intended to limit the broad aspect of the invention to the embodiments illustrated.
In the processes of this invention, a sizing composition comprising a cooked starch and powdered optical brightener is applied to at least one surface of a paper or paper board substrate. The viscosity of the sizing composition can vary widely. For example, the viscosity can be a low as about 20 cps and as high as about 350 cps or higher. The viscosity is preferably from about 100 cps to about 300 cps, more preferably from about 150 cps to about 250 cps and most is preferably from about 175 cps to about 225 cps.
The percent solids in the sizing composition can vary widely. For example, the percent solids can be a low as about 4% and as high as about 22% or higher based on the total weight of the sizing composition. The percent solids is preferably from about 8% to about 21%, more preferably from about 10% to about 19% and most is preferably from about 13% to about 18%.
The starch may be of any type, including but not limited to oxidized, ethylated, cationic and pearl, and is preferably used in aqueous solution. Illustrative of useful starches for the practice of this preferred embodiment of the invention are naturally occurring carbohydrates synthesized in corn, tapioca, potato and other plants by polymerization of dextrose units. All such starches and modified forms thereof such as starch acetates, starch esters, starch ethers, starch phosphates, starch xanthates, anionic starches, cationic starches and the like which can be derived by reacting the starch with a suitable chemical or enzymatic reagent can be used in the practice of this invention.
Useful starches may be prepared by known techniques or obtained from commercial sources. For example, the suitable starches include PG-280 from Penford Products, SLS-280 from St. Lawrence Starch, the cationic starch CatoSize 270 from National Starch and the hydroxypropyl No. 02382 from Poly Sciences, Inc.
Preferred starches for use in the practice of this invention are modified starches. More preferred starches are cationic modified or non-ionic starches such as CatoSize 270 and KoFilm 280 (all from National Starch) and chemically modified starches such as PG-280 ethylated starches and AP Pearl starches. More preferred starches for use in the practice of this invention are cationic starches and chemically modified starches.
The amount of starch in the size press composition can be varied widely and any amount can be used. For example, the amount of starch can be as high as about 100% or higher and as low as about 50% or higher based on the total weight of the composition. The amount of starch is preferably from about 60% to about 90%, more preferably from about 65% to about 85% and most preferably from about 70% to about 80%, based on the total weight of the composition.
Powdered optical brightening agents (“OBAs”) used in the practice of the process of this invention may vary widely and any conventional OBA used or which can be used to brighten mechanical or Kraft pulp can be used in the conduct of the process of this invention. Optical brighteners are dye-like fluorescent compounds are substances that absorb light in the invisible ultraviolet region of the spectrum and reemit it in the visible portion of the spectrum, particularly in the blue to blue violet wavelengths. This provides added brightness and can offset the natural yellow cast of a substrate such as paper. Optical brighteners used in the present invention may vary widely and any suitable optical brightener may be used. An overview of such brighteners is to be found, for example, in Ullmann's Encyclopedia of Industrial Chemistry, Sixth Edition, 2000 Electronic Release, OPTICAL BRIGHTENERS—Chemistry of Technical Products which is hereby incorporated, in its entirety, herein by reference. Other useful optical brighteners are described in U.S. Pat. Nos. 5,902,454; 6,723,846; 6,890,454; 5,482,514; 6,893,473; 6,723,846; 6,890,454; 6,426,382; 4,169,810; and 5,902,454 and references cited therein which are all incorporated by reference. Still other useful optical brighteners are described in; and U.S. Pat. Application Publication Nos. US 2004/014910 and US 2003/0013628; and WO 96/00221 and references cited therein which are all incorporated by reference. Illustrative of useful optical brighteners are 4,4′-bis-(triazinylamino)-stilbene-2,2′-disulfonic acids, 4,4′-bis-(triazol-2-yl)stilbene-2,2′-disulfonic acids, 4,4′-dibenzofuranyl-biphenyls, 4,4′-(diphenyl)-stilbenes, 4,4′-distyryl-biphenyls, 4-phenyl-4′-benzoxazolyl-stilbenes, stilbenzyl-naphthotriazoles, 4-styryl-stilbenes, bis-(benzoxazol-2-yl) derivatives, bis-(benzimidazol-2-yl) derivatives, coumarins, pyrazolines, naphthalimides, triazinyl-pyrenes, 2-styryl-benzoxazole or -naphthoxazoles, benzimidazole-benzofurans or oxanilides.
Most commercially available optical brightening agents are based on stilbene, coumarin and pyrazoline chemistries and these are preferred for use in the practice of this invention. More preferred optical brighteners for use in the practice of this invention are optical brighteners typically used in the paper industry based on stilbene chemistry such as 1,3,5-triazinyl derivatives of 4,4′-diaminostilbene-2,2′-disulfonic acid and salts thereof, which may carry additional sulfo groups, as for example at the 2, 4 and/or 6 positions. Most preferred are the commercially available stilbene derivatives as for example those commercially available from Ciba Geigy under the tradename “Tinopal”, from Clariant under the tradename “Leucophor”, from Lanxess under the tradename “Blankophor”, from 3V under the tradename “Optiblanc” such as disulfonate, tetrasulfonate and hexasulfonate stilbene based optical brightening agents. Of these most preferred commercial optical brightening agents, the commercially available hexa sulfonate and tetra sulfonate stilbene based optical brightening agents are more preferred and the commercially available hexa sulfonate stilbene based optical brightening agents is most preferred.
The amount of optical brightener used in the practice of the process of this invention can vary widely and any amount sufficient to provide the desired degree of brightness can be used. In general, the lesser the amount of optical brightener employed the less the enhancement in TAPPI brightness of the final pulp product. Conversely, the greater the amount of optical brightener used the greater the enhancement in pulp brightness except that while we do not wish to be bound by any theory, it is believe that at some point the addition of more optical brightener will not have any further appreciable impact on pulp brightness and may even result in a decrease in pulp brightness. The amount of optical brightener used is usually at least about 0.5 wgt % based on tons of paper produced. Preferably the amount of optical brightener is from about 0.5 to about 2 wgt %, more preferably from about 0.75 to about 1.75 wgt % and most preferably from about 1 to about 1.5 wgt % on the aforementioned basis.
The amount of powdered OBA in the size press composition can be varied widely and any amount can be used. For example, the amount of OBA can be as high as about 50% based on the total weight of the composition. The amount of OBA is preferably as high as about 25% based on the total weight of the composition. More preferably, the amount of OBA in the aqueous solution is from about 2 to about 10%. Most preferably, the amount of OBA in the aqueous solution is from about 5 to about 10%. It was determined that 2% concentration of OBA is optimum for visual purposes. Subsequent trials modifying optical properties have used higher concentrations of applied chemical. This can be dependent or independent of machine speed. The OBA application weight is at least about 0.7 wt %. More preferably, the application weight of OBA at least about 0.9 wt %. Most preferably, the basis weight of OBA is at least about 1.1 wt %. The OBA is predominately at or near a surface of the paper or paperboard substrate. For example, the amount of OBA at the surface of the paper or paperboard substrate can greater than 90%.
The sizing composition may include other optional ingredients in addition to the starch and powdered optical brightener. Such optional components include dispersants, fluorescent dyes, surfactants, deforming agents, preservatives, pigments, binders, pH control agents, coating releasing agents, and the like.
The sizing composition can be formed by conventional processes of forming a sizing composition by adding powdered optical brightener to a starch sizing composition comprising water and cooked starch. These methods are well known in the art. See for example “Handbook for Pulp & Paper Technologists” G. A. Smook 1982 TAPPI and the references cited therein and will not be described in any detail.
The sizing composition can also form the sizing composition comprising water, uncooked starch and powdered optical brightener and cooking the composition to hydrate the starch to form the cooked composition comprising cooked starch and powdered optical brightener. This method is preferred because ease of application, ease of preparation, and uniformity of OBA distribution.
In this preferred method conventional starch cooking techniques can be used. Complete hydration of a starch molecule and dispersion of the powdered optical brightener in the size composition requires four things: water, temperature, time, and agitation. The amount of water needed depends on the type of starch and how it has been modified. For example, a starch may require cooking at 6% solids, while a highly modified coating starch may cook at 400% solids. Cooking solids are very critical to starch performance: If the solids level is too high, the performance of the starch will degrade. Shear is also important in order to completely explode and disperse the starch granules and powdered optical brightener. In atmospheric cooking, it is necessary to maintain good high shear throughout the cooking process. Most starch begins to gel between 140 and 160° F. Highly modified starch begins to gel at temperatures as low as 115° F. Some cross-linked starches require elevated jet cooker temperatures, for example, up to 195° F. or higher. Starch cooked at atmospheric pressure may require a 20 to 30-min cooking time, while cooking is instantaneous in jet or thermal/chemical cooking processes.
Enzyme conversion. The enzyme conversion process consists of making up slurry of water and starch at the desired total solids and adjusting pH to the recommended value. The slurry is agitated and heated at a programmed temperature rate rise until about 170° F. After holding there, usually for about 30 min, the temperature is increased as rapidly as possible at a programmed rate to about 195° F. This temperature is usually adequate to “kill” the enzyme in about 15 to 30 min. The material is then cooled to the desired temperature.
The most common methods of cooking are atmospheric or batch, enzyme, jet, and thermal/chemical. In both batch and continuous enzyme cooking, strict control of several key factors is preferred. These include the rate of rise in temperature, holding period, and viscosity. These factors require strict regulation in order to develop reproducible, uniform results.
Thermal conversion and jet cooking. Jet cooking is the preferred method for hydrating starch, and continuous cookers have been available for years. High-temperature, pressure, and high shear conditions are applied through the use of “excess” steam. This method provides considerably lower viscosity for a given starch compared to atmospheric cooking. Starch paste produced by jet cooking provides the following advantages: (1) a reduction in manpower, (2) automated cooking process, (3) uniform viscosity, and (4) complete hydration of the starch molecules.
Paper and paperboard substrates used in the practice of this invention can vary widely. Such paper and paperboard substrates and methods and apparatus for their manufacture are well known in the art. See for example “Handbook For Pulp & Paper Technologies”, 2 nd Edition, G. A. Smook, Angus Wilde Publications (1992) and references cited therein, which are hereby incorporated, in their entirety, herein by reference. For example, the paper or paperboard web can be made from pulp fibers derived from hardwood trees, softwood trees, or alternatively, a combination of hardwood and softwood trees is prepared for use in a papermaking furnish by any known suitable digestion, refining, and bleaching operations, as for example, known mechanical, thermomechanical, chemical and semi chemical, pulping and other well known pulping processes. In certain embodiments, at least a portion of the pulp fibers may be provided from non-woody herbaceous plants including, but not limited to, kenaf, hemp, jute, flax, sisal, or abaca although legal restrictions and other considerations may make the utilization of hemp and other fiber sources impractical or impossible. Either bleached or unbleached pulp fiber may be utilized in the process of this invention. Recycled pulp fibers are also suitable for use. In the preferred embodiment, the cellulosic fibers in the paper or related web include from about 0% to about 100% by weight dry basis softwood fibers and from about 100% to about 0% by weight dry basis hardwood fibers.
In the preferred embodiments of the invention, in addition to pulp fibers and the paper or paperboard may also include various optional ingredients known for use in paper making including optical brighteners such as those described above; dispersed expanded or expandable synthetic resinous particles having a generally spherical hydrocarbon liquid-containing center; starch; mineral fillers; inorganic salts such as sodium chloride; internal sizing agents; dyes; retention aids; dry strength resins; strengthening polymers and the like.
The density, basis weight and caliper of the paper or paperboard web of this invention may vary widely. For example, any conventional basis weights, densities and calipers may be employed depending on the paper-based product formed from the web.
The Tappi brightness of the paper or paperboard substrate can vary widely. The desired for example, the Tappi brightness of the paper or paperboard substrate may be as low as 75 and as high as 96. The Tappi brightness of the paper or paperboard substrate is preferably equal to or greater that 90, more preferably equal to or greater that about 95, and most preferably equal to or greater that about 92. In the embodiments of choice, the Tappi brightness of the paper or paperboard substrate is from about 90 to about 94. CIE Whiteness of the paper or paperboard substrate can vary widely. CIE Whiteness is preferably at least about 85, more preferably at least about 130 and most preferably from about 100 to about 125. CIE Whiteness is preferably at least about 110, more preferably at least about 120. Surprisingly, it has been discovered that in the preferred embodiments of the invention the difference in brightness ceiling of paper or paperboard made by the process of this invention as compared to conventional size press application of liquid optical brightener is greater the higher the Tappi brightness of the substrate. For this reason, higher substrate brightness is preferred. The desired TAPPI brightness of the paper or paperboard substrate can be obtained using conventional methods as for example by extra bleaching and/or by addition of optical brightener to the substrate.
Methods and apparatuses for treating a web of paper or paperboard with a sizing composition are well known in the paper and paperboard art. See for example “Handbook For Pulp & Paper Technologies”, 2 nd Edition, G. A. Smook, Angus Wilde Publications (1992) and references cited therein. Any conventional size treatment method and apparatus can be used. Consequently, these methods and apparatuses will not be described herein in any great detail. By way of example, the size composition may be applied from a size press that can be any type of coating or spraying equipment, but most commonly is a puddle, gate roller or metered blade type of size press.
The paper or paperboard web is dried after treatment with the size composition. Methods and apparatuses for drying paper or paperboard webs treated with a sizing composition are well known in the paper and paperboard art. See for example G. A. Smook referenced above and references cited therein. Any conventional drying method and apparatus can be used. Consequently, these methods and apparatuses will not be described herein in any great detail. After drying, the paper may be subjected to one or more post drying steps as for example those described in G. A. Smook referenced above and references cited therein. For example, the paper or paperboard web may be coated and/or calendered to achieve the desired final caliper as discussed above to improve the smoothness and other properties of the web. The calendering may be accomplished by steel-steel calendaring at nip pressures sufficient to provide a desired caliper. It will be appreciated that the ultimate caliper of the paper ply will be largely determined by the selection of the nip pressure
In the preferred embodiments, the paper and paperboard exhibits a higher Tappi brightness ceiling as compared to the paper and paperboard in which liquid optical brightener is added to cooked starch or is cooked with starch and the resulting size composition is applied to the substrate at the size press. The increase in brightness ceiling is preferably at least about 2%, 3%, 4%, 5%, 6%, 7%, 8%, 9%, 10%, 11%, 12%, 13%, 14%, 15%, 16%, 17%, 18%, 19%, 20%, 21%, 22%, 23%, 24%, 25%, 26%, 27%, 28%, 29% and 30% greater than the brightness ceiling of the paper and paperboard in which liquid optical brightener is added to cooked starch or is cooked with starch and the resulting size composition is applied to the substrate at the size press, including any and all ranges and subranges therein The increase in brightness ceiling is more preferably at least about 5% to about 10% greater and most preferably at least about 5% to about 10% greater the brightness ceiling of the paper and paperboard in which liquid optical brightener is added to cooked starch or is cooked with starch and the resulting size composition is applied to the substrate at the size press.
In the preferred embodiments, the paper and paperboard exhibits a higher CIE Whiteness ceiling as compared to the paper and paperboard in which liquid optical brightener is added to cooked starch or is cooked with starch and the resulting size composition is applied to the substrate at the size press. The increase in CIE Whiteness ceiling is preferably at least about 2%, 3%, 4%, 5%, 6%, 7%, 8%, 9%, 10%, 11%, 12%, 13%, 14%, 15%, 16%, 17%, 18%, 19%, 20%, 21%, 22%, 23%, 24%, 25%, 26%, 27%, 28%, 29% and 30% greater than the CIE Whiteness ceiling of the paper and paperboard in which liquid optical brightener is added to cooked starch or is cooked with starch and the resulting size composition is applied to the substrate at the size press, including any and all ranges and subranges therein The increase in brightness ceiling is more preferably at least about 5% to about 10% greater and most preferably at least about 5% to about 10% greater the CIE Whiteness ceiling of the paper and paperboard in which liquid optical brightener is added to cooked starch or is cooked with starch and the resulting size composition is applied to the substrate at the size press.
The differences in brightness ceiling increase with increases in the TAPPI Brightness of the substrate. It is preferred that the initial TAPPI brightness of the substrate prior to treatment in the process of this invention is least about 90, more preferably at least about 92 and most preferably from about 93. In the embodiments of choice, the initial TAPPI brightness of the substrate prior to treatment in the process of this invention is least about 94, 95 or 96.
The differences in CIE Whiteness ceiling increase with increases in the TAPPI Brightness of the substrate. It is preferred that the initial CIE Whiteness of the substrate prior to treatment in the process of this invention is at least about 85, more preferably at least about 130 and most preferably from about 100 to about 125. CIE Whiteness is preferably at least about 110, more preferably at least about 120.
The paper and paperboard manufactured in accordance with this invention can be used for conventional purposes. For example, the paper is useful as publication paper, packaging and the like.
The following specific examples are intended to illustrate the invention in detail and are not intended to be construed as a limitation thereon.
EXAMPLE 1
(A) Preparation of Size Press Compositions with Pre Cooked Addition of Optical Brightener (“OBA”)
A series of surface starch applications were prepared using the following procedure. The starch was prepared in a lab Jet cooker. A certain amount of OBA was added to a starch slurry tank with a certain amount of dry ethylated starch. Water was added to make an ˜18% total solids slurry (based on the total weight of composition) and the slurry was cooked at 299° F. in the jet cooker. The starch was diluted to the desired starch solids for this application of 13 to 16% depending on the tolerance of the system to size press treatment viscosity, and the desired pickup. The starch solution compositions and specifications are set for the in the following Table 1.
TABLE 1
Size Press Compositions with OBA - Pre Cooked Addition
OBA
Size
Solids/
Press
Total
Total
Compo-
OBA
OBA
Ethylated
Powdered
Volume
Solids
sition
Form
Type
Starch, (g)
OBA, (g)
(L)
(%)
1 C-1
—
1963
—
10
—
1
Powdered
Hexa 2
1963
30.91
10
1.55
2
Powdered
Hexa
1963
61.81
10
3.05
3
Powdered
Hexa
2944
150.1
12
4.85
4
Powdered
Tetra 3
1963
30.91
10
1.55
5
Powdered
Tetra
1963
61.81
10
3.05
6
Powdered
Tetra
1963
120.1
12
4.85
1 “C” indicates that the composition is a comparison composition.
2 “Hexa” is hexa sulfonate stilbene obtained from Daikaffil Chemical under the trade name Dikaphor BSU.
3 “Tetra” is tetra sulfonate stilbene obtained from Aakash under the trade name SI 220.
(B) Preparation of Size Press Compositions with Post Cooked Addition of Optical Brightener
A series surface starch applications was prepared using the following procedure. Starch was prepared slurring 3532 g of ethylated in 18 L of water and cooking the slurry at 299° F. in a jet cooker. The starch was diluted to the desired starch solids for this application of 13 to 16% depending on the tolerance of the system to size press treatment viscosity, and the desired pickup. The liquid OBA/starch solution compositions were prepared by adding commercially available liquid Hexa OBA to the cooked starch. The starch composition and specifications are set for the in the following Table 2.
TABLE 2
Size Press Compositions - Post Cooked Addition
OBA
Liquid
Liquid
Solids/
Ethylated
OBA,
OBA,
Total
Total
Starch
OBA
Starch,
(g as
(g
Volume
Solids
Composition
Type
(g)
received)
dry*)
(L)
(%)
C-2
Hexa
2,643.5
304.6
59.7
17.957
2.21
C-3
Hexa
2,557.5
533.4
104.6
16.886
3.92
C-4
Hexa
2,436.3
772.9
151.6
16.462
5.83
C-5
Hexa
2,349.3
974.6
191.1
15.341
7.47
*g dry OBA was calculated by dividing the as received 5.1 based on HPLC and NMR analysis of relative OBA content of powdered and liquid products.
(C) Preparation of Laboratory Size Press Treated Paper
1. Substrate Preparation
The substrate used in this experiment was made on a paper machine from a furnish consisting of 60% softwood and 40% hardwood fibers and 12% clay filler under acid conditions. The basis weight of the substrate paper was about 116 g/m 2 and the Tappi Directional Brightness and CIE Whiteness were 77.7 and 68.9, respectively.
2. Size Press Treatment
To apply the surface starch formulation, a 12″ wide roll of paper substrate was continuously fed between two rollers, and the starch formulation was pumped into the nip reservoir (puddle), the paper being fed through the nip reservoir at a prefixed speed. By controlling the formulation solids, nip pressure, and size press running speed, a total pickup weight of 3.8 to 4.5 g/m 2 was achieved.
The size press treated substrates and their specifications are set forth in the following Table 3.
TABLE 3
Size Press Treated Substrates
Total
Size
Coverage,
Starch,
OBA,
Composition
OBA Form
OBA Type
(gsm)
(gsm)
(gsm)
C-1
—
—
6.54
6.54
—
1
Powder
Hexa
6.44
6.34
0.10
2
Powder
Hexa
6.05
5.86
0.18
3
Powder
Hexa
6.68
6.35
0.32
4
Powder
Tetra
6.29
6.20
0.10
5
Powder
Tetra
5.95
5.77
0.18
6
Powder
Tetra
5.97
5.68
0.29
C-2
Liquid
Hexa
6.50
6.36
0.14
C-3
Liquid
Hexa
6.39
6.14
0.25
C-4
Liquid
Hexa
6.99
6.59
0.41
C-5
Liquid
Hexa
6.85
6.34
0.51
The Tappi Directional Brightness was measured using Tappi Test method T-452. The CIE Whiteness was measured using ISO-11475. The results of these evaluations are set forth in the following Table 4.
TABLE 4
Tappi Directional Brightness
and CIE Whiteness
Tappi
CIE
Starch
Directional
Whiteness,
Composition
Brightness
D65
C-1
77.7
68.94
1
81.4
101.68
2
82.8
112.80
3
83.4
117.90
4
81.9
104.21
5
82.8
111.63
6
82.7
112.43
C-2
81.6
104.30
C-3
82.5
111.78
C-4
83.1
116.96
C-5
83.2
119.68
EXAMPLE 2
(D) Preparation of Size Press Compositions with Pre Cooked Addition of OBAs
A series of surface starch applications were prepared using the following procedure. The starch was prepared in a batch cooker. A certain amount of powdered OBA was added to a starch slurry tank with a certain amount of dry oxidized starch. Water was added to make an ˜16% total solids slurry and the slurry was cooked at 200° F. for twenty minutes. The starch was diluted to the desired starch solids for this application of 14 to 14.5% depending on the tolerance of the system to size press treatment viscosity, and the desired pickup. The starch solution compositions and specifications are set for the in the following Table 5.
TABLE 5
Size Press Compositions with Powdered OBA
Pre Cooked Addition
Size
Oxidized
Powdered
Total
OBA
Press
OBA
Starch,
OBA,
Volume
Solids/Total
Composition
Type
(g)
(g)
(L)
Solids (%)
7
Hexa
3178
122.4
19.1
3.71
8
Hexa
3178
203.7
19.6
6.02
9
Hexa
3178
285.1
20.0
8.23
(E) Preparation of Size Press Compositions with Post Cooked Addition of OBAs
A series surface starch applications was prepared using the following procedure. The starch was prepared in a jet cooker. A certain amount of liquid OBA was added to a starch slurry tank with a certain amount of dry oxidized starch. Water was added to make an ˜˜18% total solids slurry and the slurry was cooked at 270° F. in the jet cooker. The starch was diluted to the desired starch solids for this application of approximately 14.5%. The liquid OBA/starch solution compositions were prepared by adding commercially available liquid Hexa OBA to the cooked starch. The starch composition and specifications are set forth in the Table 6.
TABLE 6
Size Press Compositions - Post Cooked Addition
OBA
Liquid
Liquid
Solids/
Oxidized
OBA,
OBA,
Total
Total
Starch
OBA
Starch,
(g as
(g
Volume
Solids
Composition
Type
(g)
received)
dry*)
(L)
(%)
C-6
Hexa
3178
317.8
62.31
21.4
1.89
C-7
Hexa
3178
953.4
186.94
22.9
5.32
C-8
Hexa
3178
1589
311.57
24.3
8.34
*g dry OBA was calculated by dividing the as received 5.1 based on HPLC and NMR analysis of relative OBA content of powdered and liquid products.
(F) Preparation of Pilot Size Press Treated Paper
1. Substrate Preparation
The substrate used in this experiment was made on a paper machine from a furnish consisting of approximately 80% softwood and 20% hardwood fibers with 20% calcium carbonate filler under alkaline conditions. The basis weight of the substrate paper was about 116 g/m 2 and the Tappi Directional Brightness and CIE Whiteness were 94.6 and 115.80, respectively.
2. Size Press Treatment
To apply the surface starch formulation, a 14″ wide roll of paper substrate was continuously fed between two rollers, and the starch formulation was applied as a film onto the application rolls, the paper being fed through the rolls at a prefixed speed. By controlling the formulation solids, nip pressure, and size press running speed, a total pickup weight per side of 2.3 to 3.4 g/m 2 was achieved.
The size press treated substrates and their specifications are set forth in Table 7.
TABLE 7 Size Press Treated Substrates Total Starch OBA Coverage per per Starch OBA OBA per Side, Side, Side, Composition Form Type (gsm) (gsm) (gsm) 7 Powder Hexa 3.2 3.08 0.12 8 Powder Hexa 3.3 3.10 0.20 9 Powder Hexa 3.1 2.84 0.26 C-6 Liquid Hexa 3.4 3.34 0.06 C-7 Liquid Hexa 2.3 2.18 0.12 C-8 Liquid Hexa 3.4 3.12 0.28
The Tappi Directional Brightness was measured using Tappi Test method T-452. The CIE Whiteness was measured using ISO-11475. The results of these evaluations are set forth in the following Table 8.
TABLE 8
Tappi Directional Brightness
and CIE Whiteness
Tappi
CIE
Starch
Directional
Whiteness,
Composition
Brightness
D65
7
97.4
141.74
8
97.9
144.69
9
98.2
146.41
C-6
96.3
134.51
C-7
97.2
140.47
C-8
97.6
143.16 | The present invention relates to a process for applying optical brightening agent (OBA) to a sheet of paper or paperboard substrate. The process comprises applying the composition comprising a cooked starch and a powdered optical brightener to at least one surface of a paper or paperboard substrate at the size press in a paper or paperboard manufacturing process to form a sized paper or paperboard substrate; and drying the sized paper or paperboard substrate to form a dried sized paper or paperboard substrate. | 3 |
[0001] This U.S. application Ser. No. 12/133,373 is the official continuation filing of the previously filed provisional U.S. Patent Application No. 60/933,077, filed on Jun. 4, 2007, entitled “Tunable duty cycle universal electrical return-to-zero (TDC-ERZ) modulation method and apparatus for low cost optical communication”, therefore claims the priority date of Jun. 4, 2007 of the provisional application U.S. 60/933,077, which is incorporated herein by reference.
FIELD OF INVENTION
[0002] The invention relates to an optical communication system with a return-to-zero (RZ) modulation, and particularly to a method and apparatus generating a widely tunable duty cycle RZ pulse data stream through electrical means without the need for expensive and/or bulky optical RZ pulse carver. The invention provides means to a low cost, small form factor, high performance optical system with great flexibility to support various transmission applications.
BACKGROUND OF THE INVENTION
[0003] Optical fiber transmission systems are subject to distortion related to loss, noise, and nonlinearities in both the fiber and the modulation and amplification devices. One of the deleterious forms of signal distortion is that due-to fiber nonlinearities and polarization mode dispersion (PMD). The main attraction of the retuen-to-zero (RZ) modulation is its demonstrated improved immunity to fiber nonlinearities and PMD relative to non return-to-zero (NRZ) modulation.
[0004] The RZ format is being used in commercial 10 Gb/s ultra long haul systems, see P. Hoffman, E. B. Basch, S. Gringeri, R. Egorov, D. Fishman, and W. Thompson, “DWDM long haul network deployment for the Verizon nationwide network,” presented at the OFC 2005, Anaheim, Calif., Paper OtuP5. For 40 Gb/s systems, the addition of phase modulation to the RZ format reduces intra-channel nonlinear effects, see S. Appathurai, V. Mikhailov, R. I. Killey, and P. Batvel, “Investigation of the optimum alternative-phase RZ modulation format and its effectiveness in the suppression of intra-channel nonlinear distortion in 40 Gb/s transmission over the standard single mode fiber,” IEEE J. Sel. Topics Quantum Electron., vol. 10, no. 2, pp. 239-249, March-April 2004. Those RZ techniques, variously referred to as alternative phase RZ (AP-RZ) or carrier suppressed RZ (CS-RZ) have been successfully used in early 40 Gb/s applications, see D. Chen, T. J. Xia, G. Wellbrock, D. Petersen, S. Y. Park, E. Thoen, C. Burton, J. Zyskynd, S. J. Penticost, and P. Mamyshev, “Long span 10×160 km 40 Gb/s line side, OC-768c client side field trial using hybrid Raman/EDFA amplifiers,” in Proc. ECOC 2005, vol. 1, pp. 15-16.
[0005] In other modulation schemes, RZ is also commonly used to improve the system performance. For example, in phase shifted key (PSK) modulation schemes suitable for high bit rate applications such as for 40 Gb/s and 100 Gb/s systems, RZ version of differential phase shift keying (DPSK) and differential quadrature phase shift keying (DQPSK) have been shown to provide improved PMD tolerance and approximately 1 to 2-dB improvement in OSNR sensitivity relative to their current NRZ implementation but also requires more bandwidth, see E. Bert Basch, R. Egorov, S. Gringeri, and S. Elby, “Architectural tradeoffs for reconfigurable dense wavelength-division multiplexing systems,” IEEE J. of Selected Topics in Quantum Electronics, vol. 12, no. 4, July/August 2006.
[0006] The two most commonly used techniques to generate optical RZ data streams either employ a sinusoidal driven intensity modulator or an actively mode locked laser, in addition to a NRZ data modulator, see, A. Ougazzaden et al, “40 Gb/s tandem electron-absorption modulator,” in Proc. OFC'01, 2001, Post-deadline paper PD14. Apart from the need for two or more high power RF components, these techniques need the accurate synchronization between the data modulator and the pulse source.
[0007] Yet another technique is the use of the a single NRZ driven phase modulator followed by a passive optical delay interferometer, eliminating the need for any synchronization between the two signals and considerably alleviates the requirements on the driver amplifiers, see P. J. Winzer and J. Leuthold, “Return to Zero modulator using a single NRZ drive signal and an optical delay interferometer,” IEEE Photon. Technol. Lett., vol. 13, no. 12, pp. 1298-1300, December 2001
[0008] In yet another approach, a variable duty cycle RZ pulse can be generated using cascaded optical modulators, see J. C. Mauro, S. Raghavan, S. Ten, “Generation and system impact of variable duty cycle alpha-RZ pulses,” J. Opt. Commun. Vol. 26, pp. 1015, 2005. This is different from all other RZ pulse generation scheme in that the duty cycle of the pulse is variable. However it is implemented in optical domain and therefore expensive to the systems.
[0009] In summary, optical RZ pulses are mostly generated by optical means, and commonly implemented by the separate cascaded Mach-Zehnder modulators driven by an NRZ data stream for one section and a clock pulse carver for the second section. The approach requires precise control of amplitude and phase, as well as separate microwave amplifiers for the two sections. In all cases, RZ format is more complex and costly to implement in its current optical format.
[0010] Therefore, due to the advantages RZ has over NRZ modulation, there is a need for cost effective solutions to generate the RZ modulation with less cost, less size, less power and better performance so that it can be more readily integrated into more compact form factors for the transmitters, such as for the small form factor modules for 40 Gb/s and 100 Gb/s.
[0011] To the best knowledge of the inventors, there is not any RZ pulse generator that is implemented in pure electrical domain and at the same time has a widely tunable duty cycle. It is therefore the objective of the present invention to generate a tunable duty cycle RZ pulse with a universal electrical means, reducing the size, cost, and increasing the flexibility of the systems to adapt to various applications in metro and long haul networks.
SUMMARY OF THE INVENTION
[0012] This U.S. application Ser. No. 12/133,373 is the official continuation filing of the previously filed provisional U.S. Patent Application No. 60/933,077, filed on Jun. 4, 2007, entitled “Tunable duty cycle universal electrical return-to-zero (TDC-ERZ) modulation method and apparatus for low cost optical communication”, and incorporated herein by reference.
[0013] The present invention is an electrical RZ pulse generating method and apparatus that has a widely tunable duty cycle that covers the most desirable duty cycle of 33%, 50% and 67% in the single apparatus for high speed 10 Gb/s, 40 Gb/s and 100 Gb/s signals and low cost RZ modulation.
[0014] Briefly, as shown in FIG. 1( a ) and FIG. 1( b ), a preferred embodiment of the present invention includes an AC coupled dual differential input limiting amplifier with a DC-driven bias tee. The AC coupled dual input ports 103 are drive by the incoming NRZ data 102 and the input clock 101 respectively. The DC bias voltage 110 is used for the continuous adjustment of bias voltage of the limiting amplifier and therefore the resulting duty cycle of the generated RZ pulse. In addition, in FIG. 2( a ), FIG. 2( b ) and FIG. 2( c ), some typical examples are shown for a RZ transmitter with present invention.
1) FIG. 2( a ) shows a tunable duty cycle electrical RZ driven optical differential coded binary modulation, where a duobinary encoder 109 is inserted into the NRZ data input port and the output port of the encoder is then connected into the input port 102 of the apparatus, in such a tunable duty cycle optical duo-binary transmitter is obtained, without the use of more expensive optical MZ modulator for RZ modulation, as is normally implemented. The present invention offers more features, functions, flexibilities, but less cost and smaller size. 2) FIG. 2( b ) shows a traditional NRZ based optical duobinary (NRZ-ODB) transmitter, where both data and the inverted data (data_bar) are fed into the input ports 101 and 102 of the differential limiting amplifier 105 , followed by a duobinary encoder 109 to drive a MZ modulator 107 . This is a very simple implementation of NRZ ODB transmitter, using the similar architectural design as those in the design in FIG. 2( a ). 3) FIG. 2( c ) shows a traditional NRZ transmitter using the same design as in FIG. 2( a ) and FIG. 2( b ) with differential limiting amplifier 105 .
[0018] Several other preferred embodiments and some application examples for combining this type of RZ pulse generating apparatus with other modulation formats are also shown in FIG. 3 , FIG. 4 , and FIG. 5 .
[0019] In summary, a universal design can be implemented based on the present invention such that not only a widely tunable duty cycle electrical RZ pulse generating apparatus is produced cost effectively, but also, other types of transmitters can also be produced by populating or depopulating the building blocks of present invention (duobinary encoder in this case). All in the same design with some by-pass functions to the encoders.
[0020] One of the advantages of the present invention is that it can be used to convert many different modulation formats from other pulse formats such as NRZ to RZ cost effectively, and with smaller size for further package integration. For example, the traditional NRZ modulation, the NRZ duobinary modulation, the optical single side band (OSSB) NRZ modulation, the DPSK modulation, and the DQPSK modulation, can be converted into their corresponding RZ format.
[0021] The other advantage is its smaller size of the present invention, since it eliminates some of the bulky and/or expensive optical components, such as LiNbO3 or InP Mach-Zehnder modulator. Because of this, many transmitters that employs RZ format can be integrated into the small form factor modules or XFP pluggable package for 10 Gb/s, 40 Gb/s and 100 Gb/s applications.
[0022] The other advantage of the present invention is its widely tunable duty cycle, which is suitable for many different applications, such as for metro, long haul, and submarine optical transmission systems due to the needs for different duty cycles.
[0023] The other advantage of the present invention is its unique implementation, which produces nearly identical RZ pulse with zero chirps, compared with the optical RZ pulse generation for high speed transmitters.
[0024] These and other objects and advantages of the present invention will no doubt become obvious to those of ordinary skill in the art after having read the following detailed description of the best mode operations.
BRIEF DESCRIPTION OF THE DRAWING
[0025] The invention will now be described in great details with reference to the drawings, in which
[0026] FIG. 1 is one of the preferred embodiments of the present invention for transmitter with tunable duty cycle electrical RZ modulation (ERZ).
[0027] FIG. 2 : Several other preferred embodiments and application examples for combining the present invention with other modulation formats.
[0028] FIG. 2( a ): Tunable duty cycle electrical RZ (ERZ) driven optical differential coded binary modulation (this invention)
[0029] FIG. 2( b ): Tunable duty cycle electrical RZ (ERZ) transmitter with also electrical duobinary modulation (DB) generation.
[0030] FIG. 2( c ): Tunable duty cycle electrical RZ transmitter (ERZ).
[0031] FIG. 3 : One of the embodiments of electrical based RZ-DPSK and electrical RZ-DQPSK utilizing the present invention in the electrical domain to remove the need for expensive and/or bulky optical RZ pulse carver such as MZ modulator in their traditional optical domain implementation.
[0032] FIG. 4 : One of the embodiments for NRZ-DQPSK transmitter using single MZ modulator with dual drive in order to further reduce the cost of DQPSK transmitter implementation, in addition to the benefit resulting from the present invention as shown in FIG. 1 . The implementation of DQPSK itself is also further simplified utilizing a single MZ modulator with dual electrical drive, instead of the two parallel MZ modulators.
[0033] FIG. 5 : One of the embodiments for electrical RZ-DQPSK transmitter using single MZ modulator with dual drive in order to reduce the cost of RZ-DQPSK transmitter implementation. The present invention as shown in FIG. 1 is used to produce electrical RZ-DQPSK transmitter.
DESCRIPTION OF PREFERRED EMBODIMENTS
[0034] Accordingly to one of the preferred embodiments of the present invention, a tunable duty cycle electrical RZ pulse generating apparatus to convert NRZ data stream to RZ data stream is shown in FIG. 1( a ) and FIG. 1( b ). The incoming NRZ data input 102 and the clock input 101 are both fed through AC coupling 103 , into the electrical RZ (ERZ) encoder and driver, which is made of a differential limiting amplifier 105 and a Bias Tee 104 for the limiting amplifier. The DC voltage 110 of the Bias-Tee 104 can be used as the single parameter to adjust the RZ pulse duty cycle as shown in the diagram in FIG. 1( b ). The different limiting amplifier 105 is driven by the NRZ data 102 and the associated clock 101 , therefore generates a RZ pulse output with a tunable duty cycle based on the Bias Tee 103 's DC bias voltage 110 , which can be continuously fine tuned. FIG. 1( b ) shows the input NRZ data stream, the input clock, and the DC bias on the Bias-Tee, and the resulting electrical RS pulse stream. The benefits of this implementation are multi-folded. Firstly, a single RF driver to provide RZ encoding and RZ pulse amplification is needed. There is no need for a 2nd MZ modulator and clock driver for RZ pulse generation in optical domain. Secondly, comparing to the conventional RZ generation, the high-speed AND gate can be removed, which results in further power and cost reduction. Thirdly, using a simple bias-tee and DC offset for the input clock, the duty cycle of the RZ data can be adjusted by greater than ±15% from its default 50% value. Thus this RZ transmitter design is also capable for submarine (33% duty cycle) and terrestrial ultra-long haul, e.g. CSRZ (67%) application. Fourthly, this scheme can be combined with differential encoder to be used for RZ-DPSK applications.
[0035] According to one of the other embodiments, several preferred implementations and applications for, combining the present invention with other modulation formats are shown in FIG. 2 . As shown in FIG. 2( a ), a tunable duty cycle electrical RZ driven optical differential coded binary modulation is presented based on the current invention, where an duobinary encoder 109 is inserted into the NRZ data input port and the output port of the encoder is then connected into the input port 102 of the data input port, in such a tunable duty cycle RZ duobinary transmitter is obtained, without the use of more expensive optical MZ modulator, as is normally implemented. The present invention offers more features, functions, flexibilities, but less cost and smaller size. The encoder portion is a typical data pass summed up with its one-bit delay line (the delay time can be optimized to be less or more than one bit period) with the use of exclusive OR gate logic (XOR gate), or a FIR filter (finite impulse response filter), or a FFE based EDC (electrical dispersion compensator) chip with 3 taps and each tap has a half bit period of delay. As shown in FIG. 2( b ), a tunable duty cycle transmitter with an electrical RZ modulation and also an electrical duobinary signal encoding is presented, where both data and the inverted data (data_bar) are fed into the input ports 101 and 102 of the differential limiting amplifier, followed by an electrical duobinary encoder (also the present invention) to drive a MZ modulator. This is a very simple implementation of RZ duobinary transmitter, using the similar architectural design as those in the design in FIG. 2( a ). As shown in FIG. 2( c ), a tunable duty cycle transmitter with electrical RZ modulation, but without the duobinary encoding is presented using the same design with differential limiting amplifier. In summary, a universal design is implemented based on the present invention such that not only a widely tunable duty cycle electrical RZ pulse generating apparatus is produced cost effectively, but also, other types of transmitters can be produced by populating or depopulating the building blocks (pre-coder and en-coder in this case) in the same design with some by-pass functions to the pre-coders/encoder 109 placed either in the NRZ data incoming path right before the input to the AC coupling port 104 of the differential limiting amplifier 105 , or right after the output of the differential limiting amplifier 105 .
[0036] According to another embodiment of the present invention, an electrical RZ-DPSK transmitter and an electrical RZ-DQPSK transmitter utilizing the present invention in the electrical domain to remove the need for expensive and/or bulky optical RZ pulse carver such as MZ modulator in their traditional optical domain implementation is shown in FIG. 3 . For electrical RZ-DPSK, instead of using NRZ “Data” and “Data_Bar” to drive the first MZ modulator, the embodiment as shown in FIG. 1 is used to generate two output RZ pulse streams of the respective differential limiting amplifiers from individual “Data” signal and “Data_Bar” signal sampled and limited by the input NRZ clock, to drive the first MZ modulator. Since the resulting pulse is now an optical RZ stream, there is no need for the second MZ modulator as the RZ pulse carver and therefore, it can be removed. In this case, the MZ modulator can be the standard MZ normally used for DPSK modulation. It can also be the dual drive MZ modulator designed for DQPSK modulation. For the electrical RZ-DQPSK transmitter, similarly, instead of using NRZ “Data” and “Data1” to drive the two parallel MZ modulators, the embodiment as shown in FIG. 1 is used to generate two output RZ pulse streams of the respective differential limiting amplifiers 105 from individual “Data” signal and “Data1” signal sampled and limited by the input NRZ clock, to drive the first two MZ modulators in parallel. Since the resulting pulse stream is now an optical RZ stream, there is no need for the third MZ modulator cascaded after as the RZ pulse carver and therefore, it can be removed.
[0037] According to another embodiment of the present invention, a NRZ-DQPSK transmitter using single MZ modulator with dual drive is shown in FIG. 4 . In order to further reduce the cost of DQPSK transmitter implementation, in addition to the benefit resulting from the present invention as shown in FIG. 1 , the implementation of DQPSK itself can also be further simplified utilizing a single MZ modulator with dual electrical drive, instead of the two parallel-MZ modulators. The diagram is shown for the preferred embodiment for low cost DQPSK modulator, where a single MZ modulator is used. Firstly, the differential pre-coder 202 is used convert the input data stream into two tributary data stream “Data1” and “Data2”. Then each of the data streams is used to drive independently one of the arms of the single MZ modulator with its own bias voltage. In each of the MZ modulator arms, there is an independent phase control section that can be used to set the phase delay in each of the arms independently. Normally, for DQPSK application, the phase in one arm is set to zero and in another is set to 90 degrees. If the input data into the pre-coder is the NRZ stream, and then this embodiment of DQPSK is the NRZ-DQPSK. It has the advantage over traditional implementation that it reduces the cost, size, power consumption, and therefore allows for the integration into a much smaller package, such as XFP and small form factor modules. This implementation is flexible and versatile in that the two independent drives into the MZ modulator arms can be of various amplitude and phase relationship in order to produce various types of phase or amplitude modulation formats. The details will not be discussed here, but anyone with ordinary skills can derive obvious alterations based on this.
[0038] According to another embodiment of the present invention, an electrical RZ-DQPSK transmitter using single MZ modulator with dual drive is shown in FIG. 5 .
[0039] In order to further reduce the cost of RZ-DQPSK transmitter implementation, the present invention as shown in FIG. 1 is used to produce an electrical RZ-DQPSK transmitter. Firstly, the differential pre-coder is used to convert the input data stream into two tributary data stream “Data1” and “Data2”. Then each of the data streams is then paired with the input clock signal to feed into one AC-coupled differential limiting amplifier 105 to produce the electrical RZ pulse stream based on the input data stream “Data1” or “Data2”. The bias voltage 110 of the two limiting amplifiers 105 are set as the same in order to produce the same output ERZ pulse duty cycle for input data stream“Data1” and “Data2”. The two output electrical RZ pulse streams from the two limiting amplifiers are then fed into the single dual drive MZ modulator 107 to drive the two arms independently. In each of the MZ modulator arms, there is an independent phase control section that can be used to set the phase delay in each of the arms independently. Normally, for DQPSK application, the phase in one arm is set to zero and in another is set to 90 degrees. This type of electrical RZ-DQPSK transmitter has the advantage that it is much simpler in design, smaller in size, much less expensive in cost, and offers similar or better performance, and can be easily integrated into a much smaller package, such as XFP and small form factor package, which cannot be achieved currently with the exiting solutions due to its bulky size and need of more optical components.
[0040] Although the present invention has been described in terms of the presently preferred embodiments, it is to be understood that such disclosure is not to be interpreted as limiting. Various alterations and modifications will no doubt become apparent to those skilled in the art after having read the above disclosure. Accordingly, it is intended that the appended claims be interpreted as covering all alterations and modifications as fall within the true spirit and scope of the present invention. | A tunable duty cycle electrical return-to-zero (RZ) modulation method is realized through tuning of some electrical parameters of an encoder without the need for expensive and/or bulky optical pulse carver, therefore providing a universal RZ apparatus suitable for various high speed applications such as at 10 Gb/s, 40 Gb/s and 100 Gb/s. The electrical RZ modulation scheme is readily combined with other known modulation technologies on the transmitter side to support low cost RZ modulation for metro, long haul and submarine systems. | 7 |
This is a division of application Ser. No. 325,781, filed Nov. 30, 1981.
RELATED APPLICATION
U.S. patent application Ser. No. 226,562, filed Jan. 19, 1981 describes (S)-3-acylamino-2-oxo-1-azetidinesulfonic acids having various substituents in the 4-position. One of the processes described by this application utilizes a starting material having the formula ##STR3## wherein A is a nitrogen protecting group (triphenylmethyl is said to be preferred) and X is alkyl or phenyl. As disclosed therein, a compound of the above formula can be reacted with one (1) equivalent of a methyl Grignard reagent followed by slightly more than one (1) equivalent of the appropriate Grignard reagent having the formula
halo-Mg-R
wherein R is alkyl, alken-1-yl, alkyn-1-yl, 2-phenylethenyl or 2-phenylethynyl to yield a compound having the formula ##STR4##
BACKGROUND OF THE INVENTION
"A New Method for the Carbon-extension Reactions of Azetidin-2-ones", Kobayashi et al., J.C.S. Chem. Comm., 1980, 736-737, describes treatment of 4-sulfonylazetidin-2-ones and 3-triphenylmethyl-4-sulfonylazetidin-2-ones with Grignard reagent. Specifically utilized as starting materials are 4-phenylsulfonylazetidin-2-one and 3-triphenylmethyl-4-methylsulfonylazetidin-2-one.
U.K. Patent Application No. 2,071,650, published Sept. 23, 1981, describes (S)-3-acylamino-2-oxo-1-azetidinesulfonic acids having various substituents in the 4-position, and the use of these compounds as antibacterial agents.
"Transformations of Penicillins. Part V. Reactions of Olefin and Acetylene Derivatives with the Sulphenic Acid Intermediates from Penicillin S-Oxides", Ager et al., J. Chem. Soc., Perkin Trans. I, 1187 (1973), describes the trapping reaction of, inter alia, norbornadiene with the sulphenic acids produced by heating penicillin S-oxides followed by reduction to yield ##STR5##
Brief Description of the Invention
While the prior art deals with carbon-extension reactions of 3-unsubstituted and 3-protected amino azetidin-2-ones, it has now been surprisingly found that compounds having the formula ##STR6## wherein R 1 is one of the simple acyl groups phenylacetyl or phenoxyacetyl, can be treated with a Grignard reagent having the formula ##STR7## to yield the corresponding compounds having the formulas ##STR8## In the above formulas, and throughout the specification, the symbols are as defined below.
R 1 is phenylacetyl or phenoxyacetyl;
R 2 is a not readily enolizable alkyl group, aryl or norbornyl;
R 3 is alkyl, alken-1-yl, alkyn-1-yl, 2-phenylethenyl, 2-phenylethynyl, aryl or arylalkyl; and
X 1 is bromine or chlorine, preferably chlorine.
Listed below are definitions of various terms used herein. These definitions apply to the terms as they are used throughout the specification (unless they are otherwise limited in specific instances) either individually or as part of a larger group.
The term "alkyl" refers to both straight and branched chain groups. Those groups having 1 to 10 carbon atoms are preferred.
The term "aryl" refers to phenyl or phenyl substituted with 1, 2 or 3 alkyl (of 1 to 4 carbon atoms) or alkoxy (of 1 to 4 carbon atoms) groups.
The terms "alken-1-yl[ and "alkyn-1-yl" refer to both straight and branched chain groups. Those groups having 2 to 10 carbon atoms are preferred.
The term "a not readily enolizable alkyl group" refers to groups that enolize at a rate slower than the rate of the substitution reaction of this invention. Exemplary of such groups are the branched chain alkyl groups such as isopropyl and t-butyl.
Those compounds of formula I wherein R 2 is norbornyl are novel compounds, and as such, they form an integral part of this invention.
DETAILED DESCRIPTION OF THE INVENTION
The discovery that the prior art processes discussed above can be modified to utilize starting materials of formula I is of great significance. Compounds of formula I are obtained from the well known fermentation products penicillin G (benzyl penicillin), penicillin V, or 6-APA(6-aminopenicillanic acid), using any one of several reaction sequences.
One such reaction sequence comprises conversion of pen G or pen V to the corresponding sulfoxide ester (see, for example, Cephalosporins and Penicillins, Chemistry and Biology, E. H. Flynn, editor., Academic Press, 1972), followed by rearrangement, in-situ norbornylene trapping and conjugation to give a compound having the formula ##STR9## wherein the "CO 2 R" group is an esterified carboxyl group, such as an alkyl ester or trialkylsilyl ester. Subsequent oxidation and cleavage by treatment with an acid yields the corresponding (3R-cis)-3-acylamino-4-norbornylsulfonyl-2-azetidinone having the formula ##STR10## as a mixture of diastereomers. The mixture can be separated using conventional techniques or preferably, will be used in the next step of the process of this invention as a mixture. Compounds of formula V form an integral part of this invention.
Treatment of the above (3R-cis)-3-acylamino-4-norbornylsulfonyl-2-azetidinone with the appropriate mercaptan having the formula R 2 -SH in the presence of a base yields the corresponding compound having the formula ##STR11## (see J. Org. Chem., 38:940 (1973)), which can be oxidized to yield the desired starting material of formula I.
Alternatively, pen G or pen V can be converted to 6-APA, which can be converted to a compound having the formula ##STR12## (see J. Chem. Soc., Perkin I, 562 (1975)). Treatment of a compound of formula VII with sodium aryl sulfinate in the presence of tetra-n-butyl ammonium bromide under phase transfer conditions gives the corresponding compound having the formula ##STR13## Deprotection of a compound of formula VIII followed by acylation yields the desired starting material of formula I (wherein R 2 is aryl) as a mixture of the cis and trans isomers, which are separable by fractional crystallization and/or column chromatography.
The conversion of a compound of formula I to a mixture of compounds of formulas IIIa and IIIb is accomplished by treating a compound of formula I with a Grignard reagent of formula II, preferably in the presence of a Lewis acid. Magnesium chloride is the preferred Lewis acid. The conversion is accomplished most efficiently using an excess of Grignard reagent, preferably three (3) molar equivalents, and most preferably, four (4) or five (5) molar equivalents. Preferably about four (4) to six (6) molar equivalents of Lewis acid are used.
A mixture of compounds of formulas IIIa and IIIb can be separated using art-recognized techniques such as column chromatography and fractional crystallization.
The compounds of formulas IIIa and IIIb can be converted to the corresponding compound having the formula ##STR14## wherein M.sup.⊕ is hydrogen or a cation, using the procedures described in U.K. patent application 2,071,650. As described therein, a sulfo substituent (-SO 3 .sup.⊖ M.sup.⊕) can be added to the 1-position of an azetidin-2-one by treatment of the azetidin-2-one with a complex of pyridine, 2,6-lutidine or dimethylformamide and sulfur trioxide. An alternative procedure described by the United Kingdom patent comprises silylating an azetidin-2-one (unsubstituted in the 1-position) and then subjecting the silated compound to a silyl interchange reaction. Exemplary silylating agents are monosilyltrifluoroacetamide, trimethylsilylchloride/triethylamine, and bis-trimethylsilyltrifluoroacetamide, and an exemplary reagent useful for the silyl interchange reaction is trimethylsilyl chlorosulfonate.
A compound of formula IX can be converted to the corresponding compound having the formula ##STR15## by treatment with phosgene followed by treatment with methanol and acid.
Using conventional acylation techniques, a compound of formula X can be converted to the corresponding compound having the formula ##STR16## As described in U.K. patent application No. 2,071,650, a compound of formula X can be reacted with a carboxylic acid, or corresponding carboxylic acid halide or anhydride. The reaction with a carboxylic acid proceeds most readily in the presence of a carbodiimide such as dicyclohexylcarbodiimide and a substance capable of forming an active ester in situ such as N-hydroxybenzotriazole. In those instances when the acyl group contains reactive functionality (such as amino or carboxyl groups) it may be necessary to first protect those fuunctional groups, then carry out the acylation reaction, and finally deprotect the resulting product.
The β-lactam antibiotics of formula XI can be used as agents to combat bacterial infections (including urinary tract infections and respiratory infections) in mammalian species, such as domesticated animals and humans. The prior art discloses that for combating bacterial infections in mammals a compound of formula XI can be administered to a mammal in need thereof in an amount of about 1.4 mg/kg/day to about 350 mg/kg/day, preferably about 14 mg/kg/day to about 100 mg/kg/day.
The following examples are specific embodiments of this invention.
Preparation of Starting Materials
(3R-cis)-3-Phenylacetylamino-4-norbornylsulfonyl-2-azetidinone
(A) Penicillin G Sulfoxide
Penicillin G, potassium salt (349.9 g) was dissolved in 3 liters of water. Sodium periodate (194 g) was added and the mixture was stirred for three hours. Dichloromethane (500 ml) was added and the pH of the water layer was adjusted to 2.3 with 6 N hydrochloric acid with vigorous stirring. The aqueous layer was separated and extracted with four 400 ml portions of dichloromethane. The combined extract was washed with aqueous sodium bisulfite to remove any iodine color, dried over sodium sulfate, filtered, and evaporated. The solid residue was empasted with 400 ml of ethyl acetate and allowed to stand at 0° C. overnight. The solid was isolated by filtration and dried in vacuo to afford 322 g of penicillin G sulfoxide.
(B) Penicillin G Sulfoxide, methyl ester
Penicillin G sulfoxide (321.9 g) and 1000 ml of dichloromethane were cooled in an ice/water bath. A solution of 139.7 g dicyclohexylcarbodiimide in 50 ml of dichloromethane was added followed by a solution of 1.5 g of dimethylaminopyridine in 80 ml of anhydrous methanol. The cold bath was removed and the mixture was stirred for 3.5 hours. The dicyclohexylurea was removed by filtration and 1000 ml of ethyl acetate was added to the filtrate. The organic layer was washed with sodium bicarbonate solution, water, aqueous sodium dihydrogen phosphate, and water, then dried over sodium sulfate. The solvent was evaporated and the residue was slurried with ethyl acetate to afford 149.6 g of the methyl ester of penicillin G sulfoxide.
(C) (3R-cis)-3-Phenylacetylamino-4-norbornylsulfonyl-2-azetidinone
Finely ground penicillin G sulfoxide methyl ester (25 g) was added in small portions to 250 ml of hot norbornylene containing 6 ml of dioxane. The mixture was refluxed for 16 hours, then most of the excess norbornylene was removed by distillation at 1 atmosphere. Toluene (200 ml) was added and the mixture was evaporated in vacuo. The residue was dissolved in 50 ml of dichloromethane and 50 ml of triethylamine was added. After 30 minutes, the mixture was evaporated and chased with toluene. The resulting dark oil was dissolved in 300 ml of dimethylformamide, 80 ml of acetic acid, and 50 ml of water in a 2000 ml flask equipped with a mechanical stirrer. Powdered potassium permanganate (40 g) was added in portions over 20 minutes with cooling in an ice/acetone bath (the temperature was maintained below -5° C.). After another 40 minutes 500 ml of ethyl acetate and 500 ml of water were added. Sodium sulfite was added slowly until all of the brown manganese dioxide was dissolved. Additional ethyl acetate was added and the organic phase was washed four times with water, then with sodium bicarbonate solution, and then with saturated brine. The organic layer was dried over sodium sulfate, the ethyl acetate was evaporated and the residue was crystallized from 20 ml of chloroform plus 150 ml of diethyl ether to give 8.2 g of (3R-cis)-3-phenylacetylamino-4-norbornylsulfonyl-2-azetidinone.
(3R-cis and trans)-3-Phenoxyacetylamino-4-phenylsulfonyl-2-azetidinone
(A) (3R-cis and trans)-3-Triphenylmethyl-4-phenylsulfonyl-2-azetidinone
A mixture of 30 g of (3R-cis)-3-triphenylmethyl-4-methylsulfonyl-2-azetidinone, 40 g of sodium benzenesulfinate, 25 g of tetra-n-butylammonium bromide, 400 ml of 1,2-dichloroethane, and 100 ml of water were refluxed under nitrogen for 30 minutes. The dichloroethane was removed in vacuo and the residue was extracted with 700 ml of ethyl acetate. The extract was washed with saturated aqueous sodium bicarbonate solution, then water, then saturated aqueous sodium chloride solution. The extract was dried over sodium sulfate and evaporated. The residue was chromatographed on a 50×280 mm silica gel column eluted with 1000 ml 1:4 ethyl acetate:hexane, then 1000 ml 1:1 ethyl acetate:hexane. (3R)-3-triphenylmethyl-4-phenylsulfonyl-2-azetidinone (25.3 g) was obtained as a mixture of cis and trans isomers.
(B) (3R-cis and trans)-3-Amino-4-phenylsulfonyl-2-azetidinone,hydrochloride
(3R-cis and trans)-3-triphenylmethyl-4-phenylsulfonyl-2-azetidinone (20.3 g) was dissolved in 200 ml of acetone. Hydrochloric acid (7.2 ml, 12 N) was added with stirring. After 2.5 hours, the resulting solid was isolated by filtration, washed with acetone, and dried in vacuo to afford 7.6 g of (3R-cis and trans)-3-amino-4-phenylsulfonyl-2-azetidinone, hydrochloride.
(C) (3R-cis and trans)-3-Phenoxyacetylamino-4-phenylsulfonyl-2-azetidinone
To an ice-cooled mixture of 7.6 g of 3-amino-4-phenylsulfonyl-2-azetidinone (mixture of cis and trans isomers), 5.1 g of sodium bicarbonate 100 ml of dichloromethane, and 50 ml of water was added dropwise with vigorous stirring 4.0 ml phenoxyacetyl chloride. After 90 minutes the resulting solid was removed by filtration and washed with water and dichloromethane. The solid was dissolved in tetrahydrofuran and precipitated with toluene to give 3.85 g of (3R-trans)-3-phenoxyacetylamino-4-phenylsulfonyl-2-azetidinone, melting point 192°-193° C., dec.
The reaction mixture filtrate was diluted with dichloromethane, washed with water, dried over sodium sulfate, and evaporated to give 4.7 g of a residue which contained both cis and trans isomers. The residue was triturated with 150 ml of hot chloroform, let stand for 2 hours at 25° C., and then filtered to give 1.2 g of the trans isomer. The mother liquor was evaporated and taken up in hot methanol from which 1.35 g of (3R-cis)-3-phenoxyacetylamino-4-phenylsulfonyl-2-azetidinone, melting point 178°-180° C. (dec), crystallized.
(3R-cis and trans)-3-Phenylacetylamino-4-phenylsulfonyl-2-azetidinone
The title compound is prepared using the procedure described above for the preparation of the analogous 3-phenoxyacetylamino compound; phenylacetyl chloride is substituted for phenoxyacetyl chloride in part C of the procedure.
(3R-cis)-3-Phenoxyacetylamino-4-norbornylsulfonyl-2-azetidinone
The title compound is prepared using the procedure described above for the preparation of the analogous 3-phenylacetylamino compound; penicillin V, potassium salt is substituted for penicillin G, potassium salt in part A of the procedure.
Processes for Preparing (S)-3-Acylamino-4-Substituted-2-Azetidinones
(cis) and (trans)-3-Phenoxyacetylamino-4-methyl-2-azetidinone
Methyl magnesium chloride (2.9 ml, of 2.9 M in tetrahydrofuran) was added to a solution of 500 mg (3R-trans)-3-phenoxyacetylamino-4-phenylsulfonyl-2-azetidinone in 11.1 ml of 0.5 M magnesium dichloride in tetrahydrofuran under nitrogen and chilled in an ice/acetone bath (-10° C.). After 2 hours, the mixture was added to saturated aqueous ammonium chloride and extracted with ethyl acetate. The extract was washed with water, dried over sodium sulfate, and evaporated. Treatment of the residue with dichloromethane/ethyl ether gave 106 mg of cis-3-phenoxyacetylamino-4-methyl-2-azetidinone. The corresponding trans isomer, as well as some cis isomer, was present in the mother liquor, as shown by NMR.
(cis) and (trans)-3-Phenylacetylamino-4-methyl-2-azetidinone
METHOD I
To 500 mg (3R-trans)-3-phenylacetylamino-4-phenylsulfonyl-2-azetidinone in 20 ml tetrahydrofuran under nitrogen and cooled in ice/acetone (-18° C.) was added 2.5 ml of 2.9 M methyl magnesium chloride in tetrahydrofuran. After 3.5 hours, the bath temperature had risen to -5° C.; the reaction mixture was then added to saturated aqueous ammonium chloride. The mixture was extracted twice with dichloromethane. The combined extract was dried over sodium sulfate, filtered, and evaporated in vacuo to give 300 mg residue. NMR indicated an approximate ratio of 15:85 trans:cis-3-phenylacetyl-4-methyl-2-azetidinone. The product was dissolved in 2 ml chloroform and precipitated with 3 ml ethyl ether to give 184 mg cis-3-phenylacetylamino-4-methyl-2-azetidinone.
METHOD II
Methyl magnesium chloride (3.0 ml of 2.9 M in tetrahydrofuran) was added to 500 mg (3R-trans)-phenylacetylamino-4-phenylsulfonyl-2-azetidinone dissolved in 11.6 ml of 0.5 M magnesium chloride in tetrahydrofuran under nitrogen and chilled in an ice/acetone bath to -10° C.; the reaction mixture was poured into saturated aqueous ammonium chloride. The mixture was extracted with ethyl acetate. The extract was washed with water, dried over sodium sulfate, and evaporated. The residue was treated with dichloromethane/ethyl ether to afford 126 mg cis-3-phenylacetylamino-4-methyl-2-azetidinone. As shown by NMR, the mother liquor contained the corresponding trans isomer as well as some cis isomer.
METHOD III
A solution of methylmagnesium chloride (2.9 M in tetrahydrofuran, 2.2 ml, 6.36 mM) was added to 384 mg (1.06 mM) (3R-cis-3-phenylacetylamino-4-norbornylsulfonyl-2-azetidinone dissolved in 8.5 ml of 0.5 M magnesium chloride in tetrahydrofuran (prepared by the reaction of 2 ml, 1,2-dichloroethane with 0.73 g magnesium in 50 ml of tetrahydrofuran) at 0° C. in an ice water bath. The bath was allowed to warm to room temperature over 90 minutes. After another 60 minutes, the reaction mixture was poured into saturated aqueous ammonium chloride. The mixture was extracted with ethyl acetate; the extract was washed with water, dried, and evaporated. The residue was chromatographed on a silica gel column with ethyl acetate/hexane, to afford 3-phenylacetylamino-4-methyl-2-azetidinone as a 1:2 mixture of cis and trans isomers, respectively.
(cis) and (trans)-3-Phenylacetylamino-4-ethyl-2-azetidinone
To 420 mg (3R-trans)-3-phenylacetylamino-4-phenylsulfonyl-2-azetidinone in 20 ml tetrahydrofuran under nitrogen and cooled in an ice/acetone bath to -10° C. was added 3.8 ml of 2.08 M ethyl magnesium chloride in tetrahydrofuran. After 4.5 hours, the bath temperature had risen to 0° C.; the mixture was added to saturated aqueous ammonium chloride and extracted twice with dichloromethane. The combined extract was washed with water, dried over sodium sulfate, filtered and evaporated. The residue was chromatographed on a silica gel column eluted with 40% ethyl acetate in dichloromethane to give 103 mg product as a cis and trans mixture of 3-phenylacetylamino-4-ethyl-2-azetidinone in an approximate 5:2 cis:trans ratio. | Compounds having the formula ##STR1## can be prepared by reacting a compound having the formula ##STR2## with a Grignard reagent having the formula
R.sub.3 -Mg-X.sub.1 ,
wherein R 1 is phenylacetyl or phenoxyacetyl;
R 2 is a not readily enolyzable alkyl group, aryl or norbornyl;
R 3 is alkyl, alken-1-yl, alkyn-1-yl, 2-phenylethenyl, 2-phenylethynyl, aryl or arylalkyl;
X 1 is bromine or chlorine.
(3R-cis)-3-Acylamino-4-norbornylsulfonyl-2-azetidinones are novel compounds that form an integral part of this invention. | 2 |
FIELD OF THE INVENTION
The present invention relates to a method for taking a soil sample from a horizontal borehole.
BACKGROUND OF THE INVENTION
The need to develop improved soil sampling techniques for horizontally drilled boreholes has become apparent by the increasing use of horizontal drilling to characterize soil at contaminated sites and on linear projects such as tunnels. Horizontal boreholes are presently used for installing utility lines, such as gas lines, electrical or communications conduit and the like. When using horizontal boreholes to characterize sites they provide some obvious advantages over vertical drilling. With vertical drilling, the drilling rig must be positioned directly above the location from which samples are to be taken. With horizontal drilling samples can be taken by extending a borehole horizontally underneath rivers, structures, highways, or environmentally sensitive areas. In addition, vertical drilling is associated with the risk of penetrating impermeable layers, potentially causing crosscontamination between aquifers. This risk can be avoided by horizontal drilling technology.
There are two soil samplers presently in use in conjunction with horizontal directional drilling. One soil sampler is being produced under the Trademark PunchMaster 2000 Core Barrel, by Eastman Christensen Environmental Systems corporation. This soil sampler c onsists of an inner barrel which is encased in an outer tube. The sampler works on a principal similar to a split-spoon or a Shelby Tube core sampler. First a horizontal borehole is drilled up to the target area. The drill string is than withdrawn from the borehole and the boring head is replaced with the sampling tool. The PunchMaster 2000™ is advanced into the borehole to the target area while the load on the outer tube is kept constant with an applied hydraulic pressure. At a predetermined location an inner tube is accelerated into the formation by hydraulic pressure. The sample is then drawn back into the outer tube while pressure on the outer tube is maintained to prevent drilling media from contaminating the sample, and the PunchMaster is brought to the surface. This process is repeated for each sample. Another soil sampler is being produced under the by DitchWitch Environmental Systems corporation, located in Perry Okla. This soil sampler consists of a long metal tube with a spring loaded cone-shape cap. A pilot bore is drilled to a distance of approximately 0.3-0.6 of a meter (1 to 2 ft) from the target area. The drill string is then retracted, the cutting head removed, and a soil sampler is connected to the end of the drill string. The sampler is pushed through the bore, then continued to be pushed through the undisturbed soil until the target area is reached. The drill string is retracted approximately 0.46 of a meter (18 inches), and the sampler tube is automatically locked in open position. The sampler is pushed forward 0.3 to 0.6 of a meter (1 to 2 ft), filling the tube with soil. The sampler and drill string are then removed from the bore. The sampling tube is removed and replaced with the drilling head, and the process is repeated.
One disadvantage of both the PUNCHMASTER 2000™ and the DITCHWITCH™ soil samplers is that the sample must be collected ahead of the drilling bit. To facilitate this the drill string is withdrawn from the borehole and the drill bit is removed in order to attach the soil sampler. A sample is then taken, the drill string is withdrawn from the borehole and the soil sampler is recovered, then the drill bit is reattached in order to drill to the next target location. This requires the entire length of the drill string to be removed from the borehole twice for every sample that is taken. In addition, for contaminated site assessment the soil sampler must be de-contaminated between successive samples to avoid cross-contamination.
SUMMARY OF THE INVENTION
What is required is a less time consuming method for taking a soil sample from a horizontal borehole.
According to the present invention there is provided a method for taking soil samples from horizontal boreholes. A first step involves making a substantially horizontal borehole from an entry pit to an exit pit. A second step involves towing a soil sampling apparatus through the borehole.
The method, as described above, represents a radical departure from the teachings in the prior art. Instead of disrupting the drilling process by requiring the drill string to be withdrawn from the borehole, the soil sampling apparatus is pulled through the borehole after the drilling has been completed. The soil sampler can be pulled through the horizontal borehole from the exit pit to the entry pit, or vice versa, by a variety of mechanical means.
Although beneficial results may be obtained through the use of the method, as described above, it is preferred that the soil sampling apparatus be pulled back through the borehole from the exit pit to the entry pit by the drill string as the drill string is withdrawn from the borehole. The drilling drill string must always be withdrawn from the borehole upon completion of the drilling process. Collecting samples during the pull-back operation rather than during the forward drilling operation not only eliminates disruption of the drilling process, it conveniently incorporates the sampling procedure into existing drilling procedures. The sampling procedure, therefore, does not involve any additional steps that would increase the cost of drilling the borehole. This represents a significant cost saving over the prior art.
Although beneficial results may be obtained through the use of the method, as described above, even more beneficial results may be obtained when the soil sampling apparatus used includes means for taking more than one soil sample. The pulling of the soil sampling apparatus through the borehole can be temporarily halted at spaced intervals along the borehole in order to take soil samples at such spaced intervals. This allows all necessary soil sampling along the horizontal borehole to be completed in a single pass.
BRIEF DESCRIPTION OF THE DRAWINGS
These and other features of the invention will become more apparent from the following description in which reference is made to the appended drawings, wherein:
FIG. 1 is a side elevation view, in section, of a soil sampler constructed in accordance with the teachings of the present invention, with the actuator pushing a selected sample container to the extended sample collecting position.
FIG. 2 is a side elevation view, in section, of a soil sampler constructed in accordance with the teachings of the present invention, with the actuator holding a selected sample container in the retracted rest position.
FIG. 3 is a transverse section view of the sample container support cylinder of the soil sampler illustrated in FIGS. 1 and 2.
FIG. 4 is a side elevation view of the soil sampler illustrated in FIGS. 1 and 2, showing the connection between the remote end of the actuator and the sampling tube.
FIG. 5 is a detailed side elevation view of the soil sampler illustrated in FIG. 4 showing the connection between the remote end of the actuator and the sampling tube.
FIG. 6 is a side elevation view, in section, showing a first of a two-stage sampling process.
FIG. 7 is a side elevation view, in section, showing a second of a two-stage sampling process with the preferred manner in which the soil sampler is to be advanced from one sampling location to the next.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The preferred embodiment, a soil sampler generally identified by reference numeral 10 , will now be described with reference to FIGS. 1 through 7.
Referring to FIGS. 1 and 2, soil sampler 10 has a hollow cylindrical housing 12 with a longitudinal axis, generally indicated by reference numeral 14 . Housing 12 has a peripheral sidewall 16 , a rear end wall 18 and a front end wall 20 that define an interior cavity 22 . A sampling port 24 extends through peripheral sidewall 16 . A cylindrical container support 26 is rotatably mounted on a base 28 within interior cavity 22 . Base 28 is offset at an angle to longitudinal axis 14 . The preferred angle is in a range of between 30 degrees and 45 degrees. Referring to FIG. 3, container support 26 has a plurality of sample container retaining chambers 30 . There is provided a plurality of tubular sample containers 32 . One of sample containers 32 is positioned in each of sample container retaining chambers 30 of container support 26 . Referring to FIGS. 1 and 2, a stepper motor 34 is provided for rotating container support 26 until one of sample container retaining chambers 30 for a selected sample container 32 is aligned with sampling port 24 . Associated with the operation of stepper motor 34 are drive gears 35 . A worm-gear driven actuator 36 is positioned within interior cavity 22 of housing 12 for moving the selected sample container 32 between an extended sample collecting position illustrated in FIG. 1 and a retracted rest position illustrated in FIG. 2 . In the illustrated embodiment, the worm-gear actuator 36 is electric and has an associated electric motor 38 . Referring to FIG. 1, in the extended sample collecting position a remote end 40 of the selected sample container 32 extends through sampling port 24 at an angle to longitudinal axis 14 . The angle is determined by the angular positioning of base 28 . Referring to FIG. 2, in the retracted rest position the selected sample container 32 is wholly within interior cavity 22 of housing 12 . A control processing unit (CPU) or microprocessor 42 is also positioned within interior cavity 22 of housing 12 . Microprocessor 42 is connected by wires 44 to stepper motor 34 and by wires 46 to electric motor 38 . Microprocessor accepts signals relayed by wireline 48 . Batteries 50 provide a source of power to stepper motor 34 , electric motor 38 and microprocessor 42 . Electrical batteries 50 are connected to Microprocessor 42 by wires 52 , to electric motor 38 by wires 54 and to stepper motor 34 by wires 56 .
Referring to FIGS. 4 and 5, an end piece 62 is attached to the remote end of the actuator 36 to facilitate the extension and retraction of the tubular sample container 32 . The end piece 62 consists of two components, a conical rod 64 and a hook 66 , and is attached to the remote end of the actuator by the mean of a pin 68 . The end of hook 66 sits in a groove 70 in sampling tube 32 . When actuator 36 is extended, conical rod 64 engage the back of sample container 32 pushing it forwards and upwards along sample container retaining chamber 30 which acts as a guiding conduit. Referring to FIG. 1, sample container 32 is aligned with sampling port 24 and upon extension of actuator 36 is pushed to the extended position. When the actuator 36 has been extended to its maximum length it stops. When actuator 36 retracts sample container 32 to drawn to the retracted position by the mean of hook 66 which engages groove 70 of sampling container 32 . Referring to FIGS. 1 and 2, housing 12 has a pulling head 58 secured to front end wall 20 . A pulling eye 60 is located within pulling head 58 and is used as a means to connect the soil sampler 10 to the drill string or a cable, as will hereinafter be further described in relation to the use and operation of soil sampler 10 .
The use and operation of soil sampling apparatus 10 will now be described with reference to FIGS. 1 through 7. Referring to FIG. 6 a drilling bit 80 connected to a drill string 76 is used to create a borehole 82 that extends from an entry pit 84 to an exit pit 86 . Upon borehole 82 being completed, drilling bit 80 is removed and soil sampler 10 is connected to drilling string 76 . Soil sampler 10 is then pulled-back along borehole 82 from exit pit 86 towards entry pit 84 by a drilling rig 88 (or another mechanical means) across a soil sampling target area, generally indicated by reference numeral 90 . Soil sampler 10 is connected to drill string 76 by the means of a backreamer 78 , which enlarges borehole 82 to a diameter slightly larger than the diameter of the soil sampler 10 . Periodically during the pullback process, the pullback operation is temporarily discontinued in order to permit a soil sample to be taken. Referring to FIG. 1, a signal is sent to microprocessor 42 via wireline 48 . Upon receiving the signal from wireline 48 , microprocessor 42 activates stepper motor 34 to rotate container support 26 to select an unused sample container 32 . Actuator 36 is then activated to move the selected sample container 32 to the extended sample collecting position. Referring to FIG. 2, once the sample has been taken a signal is sent to microprocessor 42 via wireline 48 causing microprocessor 42 to activate actuator 36 to move the selected sample container 32 back into the retracted rest position so that the pullback operation may resume. When a further sample is desired the pull back operation is again temporarily discontinued to allow the further sample to be taken. Referring to FIG. 1, a signal is again sent to microprocessor 42 via wireline 48 . Upon receiving the signal from wireline 48 , microprocessor activates stepper motor 34 to rotate container support 26 to select the next unused sample container 32 . Actuator 36 is then activated to move the selected sample container 32 to the extended sample collecting position. Referring to FIG. 2, once the sample has been taken a signal is sent to microprocessor 42 via wireline 48 causing microprocessor 42 to activate actuator 36 to move the selected sample container 32 back into the retracted rest position so that the withdrawal of the drilling string may again resume.
It will be apparent to one skilled in the art that modifications may be made to the illustrated embodiment without departing from the spirit and scope of the invention as hereinafter defined in the Claims. | A method for taking soil samples from horizontal boreholes. A first step involves making a substantially horizontal borehole from an entry pit to an exit pit. A second step involves towing a soil sampling apparatus through the borehole. It is preferred that the apparatus be pulled by the drill string as the drill string is withdrawn from the borehole. By using a soil sampling apparatus that is capable of taking multiple soil samples, all necessary soil sampling along the horizontal borehole may be completed in a single pass. | 4 |
CROSS REFERENCE TO RELATED APPLICATION
This application claims the priority of German Application No. P 44 38 883.7 filed Oct. 31, 1994, which is incorporated herein by reference.
BACKGROUND OF THE INVENTION
This invention relates to a sliver guiding assembly for guiding simultaneously running slivers and sensing the sliver thickness in a drawing frame, for example, a regulated drawing frame. The assembly which is arranged at the inlet of the drawing frame includes a sliver guiding device having at least two oppositely located converging walls which bring together the simultaneously introduced slivers to form a sliver assembly in which the individual slivers are in a lateral contact with one another and lie in a single plane. The sliver guiding assembly further has a withdrawing roller pair which is situated downstream of the sliver guiding device and through which the sliver assembly passes and thereafter the individual slivers assume a divergent orientation. The sliver guiding device is associated with a biased, movable sensor element which cooperates with an operationally stationary countersurface and defines therewith a constriction for the sliver assembly. The sensor element changes its position as the thickness of the sliver assembly varies and the excursions of the sensor element are converted into control pulses.
In a known arrangement one end of a biasing spring is attached to the sensor element, while its other end is connected to a fixed spring support.
SUMMARY OF THE INVENTION
It is an object of the invention to provide an improved apparatus of the above-outlined type in which the pressing effect of the sensor element is adapted to different types or numbers of simultaneously inputted slivers.
This object and others to become apparent as the specification progresses, is achieved by the invention, according to which, briefly stated, the apparatus for measuring sliver thickness in a drawing frame includes a sliver guiding device which has an inlet for simultaneously receiving a plurality of side-by-side running slivers having an advancing direction; and a sliver combining arrangement defining a plane extending parallel to the advancing direction for bringing the slivers together to form a sliver assembly constituted by a plurality of side-by-side positioned running slivers arranged in the plane and laterally contacting one another. A movable sensor element is situated at the apparatus outlet and laterally contacts the sliver assembly with an adjustable force. The sensor element undergoes excursions upon variation of thickness of the sliver assembly. The sensor element and a counterelement together define a restriction through which the sliver assembly passes. A transducer converts excursions of the sensor element into electric pulses. The apparatus further has a withdrawing roller pair which is supported downstream of the sliver guiding device as viewed in the advancing direction and which defines a nip through which the sliver assembly passes.
By providing an adjustable bias for the sensor element, the pressing force of the sensor element on the sliver assembly is adapted in a simple manner to the type or number of the slivers.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1a is a schematic side elevational view, with block diagram, of a regulated drawing frame, incorporating the invention.
FIG. 1b is an enlarged top plan view of a component illustrated in FIG. 1a, showing further details.
FIG. 2 is a sectional top plan view of the component illustrated in FIG. 1b, showing further details.
FIG. 3a is a sectional top plan view of a preferred embodiment, showing structural details and illustrating the construction in a first setting.
FIG. 3b is a view similar to FIG. 3a, illustrating the construction in a second setting.
FIG. 4 is a sectional top plan view of a preferred embodiment, showing structural details and illustrating the construction in a third setting by virtue of component replacement.
FIG. 4a is an enlarged top plan view of a detail of FIG. 3a.
FIG. 5 is a perspective view of a sliver guiding device according to a preferred embodiment of the invention.
FIGS. 6a and 6b are sectional top plan views of another preferred structural embodiment of the invention, showing two different operational positions.
FIGS. 7a and 7b are sectional top plan views of yet another preferred structural embodiment of the invention, showing two operational positions.
FIGS. 8, 9 and 10 are schematic sectional top plan views of three additional preferred embodiments of the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1a illustrates a high production drawing frame which may be, for example, an HS 900 model, manufactured by Tr utzschler GmbH & Co. KG, M onchengladbach, Germany. A plurality of slivers 3, paid out from non-illustrated coiler cans, enter a sliver guiding device 2, through which they are drawn and further advanced by a pair of cooperating withdrawing rollers 4 and 5. In their travel through the sliver guiding device, the slivers 3 move past a measuring member 6. The drawing frame 1 includes an upper inlet roller 7 and a lower inlet roller 8 which are associated with the pre-drawing zone 9 delimited at the downstream end by the upper predrawing roller 10 and the lower predrawing roller 11. Between the roller pair 10, 11 as well as a roller pair formed of the upper main drawing roller 13 and the lower main drawing roller 15 the main drawing zone 12 extends. The lower main drawing roller 15 is associated with a second upper main drawing roller 14. Such an arrangement is referred to as a four over three drawing system.
The drafted slivers 3, after passing through the roller pair 14, 15, reach the inlet of a sliver guide 16 and are drawn through a sliver trumpet 17 arranged at the downstream end of the sliver guide 16 by cooperating delivery rolls 18, 18'. In the sliver trumpet 17 the slivers are combined into a single sliver deposited into a non-illustrated coiler can. The main drawing rollers 13, 14, 15 and the delivery rollers 18, 18' are driven by a main motor 19 controlled by a computer 21. The signals generated by the measuring member 6 at the sliver guiding device 2 are applied to the computer 21 and are converted into control signals which are applied to a regulating motor driving the withdrawing rollers 4, 5 as well as the rollers 7, 8, 10 and 11 of the pre-drawing zone 9. According to the signals of the measuring unit 6, representing the fluctuating thickness values of the sliver assembly formed of the slivers 3, the computer 21 sends control signals to the regulating motor 20 which accordingly varies the rpm's of the rollers 4, 5, 7, 8, 10 and 11.
Turning to FIG. 1b, in the top plan view illustrated therein the upper withdrawing roller 4 is not shown for clarity. The slivers 3 are brought together in the sliver guiding device 2 to form the sliver assembly in which the individual slivers are in a mutually contacting relationship and extend in a single plane. The measuring unit 6 symbolically shown in FIG. 1a includes a sensor element 22 which is rotatably supported by a bearing 30 for swinging motions in a direction parallel to the single plane in which the slivers 3 of the sliver assembly lie. The structure and function of the sensor element 22 will be described later.
Opposite the sensor element 22 a counterelement 34 is provided which is adjustable to vary, in cooperation with the sensor element 22, the passage width of a constriction 23 at the outlet end of the sliver guiding device 2. As will be described later, the counterelement 34 is adjustable by swinging it about a pivot 36 in a direction parallel to the single plane in which the slivers 3 of the sliver assembly lie. The counterelement 34 may be immobilized in its adjusted position, as will also be described later.
FIG. 2 shows how the individual slivers 3 are brought together by the sliver guiding device 2 to assume therein a side-by-side contacting relationship to form the sliver assembly and how they are sensed in the constriction 23 by means of the sensor element 22. The sensor element 22 has a lever arm 31a which is exposed to the pulling force of a tension spring 32 and is coupled with a measuring element 33 which may be a plunger-and-solenoid arrangement. Another lever arm 31b laterally continuously engages with its free end the sliver assembly formed of slivers 3. Thickness changes in the throughgoing fiber quantities of the slivers 3 are thus sensed as volume changes. Departing from FIG. 1b, the withdrawing rollers 4 and 5 are arranged vertically, that is, the slivers are laterally clamped by the nip 26 of the rollers 4 and 5.
FIGS. 3a, 3b and 5 show the apparatus for measuring the thickness of a sliver assembly formed of slivers 3. The guiding device 2 has four walls 2a, 2b, 2c and 2d, of which at least two oppositely located walls converge towards one another in the downstream direction, that is, in the sliver advancing direction L. The walls 2a-2d cause the slivers 3 to converge and assume a side-by-side position in a single plane to form the sliver assembly. As the sliver assembly exits from the device 2, it enters the withdrawing rollers 4 and 5 after which the sliver assembly is dissolved as the individual slivers 3 assume a divergent course. In the downstream zone of the sliver guiding device the pivotal sensor element 22 is arranged which, together with the facing counterelement 34 forms the constriction 23 for the sliver assembly. The change in position of the sensor element 22 caused by a thickness variation of the sliver assembly applies mechanical signals to a transducer 33 which, accordingly, emits electric control pulses.
The counterelement 34 is pivotal in the direction of the arrows A, B about the axis of a rotary bearing (pivot pin) 36 parallel to the plane in which the slivers 3 are arranged side-by-side. The rotary bearing 36 is arranged at the outlet end of the guide wall 2c, as best seen in FIG. 3a. The counterelement 34 may be adjusted and immobilized in the adjusted position, for example, by a setscrew 35 having a stem 37 engaging the counterelement 34 at a location spaced from the pivot pin 36. The setscrew 35 is held in a support bracket 35'. The support bracket 35' and the rotary bearing 36 are secured in threaded bores 42 in a base plate 40 by means of screws 41a, 41b, and are laterally shiftable to new adjusted positions as indicated by the arrows C and D. The sensor element 22 and the counterelement 34 project through the lateral walls 2b and 2c. By means of the setscrew 35 the counterelement 34 is rotated about the rotary axis 36, for example, when the processed sliver type is changed (the drawing frame 1 is inoperative during such changing operation), so that the distance between the counterelement 34 and the sensor element 22 is, in the constriction 23, changed from the distance a (FIG. 3a) to the distance b (FIG. 3b). At the same time, the angle α between the wall 2c and the counterelement 34 is also changed. The sensor element 22 biased by the spring 32 engaging the lever arm 31a of the sensor element 22 reacts to all changes of thicknesses of the throughgoing slivers 3, as a result of which the distance between the sliver engaging tip of the sensor element 22 and the finely adjusted counterelement 34 varies as a function of the thickness fluctuations.
As seen in FIG. 3a, the sliver guiding device 2 has two opposite, converging side walls 2b, 2c having an inlet width c and an outlet width d. The side wall 2b lies with its outer face against a web-like holding element 38 which, as best shown in FIG. 5, is secured to a base plate 39. The holding element extends perpendicularly to the base plate 39 and parallel to the side wall 2b.
In the construction shown in FIG. 4, the sliver guiding device 2 of the earlier described embodiment is replaced by a sliver guiding device 2' having a greater inlet width c' and a greater outlet width d' than the respective dimensions c and d of the sliver guiding device 2. The converging walls of the sliver guiding device 2' are inclined at a different angle than in the sliver guiding device 2. As an alternative, it may be feasible to nest a smaller sliver guiding device in a permanently attached sliver guiding device of larger dimensions. A replacement of a sliver guiding device 2' for a sliver guiding device 2 is effected, for example, because of a change in the type of the sliver to be processed by the drawing frame.
Reverting to FIG. 5, the guide wall 2a in the zone of the constriction 23, that is, in the zone of the outlet of the sliver guiding device 2 for the fiber slivers 3, has a zone 2a' which faces a zone 2d' of the guide wall 2d. The lateral walls 2b and 2c include a slot in the zone of the constriction 23 so that the sensor element 22 and the counterelement 34 may project therethrough and may engage, under pressure, laterally opposite sides of the sliver assembly composed of the side-by-side arranged slivers 3. The base surface 2d' merges into the base plates 39 and 40 situated externally of the sliver guiding device 2.
Turning to FIGS. 6a and 6b, the sensor element 22 is a lever pivotal about the bearing 30 and has lever arms 31a and 31b extending in opposite directions from the bearing 30. The lever 31 is swingable as indicated by the arrows E and F. At the end of the lever arm 31a, the sensor element 22 is engaged by a tension spring 32, whose other end is secured to a single-arm adjusting lever 43 which is rotatable about a pivot 44 in the direction of the arrows G and H. The free outer end of the lever 43 may form a manually engageable handle. The pivot 44 is secured to the base plate 39. In case the setting lever--which may be immobilized by detents--is moved from its position shown in FIG. 6a in the direction of the arrow H into the position shown in FIG. 6b, the securing location of the spring 32 is changed, whereby the bias and thus the spring force exerted on the sensor element 22 is altered. The base plate 39 has detents 45 and 46 such as slots and bolts for determining positions for the setting lever 43.
FIGS. 7a and 7b show a single-arm pivotal lever 47 which is swingable in the direction of the arrows I and K about a pivot 48 secured to the base plate 39. One end of a tension spring 50 is connected to the pivotal lever 47 at a location 51, while the other end of the tension spring 50 is secured to a stationary spring support 52. On the pivot lever 47 a carrier element, for example, a pin 53 is provided which is connected with the lever arm 31a of the lever 31 forming the sensor element 22. In case the pivot lever 47 is moved from its position shown in FIG. 7a in the direction of the arrow I into the position shown in FIG. 7b, then by virtue of the pressure by the pin 53 the lever arm 31a is shifted, as a result of which the distance between the sensor element 22 and the counterelement 34 is increased from a (FIG. 7a) to e (FIG. 7b). In this manner, the opening in the zone of the fiber outlet is significantly increased to what may be termed as a servicing opening e. The servicing opening e facilitates a thread-in operation for the slivers 3 upon a start of operation or readily permits a cleaning of the inner surfaces of the sliver guiding device 2. The immobilizing or detent devices for the pivot lever 47 (such as wall apertures) are designated at 54 and 55.
In FIG. 8, the rotary bearing 36 supporting the counterelement 34 and the setting device including the setscrew 35 are mounted on a shifting element 56, whose position may be changed and which may be immobilized by screws received in threaded bore holes 42 of the base plate 40, as shown in FIG. 3a. Between the side walls 2b and 2c of the sliver guiding device 2 on the one hand and the sensor element 22 and the counterelement 34 on the other hand, respective rubber seals 62 and 61 are arranged, as also shown in FIG. 3a.
According to FIG. 9, the counterelement 34 is rotatably mounted on the bearing 36.
Turning to FIG. 10, the counterelement 34 is provided with a slot 57 through which a screw 58 extends. This arrangement provides for both a pivotal and a linear shifting motion of the counterelement 34. The screw 58, in addition to functioning as a pivot and a linear guide, also serves for immobilizing the counterelement 34 in its set position.
It will be understood that the above description of the present invention is susceptible to various modifications, changes and adaptations, and the same are intended to be comprehended within the meaning and range of equivalents of the appended claims. | An apparatus for measuring sliver thickness in a drawing frame includes a sliver guiding device which has an inlet for simultaneously receiving a plurality of side-by-side running slivers having an advancing direction; and a sliver combining arrangement defining a plane extending parallel to the advancing direction for bringing the slivers together to form a sliver assembly constituted by a plurality of side-by-side positioned running slivers arranged in the plane and laterally contacting one another. A movable sensor element is situated at the apparatus outlet and laterally contacts the sliver assembly with an adjustable force. The sensor element undergoes excursions upon variation of thickness of the sliver assembly. The sensor element and a counterelement together define a restriction through which the sliver assembly passes. A transducer converts excursions of the sensor element into electric pulses. The apparatus further has a withdrawing roller pair which is supported downstream of the sliver guiding device as viewed in the advancing direction and which defines a nip through which the sliver assembly passes. | 3 |
[0001] The present application claims priority to Provisional Application Ser. No. 61/099,593 filed Sep. 24, 2008, the content of which is incorporated by reference.
BACKGROUND
[0002] As online social networks such as Facebook and MySpace gaining popularity rapidly, social networks have become an ubiquitous part of many people's daily lives. One major topic in social network analysis is the study of communities in social networks. For instance, in Wikipedia, the online social network service is defined as “A social network service focuses on building online communities of people who share interests and activities, or who are interested in exploring the interests and activities of others”. Analyzing communities in a social network, in addition to serving scientific purposes (e.g., in sociology and social psychology), helps improve user experiences (e.g., through friend recommendation services) and provides business values (e.g., in target advertisement and market segmentation analysis).
[0003] Communities have long been studied in various social networks. For example, in social science an important research topic is to identify cohesive subgroups of individuals within a social network where cohesive subgroups are defined as “subsets of actors among whom there are relatively strong, direct, intense, frequent, or positive ties”. As another example, communities also play an important role in Web analysis, where a Web community is defined as “a set of sites that have more links to members of the community than to non-members”.
[0004] Social networks are usually represented by graphs where nodes represent individuals and edges represent relationships and interactions among individuals. Based on this graph representation, there exists a large body of work on analyzing communities in static social networks, ranging from well-established social network analysis to recent successful applications such as Web community discovery . However, these studies overlooked an important feature of communities—communities in real life are usually dynamic. On a macroscopic level, community structures evolve over time. For example, a political community whose members' main interest is the presidential election may become less active after the election takes place. On a microscopic level, individuals may change their community memberships, due to the shifts of their interests or due to certain external events. In this respect, the above studies that analyze static communities fail to capture the important dynamics in communities.
[0005] Recently, there have been a growing body of work on analyzing dynamic communities in social networks. Some of these studies adopted a two-step approach where first static analysis is applied to the snapshots of the social network at different time steps, and then community evolutions are introduced afterwards to interpret the change of communities over time. Because data in real world are often noisy, such a two-step approach often results in unstable community structures and consequentially, unwarranted community evolutions. Some more recent studies attempted to unify the processes of community extraction and evolution extraction by using certain heuristics, such as regularizing temporal smoothness. Although some encouraging results were reported, none of these studies explicitly model the transition or change of community memberships, which is the key to the analysis of dynamic social network. In addition, most existing approaches consider point estimation in their studies, i.e., only estimate the most likely value for the unknown parameters. Given the large scale of social networks and potential noise in data, it is likely that the network data may not be sufficient to determine the exact value of parameters, and therefore it is important to develop methods beyond point estimation in order to model and capture the uncertainty in parameter estimation.
[0006] Finding communities is an important research topic in social network analysis. For the task of community discovery, many approaches such as clique-based, degree-based, and matrix-perturbation-based, have been proposed. Wasserman et al. gave a comprehensive survey on these approaches. Community discovery is also related to some important research issues in other fields. For example, in applied physics, communities are important in analyzing modules in a physical system and various algorithms have been proposed to discover modular structures in physical systems. As another example, in the machine learning field, finding communities is closely related to graph-based clustering algorithms, such as the normalized cut algorithm proposed by Shi et al. and the graph-factorization clustering (GFC) algorithm proposed by Yu et al. However, all these approaches focused on analyzing static networks while the focus in this study is on analyzing dynamic social networks.
[0007] In the field of statistics, a well-studied probabilistic model is the stochastic block model (SBM). This model had been originally proposed by Holland et al. and have been successfully applied in various areas such as social science and bioinformatics. Researchers have extended the stochastic block model in different directions. For example, Airoldi et al. proposed a mixed-membership stochastic block model, Kemp et al. proposed a model that allows an unbounded number of clusters, and Hofman et al. proposed a Bayesian approach based on the stochastic block model to infer module assignments and to identify the optimal number of modules. The new model is also an extension of the stochastic block model. However, in comparison to the above approaches which focused on static social networks, the approach explicitly models the change of community membership over time and therefore can discovery communities and their evolutions simultaneously in dynamic social networks.
[0008] Recently, finding communities and their evolutions in dynamic networks has gained more and more attention. Asur et al. introduced a family of events on both communities and individuals to characterize evolution of communities. Tantipathananandh et al. proposed an optimization-based approach for modeling dynamic community structure. Chi et al. proposed an evolutionary version of the spectral clustering algorithms. They used graph cut as a metric for measuring community structures and community evolutions. Lin et al. extended the graph-factorization clustering (GFC) and proposed the FacetNet algorithm for analyzing dynamic communities.
SUMMARY
[0009] In one aspect, systems and methods are disclosed to find dynamic social networks by applying a dynamic stochastic block model to generate one or more dynamic social networks, wherein the model simultaneously captures communities and their evolutions, and inferring best-fit parameters for the dynamic stochastic model with online learning and offline learning.
[0010] In another aspect, a dynamic stochastic block model is used for modeling communities and their evolutions in a unified probabilistic framework. The framework has two versions, the online learning version that iteratively updates the probabilistic model over time, and the the offline learning version that learns the probabilistic model with network data obtained at all time steps. This is in contrast to most existing studies of social network analysis that only focus on the online learning approaches.
[0011] In one embodiment, a Bayesian treatment is used for parameter estimation. In addition to social network analysis that computes the most likely values for the unknown parameters, the Bayesian treatment estimates the posterior distributions for unknown parameters, which is utilized to predict community memberships as well as to derive important characteristics of communities, such as community structures, community evolutions, among others.
[0012] Instead of an afterwards effect or a regularization term, community evolutions are modeled coherently together with communities themselves. Therefore, communities and their evolutions are captured in a unified model.
[0013] The system can learn the parameters in the dynamic stochastic block model by using Bayesian inference. In the inference framework, the following two steps are iteratively executed. First, the community of each individual at each time step is inferred and then the posterior parameters of the dynamic stochastic block model are updated.
[0014] From the learned model parameters, the system can derive important characteristics such as community structures, community evolutions, changes of individual community memberships, etc.
[0015] Advantages of the preferred embodiment may include one or more of the following. The process is highly efficient. The process is executed in an incremental fashion to minimize the computational cost. In addition, the process takes advantage of the sparseness of data. For each iteration, the process has a time complexity linear in the size of a social network provided the network is sparse. The system provides a rigorous probabilistic interpretation and can handle all frameworks including online learning frameworks. The model is advantageous in (a) achieving better accuracy in community extraction, (b) capturing community evolutions more faithfully, and (c) revealing more insights from the network data.
BRIEF DESCRIPTION OF THE FIGURES
[0016] FIG. 1 shows an exemplary process that provides a unified framework for analyzing dynamic communities in social networks and for modeling both communities and their evolutions simultaneously.
[0017] FIG. 2 shows an exemplary process to the collection of snapshot graphs.
[0018] FIG. 3 shows an exemplary process or method for extracting communities and their evolutions from dynamic social networks.
[0019] FIG. 4A-4B show a statistical model called Stochastic Block Model (SBM) used in social network analysis.
[0020] FIGS. 5A-5B show a Dynamic Stochastic Block Model (DSBM) that extends SBM to dynamic social networks.
DESCRIPTION
[0021] The process of FIG. 1 provides a unified framework for analyzing dynamic communities in social networks and for modeling both communities and their evolutions simultaneously. The dynamics of communities are modeled explicitly by transition parameters that indictates the changes in community memberships over time. A Bayesian treatment of parameter estimation is used to avoid the shortcomings of point estimation by using the posterior distributions of parameters for membership prediction.
[0022] In one embodiment, a dynamic stochastic block model is used for modeling communities and their evolutions in a rigorous probabilistic framework. The framework has two versions. The first one is an online learning approach, where the community structure learned at time step t- 1 are used together with the observed data at time step t to learn the community structure at time step t. The second version of the framework is an offline learning approach, where all available data are used to learn the community structures at all time steps simultaneously.
[0023] Turning now to FIG. 1 , in 101 , the input to the system is a dynamic social network that changes over time. Next, in 102 , the process constructs a collection of snapshot graphs over time from the input data ( 101 ). The collection of snapshot graphs is denoted by W T ={W (1) , W (2) , . . . , W (T) }, where W T corresponds to the adjacency matrix for the snapshot graph of the social network at time t. In 103 , the process applies the dynamic stochastic block model and the Bayesian inference to the collection of snapshot graphs. This process is shown in more details in FIG. 2 .
[0024] In 104 , the process determines the most likely community membership of each individual at each time step. These are the output obtained by using the dynamic stochastic block model and the Bayesian inference algorithm ( 103 ).
[0025] In 105 , the process traces and summarizes the community membership of a given individual. From 105 , the process moves to 108 to determine individual community membership and evolution over time, which describe the pattern of an individual in the social network, obtained from 105 .
[0026] Alternatively, in 106 , an aggregation process is used to aggregate the individual community memberships at a given time step t into the community structure of the social network at time t. In 109 , the process determines the community structure results from 106 .
[0027] From 104 , the process can proceed to 107 where an aggregation module aggregates the individual community memberships over all time steps into the communities and their evolutions of the dynamic social network. From 107 , the process determines the communities and their evolutions in 110 .
[0028] Turning now to FIG. 2 , in 201 , a collection of snapshot graphs that describe the dynamical social network over all time steps from 1 to T is retrieved. In 202 , the community memberships are assigned to some random initial values. In 203 , a Gibbs sampling is applied to conduct Bayesian inference. There are two versions for Bayesian inference, an offline approach and an online approach.
[0029] The Gibbs sampling algorithm handles both inference approaches with a few minor changes as discussed in more details below. In 204 , the process repeats 203 until the number of required iterations is reached. In 205 , the process returns the community membership assignments, Z T ={Z (1) , . . . ,Z (T) }, for all individuals over all time steps as the output of this procedure.
[0030] FIG. 3 shows an exemplary process or method for extracting communities and their evolutions from dynamic social networks ( 301 ). The process includes a model to simultaneously extract communities and their evolutions ( 302 ), and the corresponding Bayesian offline and online inference learning algorithms ( 308 ).
[0031] The operation of the model 302 is discussed next. In 303 , the process generates a collection of snapshot graphs for the dynamic social network. In 304 , the process generates the community membership assignments for all individuals in the social network over all time steps. From the membership assignment operation, the process continues with three possible operations. In 305 , the process applies the community assignments for an individual to track his or her community membership evolution over time. Alternatively, in 306 , the process applies the community assignments for all individuals at a given time step t to obtain the aggregated community structure at time t. In 307 , the process can apply the community assignments for all individuals at all time steps to obtain the communities and their evolutions.
[0032] From 308 , the process can use either the offline or the online Bayesian inference algorithm. In 309 , Gibbs sampling or simulated annealing can be used to learn model parameters.
[0033] The details of the processes of FIGS. 1-3 will be discussed next. For a social network, a matrix W (t) ∈R n×n represents the snapshot of a social network at a given time step t (or snapshot network), where n is the number of nodes in the network. Each element w ij in W (t) is the weight assigned to the link between nodes i and j: it can be the frequency of interactions (i.e., a natural number) or a binary number indicating the presence or absence of interactions between nodes i and j. For a dynamic social network, W T ={W (1) ,W (2) , . . . , W (T) } denotes a collection of snapshot graphs for a given social network over T discrete time steps. The system assumes nodes in the social network remain unchanged during all the time steps, followed by the extension to dynamic social networks where nodes can be removed from and added to networks.
[0034] Let z i ∈{1, . . . , K}, where K is the total number of communities, denotes the community assignment of node i and z i is the community of node i. Further, let z ik =[z i =k] indicate if node i is in the k th community where [x] output one if x is true and zero otherwise. Community assignments matrix Z=(z ik :i∈{1, . . . ,n},k∈{1, . . . , K}) includes the community assignments of all the nodes in a social network at a given time step. Finally, Z T ={Z (1) , . . . , Z (T) } denotes the collection of community assignments of all nodes over T time steps.
[0035] FIGS. 4A-4B show a statistical model called Stochastic Block Model (SBM) used in social network analysis. In the SBM model, a network is generated in the following way. First, each node is assigned to a community following a probability π={π 1 , . . . ,π K } where π k is the probability for a node to be assigned to community k. Then, depending on the community assignments of nodes i and j (assuming that z ik =1 and z jl =1), the link between i and j is generated following a Bernoulli distribution with parameter P kl . The parameters of SBM are π∈R K and P∈R K×K . The diagonal element P kk of P is called the “within-community” link probability for community k and the off-diagonal element P kl ,k≠l is called “between-community” link probability between communities k and l.
[0036] FIGS. 5A-5B show a Dynamic Stochastic Block Model (DSBM) that extends SBM to dynamic social networks. It is defined in a recursive way. Assuming the community matrix Z (t-1) for time step t- 1 is available, the system uses a transition matrix A∈R K×K to model the community matrix Z (t) at time step t in the following way. For a node i, if z ik (t-1) =1, i.e., node i was assigned to community k at time t- 1 , then with probability A kk node i will remain in community k at time step t and with probability A kl node i will change to another community l where k≠1. The system has each row of A sums to 1, i.e., Σ l A kl =1. Given the community memberships in Z (t) , the link between nodes will be then decided stochastically by probabilities in P as the SBM model. The generative process of the Dynamic Stochastic Block Model and the graphical representation are shown in FIG. 5B . Note that DSBM and SBM differ in how the community assignments are determined. In the DSBM model, instead of following a prior distribution π, the community assignments at any time t (t>1) are determined by those at time t- 1 through transition matrix A, where A aims to capture the dynamic evolutions of communities.
[0037] To express the data likelihood for the proposed DSBM model, two assumptions about the data generation process can be made. First, link weight w ij is generated independent of the other nodes/links provided membership z i and z j . Second, the community assignment z i (t) of node i at time step t is independent of the other nodes/links provided its community assignment z i (t-1) at time t- 1 . Using these assumptions, the likelihood of the complete data for the DSBM model is as follows
[0000]
Pr
(
W
T
,
Z
T
|
π
,
P
,
A
)
=
∏
t
=
1
T
Pr
(
W
(
t
)
|
z
(
t
)
,
P
)
∏
t
=
2
T
Pr
(
Z
(
t
)
|
Z
(
t
-
1
)
,
A
)
Pr
(
Z
(
1
)
|
π
)
[0000] where the emission probability Pr(W (t) |Z (t) , P) and the transition probability Pr(Z (t)|Z (t-1) , A) are
[0000]
Pr
(
W
(
t
)
|
Z
(
t
)
,
P
)
=
∏
i
:
j
Pr
(
w
ij
(
t
)
|
z
i
(
t
)
,
z
j
(
t
)
,
P
)
=
∏
i
:
j
∏
k
,
l
(
P
kl
w
ij
(
t
)
(
1
-
P
kl
)
1
-
w
ij
(
t
)
)
z
ik
(
t
)
z
jl
(
t
)
Pr
(
Z
(
t
)
|
Z
(
t
-
1
)
,
A
)
=
∏
i
=
1
n
Pr
(
Z
i
(
t
)
|
Z
i
(
t
-
1
)
,
A
)
=
∏
i
=
1
n
∏
k
,
l
A
kl
z
ik
(
t
-
1
)
z
il
(
t
)
,
[0000] respectively. Note that in this model, self-loops are not considered and so in the above equations, i: j means over all i's and j's such that i≠j . Finally, term Pr(Z (l) |π) is the probability of community assignments at the first time step and is expressed as
[0000]
Pr
(
Z
(
1
)
π
)
=
∏
i
=
1
n
∏
k
π
k
z
ik
(
1
)
.
[0038] In order to predict memberships of nodes in a given dynamic social network, one approach is to first estimate the most likely values for parameters π, P, and A from the historical data, and then infer the community memberships in the future using the estimated parameters. This is usually called point estimation in statistics, and can have instability when data is noisy. Instead of using the most likely values for the model parameters, the system utilizes the distribution of model parameters when computing the prediction.
[0039] The prior distributions for model parameters π, P, and A is discussed next. The conjugate prior for π is the Dirichlet distribution
[0000]
Pr
(
π
)
=
Γ
(
∑
k
γ
k
)
∏
k
Γ
(
γ
k
)
∏
k
π
k
γ
k
-
1
(
1
)
[0000] where Γ(·) is the Gamma function. The P matrix is assumed to be symmetric to reduce the number of parameters to
[0000]
n
(
n
+
1
)
2
.
[0000] The conjugate prior for each parameter P kl for l≧k is a Beta distribution, and therefore the prior distribution for P is
[0000]
Pr
(
P
)
=
∏
k
,
l
≥
k
Γ
(
α
kl
+
β
kl
)
Γ
(
α
kl
)
Γ
(
β
kl
)
P
kl
α
kl
-
1
(
1
-
P
kl
)
β
kl
-
1
.
(
2
)
[0000] Finally, the conjugate prior for each row A is a Dirichlet distribution and the prior distribution for A is
[0000]
Pr
(
A
)
=
∏
k
Γ
(
∑
l
μ
kl
)
∏
l
Γ
(
μ
kl
)
∏
l
A
kl
μ
kl
-
1
.
(
3
)
[0040] To make the discussion concise, the following notations are used.
[0000]
n
k
(
t
)
=
∑
i
z
ik
(
t
)
(
4
)
n
k
->
l
(
t
1
:
t
2
)
=
∑
t
=
t
1
+
1
t
2
∑
i
=
1
n
z
ik
(
t
-
1
)
z
il
(
t
)
(
5
)
n
k
->
·
(
t
1
:
t
2
)
=
∑
t
=
t
1
+
1
t
2
∑
i
=
1
n
z
ik
(
t
-
1
)
(
6
)
n
kl
(
t
1
:
t
2
)
=
∑
t
=
t
1
t
2
∑
i
:
j
(
z
ik
(
t
)
z
jl
(
t
)
+
z
il
(
t
)
z
jk
(
t
)
)
(
7
)
n
^
kl
(
t
1
:
t
2
)
=
∑
t
=
t
1
t
2
∑
i
:
j
w
ij
(
t
)
(
z
ik
(
t
)
z
jl
(
t
)
+
z
il
(
t
)
z
jk
(
t
)
)
(
8
)
[0000] Using these notations, and with the prior distributions of the model parameters, the closed form expression for the joint probability of the complete data that is marginalized over the distribution of model parameters is discussed next.
[0041] With the priors of parameters θ={π, P, A} defined in Equations (1): (3) together with the notations given in Equations (4): (8), the joint probability of observed links and unobserved community assignments is proportional to
[0000]
Pr
(
W
T
,
Z
T
)
=
∫
Pr
(
W
T
,
Z
T
θ
)
Pr
(
θ
)
θ
∝
∏
k
Γ
(
n
k
(
1
)
+
γ
k
)
∏
k
∏
l
Γ
(
n
k
->
l
(
1
:
T
)
+
μ
kl
)
Γ
(
n
k
->
·
(
1
:
T
)
+
∑
l
μ
kl
)
×
∏
k
,
l
>
k
B
(
n
^
kl
(
1
:
T
)
+
α
kl
,
n
kl
(
1
:
T
)
-
n
^
kl
(
1
:
T
)
+
β
kl
)
×
∏
k
B
(
n
^
kk
(
1
:
T
)
2
+
α
kk
,
n
kk
(
1
:
T
)
-
n
^
kk
(
1
:
T
)
2
+
β
kk
)
[0000] where B(·) is the Beta function.
[0042] In this Bayesian inference framework, to obtain the community assignment of each node at each time step, the system computes the posterior probability Pr(Z T |W T ). This is in general an intractable problem. In the next two subsections, the system introduces two versions of the inference method, i.e., an offline learning approach and an online learning approach.
Offline Learning
[0043] In offline learning, it is assumed that the link data of all time steps are accessible and therefore, the community assignments of all nodes in all time steps can be decided simultaneously by maximizing the posterior probability, i.e.,
[0000]
Z
T
*
=
arg
max
Z
T
Pr
(
Z
T
W
T
)
=
arg
max
Z
T
Pr
(
W
T
,
Z
T
)
(
9
)
[0000] where Pr(W T ,Z T ) is given in above. In offline learning, the community membership of each node at every time step t is decided by the link data of all time steps, even the link data of time steps later than t. Given this observation, offline learning can deliver more reliable estimation of community memberships than the online learning that is discussed next.
Online Learning
[0044] In online learning, community memberships are learned incrementally over time. Assume the community membership is Z (t-1) at time step t- 1 , and observed links W (t) at time t, the system can decide the community assignments at time t by maximizing the posterior probability of community assignments at time t given Z (t-1) and W (t) , i.e.,
[0000]
Z
*
(
t
)
=
arg
max
Z
(
t
)
Pr
(
Z
(
t
)
W
(
t
)
,
Z
(
t
-
1
)
)
[0000] Hence, to decide Z (t) , the key is to efficiently compute Pr(Z (t) |W (t) ,Z (t-1) ) except for time step 1 in which the system needs to compute Pr(Z (t) |W (1) ).
Next, closed form solutions for the two probabilities are discussed. Both probabilities are computed by averaging over the distribution of the model parameters.
[0046] With the priors of parameters θ={π, P, A} given in Equations (1): (3), the posterior probability of unobserved community assignments given the observed links and the community assignments at previous time step is proportional to
[0000]
Pr
(
Z
1
W
1
)
∝
∏
k
Γ
(
n
k
(
1
)
+
γ
k
)
×
∏
k
,
l
>
k
B
(
n
^
kl
(
1
)
+
α
kl
,
n
kl
(
1
)
-
n
^
kl
(
1
)
+
β
kl
)
×
∏
k
B
(
n
^
kk
(
1
)
2
+
α
kk
,
n
kk
(
1
)
-
n
^
kk
(
1
)
2
+
β
kk
)
Pr
(
Z
(
t
)
W
(
t
)
,
Z
(
t
-
1
)
)
∝
∏
k
(
∏
l
Γ
(
n
k
->
l
(
t
-
1
:
t
)
+
μ
kl
)
Γ
(
n
k
->
·
(
t
-
1
:
t
)
+
∑
l
μ
kl
)
)
×
∏
k
,
l
>
k
B
(
n
^
kl
(
t
)
+
α
kl
,
n
kl
(
t
)
-
n
^
kl
(
t
)
+
β
kl
)
×
∏
k
B
(
n
^
kk
(
t
)
2
+
α
kk
,
n
kk
(
t
)
-
n
^
kk
(
t
)
2
+
β
kk
)
.
(
10
)
[0047] In online learning, it is assumed that data arrives sequentially and historic community assignments are not updated upon the arrival of new data. Therefore, the online learning algorithm can be implemented more efficiently than the offline learning algorithm.
Inference Algorithm
[0048] To optimize the posterior probabilities in the offline and online learning algorithms introduced in the previous section, the system uses Gibbs sampling method. In Gibbs sampling, the system computes the conditional probability of the community assignment of each node conditioned on the community assignments of other nodes.
[0049] For offline learning, the system computes the conditional probability Pr(z i (t) |Z T,{i,t} − W T ) , via Pr(Z T |W T ), where Z T,{i,t} − are the community assignments of all nodes at all time steps except node i at time step t. This can be computed by marginalizing z i (t) in Equation (9). Similarly, for online learning, the system can compute the conditional probability Pr(z i (t) |Z i − (t) ,W (t) Z (t-1) , where Z i − (t) is the collection of community assignments of all nodes, except node i, at time step t. This can be computed by marginalizing Pr(Z (t) |W (t) ,Z (t-1) ). The following algorithms describe a simulated annealing version of the inference algorithm. Probabilistic Simulated Annealing Algorithm
[0050] 1. Randomly initialize the community assignment for each node at time step t (online learning) or at all time steps (offline learning); select the temperature sequence {T 1 , . . . ,T M } and the iteration number sequence {N 1 , . . . ,N M }.
[0051] 2. for each iteration m=1, . . . ,M, run N m iterations of Gibbs sampling with target distributions exp{logPr(Z (t) |W (t) ,Z (t-1) )/T m } or exp{logPr(Z T |W T )/T M }.
[0052] Gibbs Sampling Algorithm
[0053] 1. Compute the following statistics with the initial assignments:
[0000] n k (1)
[0000] n kl (1:T) ,{circumflex over (n)} kl (1:T) or n kl (t) ,{circumflex over (n)} kl (t)
[0000] n k→l (1:T) ,n k→· (1:T) or n k→l (t-1:t) ,n k→· (t-1:t)
[0054] 2. for each iteration m i =1:N m , and for each node i=1:n at each time t
Compute the objective function in Simulated Annealing
[0000] exp{logPr(z i t |Z i − (t) ,W (t) ,Z (t-1) )/T m }or
[0000] exp{logPr(z i t |Z T,{i,t} ,W T )/T m }
[0000] up to a constant using the current statistics, and then obtain the normalized distribution.
Sample the community assignment for node i according to the distribution obtained above, update it to the new one. Update the statistics.
[0058] Several techniques can be used to improve the efficiency of the algorithm. First, since in each step of the sampling, only one node i at a given time t changes its community assignment, almost all the statistics can be updated incrementally to avoid recomputing. Second, the algorithm is designed to take advantage of the sparseness of the matrix W (t) . For instance, the system exploits the sparseness of W (t) to facilitate the computation of {circumflex over (n)} kl (t 1 :t 2) .
[0059] The time complexity of the implementation of the Gibbs sampling algorithm is O(nT+eT+K 2 T+NT(eC 1 +nC 2 )) where e is the total number of edges in the social network over all the time steps, N is the number of iterations in Gibbs sampling, C 1 and C 2 are constants.
[0060] As can be seen, when the social network is sparse and when the degree of each node is bounded by a constant, the running time of each iteration of the Gibbs sampling algorithm is linear in the size of the social network.
[0061] Two extensions can be made to the basic framework, including how to handle different types of links and how to handle insertion and deletion of nodes in the network. In addition, the selection of the hyperparameters in the model is discussed next.
[0062] So far, the system has used binary links, where the binary links (i.e., either w ij =1 or w ij =0) indicate the presence or absence of a relation between a pair of nodes. However, there exist other types of links in social networks as well. Here the model can be expanded to handle two other cases: when w ij ∈N and when w ij ∈R + . If w ij indicates the frequency of interactions (e.g., the occurrence of interactions between two bloggers during a day, the number of papers that two authors co-authored during a year, etc.), then w ij can be any non-negative integer. The current model actually can handle this case with little change: the emission probability
[0000]
Pr
(
w
ij
z
i
,
z
j
)
=
∏
k
,
l
(
P
kl
w
ij
(
1
-
P
kl
)
)
z
ik
z
jl
(
11
)
[0000] remains valid for w ij ∈N, except that instead of a Bernoulli distribution (i.e., w ij =0 or 1), now w ij follows a geometric distribution. Note that the (1−P kl ) term is needed to take into account the case where there is no edge between i and j.
[0063] In other applications, w ij represents the similarity or distance between nodes i and j and therefore w ij ∈R + , the set of non-negative real numbers. In such a case, the system can first discretize the w ij by using finite bins and then introduce the emission probabilities as before. Another way to handle the case when w ij ∈R + is to introduce a k-nearest neighbor graph and therefore reduce the problem to the case when w ij =0 or 1.
[0064] In dynamic social networks, at a given time, new individuals may join in the network and old ones may leave. To handle insertion of new nodes and deletion of old ones, existing algorithm use heuristics, e.g., by assuming that all the nodes are in the network all the time but in some time steps certain nodes have no incident links. In comparison, in both the online and the offline versions of the algorithm, no such heuristics are necessary. For example, for online learning, let S t denote the set of nodes at time t, I t =S t ∩S t-1 be set of nodes appearing in both time steps t and t- 1 . U t =S t −S t-1 be the new nodes at time t. Then the system can naturally model the posterior probability of the community assignments at time t as
[0000] Pr ( Z (t) |W (t) ,Z (t-1) )∝ Pr ( Z (t) ,W (t) |Z (t-1) )= Pr ( W (t) |Z (t) ) Pr ( Z I t (t) |Z I t (t-1) ) Pr ( Z U t (t) ) (12)
[0000] and the system can directly write the part corresponding to Equation (10) as
[0000]
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[0000] where n *,S * is the corresponding statistics evaluated on the nodes set of S. Similar results can be derived for the offline learning algorithm. In brief, the model can handle the insertion and deletion of nodes without using any heuristics.
[0065] Next, the roles of the hyperparameters (γ, α, β, and μ) are discussed along with guidelines on how to choose the values for these hyperparameters. In the experimental studies section below, the impact of the values of these hyperparameters on the performance of the algorithm will be discussed.
[0066] γ is the hyperparameter for the prior of π. The system can interpret the γ k as an effective number of observations of z ik =1. Without other prior knowledge the system sets all γ k to be the same. α, β are the hyperparameters for the prior of P. As stated before, the system discriminates two probabilities in P, i.e., P kk the “within-community” link probability, and P kl,l≠k the “between-community” link probability. For the hyperparameters, the system sets two groups of values, i.e., (1) α kk ,β kk ,∀ k and (2) α kl,l≠k ,β kl,l≠k . Because the system has the prior knowledge that nodes in the same community have higher probability to link to each other than nodes in different communities, the system sets α kk ≧α kl,l≠k ,β kk ≦β kl,l≠k . μ is the hyperparameter for A. A k* ={A k1 , . . . , A kk , . . . , A kK } are the transition probabilities for nodes to switch from the k th community to other (including coming back to the k th) communities in the following time step. μ k* ={μ k1 , . . . ,μ kk , . . . ,μ kK } can be interpreted as effective number of nodes in the k th community switching to other (including coming back to the k th) communities in the following time step. With prior belief that most nodes will not change their community memberships over time, the system sets μ kk ≧η kl,l≠k .
[0067] The selection of the exact values for the hyperparameters γ, α, β, and μ is described in the empirical studies below.
[0068] Experiments
[0069] Several experimental studies have been done. First, the performance of the algorithms is not sensitive to most hyperparameters in the Bayesian inference and for the only hyperparameters that impact the performance significantly, a principled method can be used for automatic parameter selection. Second, the Gibbs-sampling-based algorithms have very fast convergence rate, which makes the instant algorithms very practical for real applications. The algorithms clearly outperform several state-of-the-art algorithms in terms of discovering the true community memberships and capturing the true evolutions of community memberships. Finally, algorithms are able to reveal interesting insights that are not directly obtainable from other algorithms.
[0070] The experiments can be categorized into two types, those with ground truth available and those without ground truth. Ground truth is defined as the true community membership of each node at each time step. When the ground truth is available, the system measures the performance of an algorithm by the normalized mutual information between the true community memberships and those given by the algorithm. More specifically, if the true community memberships are represented by C={C 1 , . . . ,C K } and those given by the algorithm are represented by C′={C′ 1 , . . . ,C′ K }, then the mutual information between the two is defined as
[0000]
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[0000] and the normalized mutual information is defined by
[0000]
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[0000] where H(C) and H(C′) are the entropies of the partitions C and C′. The value of MI is between 0 and 1 and a higher MI value indicates that the result given by the algorithm C′ is closer to the ground truth C. This metric MI has been commonly used in the information retrieval field .
[0071] Where there is no ground truth available in the dataset, performance can be measured by using the metric of modularity for measuring community partitions. For a given community partition C={C 1 , . . . , C K }, the modularity is defined as
[0000]
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[0000] where V represents all the nodes in the social network and V k indicates the set of nodes in the kth community C k . Cut(V i ,V j )=Σ p∈V i ,q∈V j w pq . As state in, modularity measures how likely a network is generated due to the proposed community structure versus generated by a random process. Therefore, a higher modularity value indicates a community structure that better explains the observed social network.
[0072] The system generates synthetic test data by following a procedure suggested by Newman et al. The data consists of 128 nodes that belong to 4 communities with 32 nodes in each community. Links are generated in the following way. For each pair of nodes that belong to the same community, the probability that a link exists between them is p in ; the probability that a link exists between a pair of nodes belonging to different communities is p out . However, by fixing the average degree of nodes in the network, which the system set to be 16 in the datasets, only one of p in and p out can change freely. By increasing p out , the network becomes more noisy in the sense that the community structure becomes less obvious and hard to detect. The system generate datasets under three different noise levels by setting p in =0.1452 (p out =0.0365), p in =0.1290 (p out =0.0417), and p in =0.1129 (p out =0.0469), respectively. The ratio of p out /p in increases from 0.2512 for level one to 0.3229 for level two and 0.4152 for level three.
[0073] The above network generator described by Newman et al. can only generate static networks. To study dynamic evolution, the system let the community structure of the network evolve in the following way. The system start with introducing evolutions to the community memberships: at each time step after time step 1 , the system randomly choose 10% of the nodes to leave their original community and join the other three communities at random. After the community memberships are decided, links are generated by following the probabilities p in and p out as before. The system generate the network with community evolution in this way for 10 time steps.
[0074] Hyperparameters
[0075] In the first experiment, the impact of the hyperparameters on the performance of the algorithm were analyzed. The process was tested under a large range of values for the hyperparameters γ (for the initial probability π) and μ (for the transition matrix A), respectively. The performance varies little under different values for γ and μ, which verifies that the algorithm is robust to the setting of these hyperparameters. These experiments show that the performance is not sensitive to γ and μ. However, the performance of the algorithm is somewhat sensitive to the hyperparameters α and β for P, which is the stochastic matrix representing the community structure at each time step. The performance varies under different α and β values. This result makes sense because α and β are crucial for the stochastic model to correctly capture the community structure of the network. For example, the best performance is achieved when α is in the same range as the total number of links in the network. In addition, a clear correlation exists between the accuracy with respect to the ground truth, which is not seen by the algorithm, and the modularity, which is available to the algorithm. As a result, modularity value can be used as a validation metric to automatically choose good values for α and β. All the experimental results reported in the following are obtained from this automatic validation procedure.
[0076] In another experiment, the performance of the online and offline versions of the DSBM algorithm was compared with those of two recently proposed algorithms for analyzing dynamic communities—the dynamic graph-factorization clustering algorithm (FacetNet) by Lin et al. and the evolutionary spectral clustering algorithm (EvolSpect) by Chi et al. . In addition, the system also provide the performances of the static versions for all the algorithms—static stochastic block models (SSBM) for DSBM, static graph-factorization clustering (SGFC) for FacetNet, and static spectral clustering (SSpect) for EvolSpect.
[0077] First, the DSBM algorithms have the best accuracy and outperform all other baseline algorithms at every time step for all the three datasets. Second, the offline version of the algorithm, which takes into consideration all the available data simultaneously, has better performance than that of the online version. Third, the evolutionary versions of all the algorithms outperform their static counterparts in most cases, which demonstrates the advantages of the dynamic models in capturing community evolutions in dynamic social networks.
[0078] Next, an experiment was conducted to see which algorithms can capture the community evolution more faithfully. The DSBM algorithms have the best precision and the best recall values for all the three datasets, which illustrates that the algorithms can capture the true community evolution more faithfully than the baseline algorithms.
[0079] The system used Gibbs sampling for Bayesian inference. One experiment shows that this Gibbs sampling procedure converges very quickly. The first time step requires more iterations but even for the first time step, fewer than 20 iterations are enough for the algorithm to converge. For the time steps 2 to 10 , by using the results at the previous time step as the initial values, the algorithm converges in just a couple of iterations. This result, together with the time complexity analysis, demonstrates that the algorithm is practical and is scalable to large social networks in real applications.
[0080] Next, the system present experimental studies on three real datasets: a traditional social network dataset, a blog dataset, and a paper co-authorship dataset. The southern women data is a standard benchmark data in social science. It was collected in 1930's in Natchez, Miss. The data records the attendance of 18 women in 14 social events during a period of one year. The system obtain the social network by assigning w ij for women i and j the number of times that they co-participated in the same events. The system first apply the static stochastic model (SBM) to the aggregated data and the system set the number of communities to be 2, the number used in most previous studies. Not surprisingly, the system obtain the same result as most social science methods reported in, that is, women 1-9 belong to one community and women 10-18 belong to the other community.
[0081] Next, based on the number of events that occurred, the system partition the time period into 3 time steps: (1) February-March, when women 1-7,9,10, and 13-18, participated social events 2,5,7, and 11; (2) April-May, when women 8,11,12, and 16 joined in and together they participated in events 3,6,9, and 12; (3) June-November, when events 1,4,8,10, and 13 happened for which women 17 and 18 did not show up. The system apply both the offline and the online versions of the algorithm on this dataset with 3 time steps. It turns out that the offline algorithm reports no community change for any woman. This result suggests that if the system take the overall data into consideration simultaneously, the evidence is not strong enough to justify any change of community membership. However, in the online learning algorithm, if the system decrease the hyperparameter μ kk for A to a very small value (around 1) and therefore encourage changes of community memberships, women 6-9 start to change their community at time step 3. The system determines that this change is due to the social event 8, which is the only event that women 6-9 participated at time step 3 and is mainly participated by women who were not in the same community as women 6-9 at time steps 1 and 2.
[0082] The system was tested against a blog dataset was collected by NEC Labs and have been used in several previous studies on dynamic social networks. It contains 148,681 entry-to-entry links among 407 blogs during 15 months. In this study, the system first partition the data in the following way. The first 7 months are used for the first 7 time steps; data in months 8 and 9 are aggregated into the 8th time step; data in months 10-15 are aggregated into the 9th time step. The reason for this partition is that in the original dataset, the number of links dropped dramatically toward the end of the time and the partition above makes the number of links at each time step to be evenly around 200.
[0083] The system was tested against the two baselines, the dynamic graph-factorization clustering (FacetNet) and the evolutionary spectral clustering (EvolSpect). The number of communities was 2 (which roughly correspond to a technology community and a political community). In terms of hyperparameters for the algorithm, for γ and μ, the system simply selected default values (i.e., γ k =1, μ kl =1, and μ kk =10), and for α and β, the system chose the ones that result in the best modularity. For the two baseline algorithms, their parameters are chosen to obtain the best modularity. Based on the result, the offline and online versions of the algorithm give similar results and they both outperform the baseline algorithms.
[0084] Actually, the system found that most blogs are stable in terms of their communities. However, there are still some blogs changing their communities detected by the algorithms based on the links information. Here, the system present the community memberships of the representative blogs. Three of them (blogs 94, 192, and 357) have the most number of links across the whole time and one of them (blog 230) has the least number of links, only at two time steps. To help the visualization, the system assign one of the two labels to each blog where the labels are obtained by applying the normalized cut algorithm on the aggregated blog graph. Therefore, these labels give us the community membership of each blog if the system use static analysis on the aggregated data. Then to visualize the dynamic community memberships, for a blog at a given time step, the system show the fractions of the blog's neighbors (through links) that have each of the two possible labels at the given time step.
[0085] Another experiment uses paper co-authorship data. This data has been studied in and it contains the co-authorship information among the papers in 28 conferences over 10 years (1997-2006). The 28 conferences span three main areas—data mining (DM), database (DB), and artificial intelligence (AI). The system applies the algorithm to this dataset with the known community number 3. By checking the conference venues of the papers published by authors each year and by checking the biographies of these authors, the system verified that the above changes all correspond to switches of research focus that really happened. The conference venues (and therefore the class labels for all the conferences and all the papers) were not used in the algorithms. This implies that by only study the interactions among individuals (the co-authorship), the algorithms can discover meaningful changes of community memberships that are related to real-world events.
[0086] The framework based on Bayesian inference succeeded in finding communities and captured community evolutions in dynamic social networks. The framework is a probabilistic generative model that unifies the communities and their evolutions in an intuitive and rigorous way; the Bayesian treatment gives robust prediction of community memberships. The processes are efficient and practical in real applications. Experimental studies showed that the instant methods and processes outperform several state-of-the-art baseline algorithms in different measures and reveal useful insights in several real social networks. The system uses a dynamic stochastic block model for modeling communities and their evolutions in a unified framework. As a result, from a dynamic social network, the system can the extract more accurately communities, more faithful community evolutions, and more insights that are not available through other methods.
[0087] The current Bayesian framework relies solely on the links to infer the community memberships of nodes in social networks. However, the the framework can incorporate information other than links such as the contents of blogs.
[0088] The invention may be implemented in hardware, firmware or software, or a combination of the three. Preferably the invention is implemented in a computer program executed on a programmable computer having a processor, a data storage system, volatile and non-volatile memory and/or storage elements, at least one input device and at least one output device.
[0089] By way of example, a block diagram of a computer to support the system is discussed next. The computer preferably includes a processor, random access memory (RAM), a program memory (preferably a writable read-only memory (ROM) such as a flash ROM) and an input/output (I/O) controller coupled by a CPU bus. The computer may optionally include a hard drive controller which is coupled to a hard disk and CPU bus. Hard disk may be used for storing application programs, such as the present invention, and data. Alternatively, application programs may be stored in RAM or ROM. I/O controller is coupled by means of an I/O bus to an I/O interface. I/O interface receives and transmits data in analog or digital form over communication links such as a serial link, local area network, wireless link, and parallel link. Optionally, a display, a keyboard and a pointing device (mouse) may also be connected to I/O bus. Alternatively, separate connections (separate buses) may be used for I/O interface, display, keyboard and pointing device. Programmable processing system may be preprogrammed or it may be programmed (and reprogrammed) by downloading a program from another source (e.g., a floppy disk, CD-ROM, or another computer).
[0090] Each computer program is tangibly stored in a machine-readable storage media or device (e.g., program memory or magnetic disk) readable by a general or special purpose programmable computer, for configuring and controlling operation of a computer when the storage media or device is read by the computer to perform the procedures described herein. The inventive system may also be considered to be embodied in a computer-readable storage medium, configured with a computer program, where the storage medium so configured causes a computer to operate in a specific and predefined manner to perform the functions described herein.
[0091] The invention has been described herein in considerable detail in order to comply with the patent Statutes and to provide those skilled in the art with the information needed to apply the novel principles and to construct and use such specialized components as are required. However, it is to be understood that the invention can be carried out by specifically different equipment and devices, and that various modifications, both as to the equipment details and operating procedures, can be accomplished without departing from the scope of the invention itself.
[0092] Although specific embodiments of the present invention have been illustrated in the accompanying drawings and described in the foregoing detailed description, it will be understood that the invention is not limited to the particular embodiments described herein, but is capable of numerous rearrangements, modifications, and substitutions without departing from the scope of the invention. The following claims are intended to encompass all such modifications. | Systems and methods are disclosed to find dynamic social networks by applying a dynamic stochastic block model to generate one or more dynamic social networks, wherein the model simultaneously captures communities and their evolutions, and inferring best-fit parameters for the dynamic stochastic model with online learning and offline learning. | 6 |
CROSS-REFERENCE TO RELATED PATENT APPLICATIONS
[0001] This patent application is a continuation of pending PCT Patent Application No. PCT/EP2010/057071, filed May 21, 2010, which claims the benefit of European Application No. 09164221.5, filed Jun. 30, 2009, the entire teachings and disclosure of which are incorporated herein by reference thereto.
FIELD OF THE INVENTION
[0002] The invention relates to a method for producing a strip from an AlMgSi alloy, in which a rolling ingot is cast from an AlMgSi alloy is poured, the rolling ingot is subjected to homogenization, the rolling ingot is brought to rolling temperature and hot-rolled then optionally cold-rolled to final thickness. The invention further relates to an aluminium strip made from an AlMgSi alloy and advantageous use thereof.
BACKGROUND OF THE INVENTION
[0003] Particularly in automotive engineering but also in other application area, such as aircraft construction or rail vehicle construction, metal sheets made from aluminium alloys are required that not only have particularly high strength values but also very good formability characteristics, and enable a high degree of deformation. In automotive engineering, typical application areas are the body and chassis parts. For visible, painted components, for example body sheet metal that is visible from the outside, the deformation of the materials must also occur in such a way that the surface is not marred by faults after painting, such as slip lines or roping. This is particularly important, for example, when aluminium alloy sheets are used to manufacture engine bonnets and other body components of a vehicle. However, it also limits the choice of material in terms of the aluminium alloy. In particular, AlMgSi alloys, the main alloy components of which are magnesium and silicon, have relatively high strengths and at the same time good formability characteristics and exceptional corrosion resistance. AlMgSi alloys are the AA6XXX alloy types, for example alloy types AA6016, AA6014, AA6181, AA6060 and AA6111. Aluminium strips are usually manufactured from an AlMgSi alloy by casting a rolling ingot, homogenising the rolling ingot, hot-rolling the rolling ingot and cold-rolling the warm strip. The rolling ingot is homogenised at a temperature from 380 to 580° C. for more than one hour. With final solution annealing and subsequent quenching and natural aging at about room temperature for at least three days, the strips can be shipped in condition T4. Condition T6 is adjusted after quenching by artificial aging at temperatures between 100 and 220° C.
[0004] It is problematic that hot-rolled aluminium strips made from AlMgSi alloys contain coarse precipitates of Mg 2 Si, which are broken up and reduced in size in the subsequent cold rolling due to their high degrees of deformation. Hot strips of an AlMgSi alloy are usually produced in thicknesses from 3 mm to 12 mm and then passed to a cold rolling stage with high degress of deformation. Since the temperature range in which the AlMgSi phases are formed is passed through very slowly in conventional hot rolling, the phases produced thereby are very coarse. The temperature range for forming the phases referred to above depends on the alloy, but is between 550° C. and 230° C. It has been demonstrated experimentally that these coarse phases in the hot strip impair the elongation of the end product. This means that it has not previously been possible to fully exploit the formability characteristics of aluminium strips made from AlMgSi alloys.
[0005] The object underlying the present invention is therefore to provide a method for producing an aluminium strip from an AlMgSi alloy and an aluminium strip that has a higher elongation in the T4 state, and to this extent enables higher degrees of deformation when producing structured components for example. A further object underlying the invention is also to suggest advantageous uses for a metal sheet produced from the aluminium strip according to the invention.
SUMMARY OF THE INVENTION
[0006] According to a first teaching of the present invention, the object of a method for manufacturing a strip from an AlMgSi alloy as described in the preceding is solved in that immediately after the exit from the last hot rolling pass the hot strip has a temperature not exceeding 130° C., preferably a temperature not exceeding 100° C., and the hot strip is coiled at that temperature or a lower temperature.
[0007] It has been found that the size of the Mg 2 Si precipitations in a hot strip of an AlMgSi alloy may be reduced significantly by quenching, that is to say by accelerated cooling. By rapid cooling from a hot strip temperature between 230° C. and 550° C. to not more than 130° C., preferably not more than 100° C. at the output from the last hot rolling pass, the state of the hot strip's microstructure is frozen, so that coarse precipitations are no longer able to form. After solution annealing and quenching to obtain the final thickness, the resulting aluminium strip has significantly improved elongation with usual strengths in the T4 state, and the same or even better aging hardenability in the T6 state. This combination of properties has not been achieved previously with strips made from AlMgSi alloys.
[0008] According to an advantageous embodiment of the method according to the invention, this cooling operation is carried out within the last two hot rolling passes, that is to say the cooling to 130° C. and below takes place within seconds, and at all events not more than five minutes. It has been found that with this method the increased elongation values, with usual strength and yield point values in the T4 state, and the improved aging hardenability in the T6 state are achievable with a particularly high degree of process reliability.
[0009] According to a first embodiment of the method according to the invention, a particularly cost-effective arrangement for carrying out the method is provided if the hot strip is quenched by using at least one plate cooler and the hot rolling pass charged with emulsion itself to the coiling temperature. A plate cooler comprises an array of coolant and lubricant nozzles, which spray a rolling mill emulsion onto the aluminium strip. The plate cooler is often present in a hot rolling mill for the purpose of cooling rolled hot strips to the rolling temperature before the hot rolling stage and to set the coiling temperature. The method according to the invention may be carried out on conventional systems without any special additional equipment. By definition, the hot rolling temperature is higher than the recrystallisation temperature of a metal, which in the case of aluminium means it is higher than about 230° C. Though, according to the teaching of the present invention the coiling temperature at 130° C. is significantly below these standard conditions for the process.
[0010] If the hot rolling temperature of the hot strip is at least 230° C., preferably higher than 400° C. before the penultimate hot rolling pass, according to a next embodiment of the method according to the invention it is possible to ensure that particularly small Mg 2 Si precipitates are present in the quenched hot strip, since the predominating components of the alloy, magnesium and silicon, are present in the aluminium matrix in the dissolved state at these temperatures. This advantageous state of the hot strip is “frozen” as it were by the quenching step.
[0011] The thickness of the finished hot strip 3 mm to 12 mm, preferably 3.5 mm to 8 mm, which means that standard cold rolling mills may be used for the cold rolling.
[0012] The aluminium alloy used is preferably of alloy type AA6xxx, preferably AA6014, AA6016, AA6060, AA6111 or AA6181. A common property of all AA6xxx alloy types is that they have exceptionally good formability, characterized by high elongation values in the T4 state, and very high strengths or yield points in the T6 usable state, for example after artificial aging at 205° C./30 min.
[0013] According to a further embodiment of the method according to the invention, the finished, rolled aluminium strip is subjected to a heat treatment, in which the aluminium is heated to more than 100° C. and then coiled and aged at a temperature over 55° C., preferably over 85° C. This embodiment of the method makes it possible to implement after the natural aging a shorter heating phase with lower temperatures to adjust the T6 state in the aluminium strip or sheet, in which state the sheets or strips that have been shaped into components are used in the application. To do this, these rapidly aging aluminium strips are heated to temperatures of about 185° C. for just 20 minutes in order to reach the higher yield point values in the T6 state. Though, the breaking elongation values A 80 of the aluminium strips produced with this embodiment of the method according to the invention are slightly less than 29%. However, the aluminium strip produced according to the invention is noteworthy in that after aging in the T4 state it still has very good uniform elongation A g greater than 25%. The term uniform elongation A g refers to the maximum elongation of the specimen at which no sign of necking is observed during the stretching test. That is to say the specimen stretches evenly in the uniform elongation range. Previously, similar materials did not reach values for uniform elongation greater than 22% to 23%. Uniform elongation is a decisive factor in forming behavior, since it determines the maximum degree of deformation that may be applied to the material in practice. To this extent, the method according to the invention may thus be used to provide an aluminium strip with very good formability characteristics, and which may be converted to the T6 state with an accelerated artificial aging process (185° C./120 min.).
[0014] An aluminium alloy of type AA6016 includes the following alloy components, in the corresponding percentages by weight:
0.25%≦Mg≦0.6%, 1.0%≦Si≦1.5%,
[0017] Fe≦0.5%,
[0018] Cu≦0.2%,
[0019] Mn≦0.2%,
[0020] Cr≦0.1%,
[0021] Zn≦0.1%,
[0022] Ti≦0.1%
[0000] the remainder being Al and unavoidable impurities, constituting not more than 0.15% in total and not more than 0.05% individually.
[0023] With magnesium contents of less than 0.25% by weight, the strength of the aluminium that is intended for structural applications is too low, but on the other hand formability deteriorates with magnesium contents higher than 0.6% by weight. Silicon and magnesium together are essentially responsible for the hardenablity of the aluminium alloy, and thus also for the high strengths that are achievable in the application case, for example after paint has been burned in. With Si contents lower than 1.0% by weight, the aging hardenability of the aluminium strip is reduced, so that in the application case only reduced strength properties are achievable. However, Si contents of more than 1.5% by weight result in casting problems with regard to the production of the rolling ingot. The Fe fraction should be limited to not more than 0.5% by weight in order to prevent coarse precipitations. Limiting the copper content to a maximum of 0.2% by weight results particularly in improved corrosion resistance of the aluminium alloy in the specific application. The manganese content of less than 0.2% by weight reduces the tendency to form coarser manganese precipitations. Although chromium is responsible for a fine microstructure, it must still be limited to 0.1% by weight, to also prevent coarse precipitations. In contrast, the presence of manganese improved the weldability of the aluminium strip according to the invention by reducing its tendency to crack and its sensitivity to quenching. A reduction in the zinc content to no more than 0.1% by weight particularly improves the corrosion resistance of the aluminium alloy or of the finished metal sheet in the respective application. In contrast, titanium provides for grain refinement during casting, but should be limited to not more than 0.1% by weight in order to ensure that the aluminium alloy is able to be cast easily.
[0024] An aluminium alloy of type AA6060 includes the following alloy ingredients, listed with their weight percent:
0.35%≦Mg≦0.6%, 0.3%≦Si≦0.6%, 0.1%≦Fe≦0.3%
[0028] Cu≦0.1%,
[0029] Mn ≦0.1%,
[0030] Cr≦0.05%,
[0031] Zn≦0.10%,
[0032] Ti≦0.1% and
[0000] the remainder being Al and unavoidable impurities, constituting not more than 0.15% in total and not more than 0.05% individually.
[0033] The combination of a precisely preset magnesium content with a lower Si content than was the case in the first embodiment and a closely specified Fe content yields an aluminium alloy, in which the formation of Mg 2 Si precipitations after hot rolling with the method according to the invention may be prevented particularly effectively, so that it is possible to produce a metal sheet having improved elongation and high yield points compared with metal sheets that are produced conventionally. The lower upper limits of the alloy components Cu, Mn and Cr further reinforce the effect of the method according to the invention. Regarding the effects of the upper limit for Zn and Ti, reference is made to the notes regarding the first embodiment of the aluminium alloy.
[0034] An aluminium alloy of type AA6014 includes the following alloy ingredients, listed with their weight percent:
0.4≦Mg≦0.8%, 0.3%≦Si≦0.6%,
[0037] Fe≦0.35%
[0038] Cu≦0.25%,
0.05%≦Mn≦0.20%,
[0040] Cr≦0.20%,
[0041] Zn≦0.10%,
0.05%≦V≦0.20%,
[0043] Ti≦0.1% and
[0000] the remainder being Al and unavoidable impurities, constituting not more than 0.15% in total and not more than 0.05% individually.
[0044] An aluminium alloy of type AA6181 includes the following alloy ingredients, listed with their weight percent:
0.6%≦Mg≦1.0%, 0.8%≦Si≦1.2%,
[0047] Fe≦0.45%
[0048] Cu≦0.10%,
[0049] Mn≦0.15%,
[0050] Cr≦0.10%,
[0051] Zn≦0.20%,
[0052] Ti≦0.1% and
[0000] the remainder being Al and unavoidable impurities, constituting not more than 0.15% in total and not more than 0.05% individually.
[0053] An aluminium alloy of type AA6111 includes the following alloy ingredients, listed with their weight percent:
0.5%≦Mg≦1.0%, 0.7%≦Si≦1.1%,
[0056] Fe≦0.40%
0.50%≦Cu≦0.90%, 0.15%≦Mn≦0.45%,
[0059] Cr≦0.10%,
[0060] Zn≦0.15%,
[0061] Ti≦0.1% and
[0000] the remainder being Al and unavoidable impurities, constituting not more than 0.15% in total and not more than 0.05% individually. Because of its higher copper content, the AA6111 alloy generally exhibits greater strength values in the T6 application state, but it must be classified as more susceptible to corrosion.
[0062] The alloy components of all of the aluminium alloys have been adapted specifically with regard to different applications. As was noted in the preceding, strips made from these aluminium alloys that have been produced according to the method according to the invention exhibit particularly high elongation values in the T4 state, combined with a particularly marked increase in the yield point for example following artificial aging at 205° C./30 min. This is also true for the aluminium strips in state T4 that have undergone solution annealing after a heat treatment.
[0063] According to a second teaching of the present invention, the object stated above is achieved by an aluminium strip constituted of an AlMgSi alloy in that the aluminium strip in the T4 state has a breaking elongation A 80 of at least 30% with an yield point Rp0.2 of 80 to 140 MPa. The shipment state T4 is usually achieved by solution annealing with quenching followed by storage at room temperature for at least three days, since by then the properties of the solution-annealed metal sheets or strips are stable. The combination of breaking elongation A 80 and yield point Rp0.2 of the aluminium strip according to the invention has not been achieved with the previously known AlMgSi alloys. The aluminium strip according to the invention thus enables maximum degrees of deformability due to the high elongation values with maximum values for the yield point Rp0.2 in the finished sheet and component.
[0064] One embodiment of the MgSi aluminium strip is endowed with particularly advantageous formability characteristics because additionally its uniform elongation A g is more than 25%. Uniform elongation is a decisive factor in determining the maximum degree of deformability of the aluminium strip and the metal sheet produced therefrom in component manufacturing, because it is imperative to avoid unchecked necking during manufacturing. The aluminium strip according to the invention has particularly high deformation capability with regard to necking and may therefore be formed to produce components with greater process reliability.
[0065] When in state T6, that is to say a state of readiness for use or application, the aluminium strip according to the invention preferably has an yield point Rp0.2 greater than 185 MPa for an elongation A 80 of at least 15%. These values were measured in aluminium strips produced according to the invention and in state T6, having undergone an artificial aging process at 205° C./30 min. following solution annealing and quenching (state T4). Because of its high yield points in state T6 and excellent elongation values in state T4, the aluminium strip according to the invention is particularly well suited for use in automotive construction, for example.
[0066] According to a further embodiment of the invention, the solution-annealed and quenched aluminium in state T6 following artificial aging at 205° C./30 min. has an yield point difference ΔRp0.2 between states T6 and T4 of at least 80 MPa. The increase in the yield point between state T4 and state T6 is particularly high for the aluminium strip according to the invention. The aluminium strip according to the invention therefore lends itself very well to forming in state T4, and may subsequently be transformed into a very strong usage state (state T6) by arrificial aging. Given the necessary and highly complex forming operations and the high strength values and yield points demanded for example in the carbuilding industry, good hardenability is particularly advantageous for manufacturing complex components. A rapidly aged MgSi aluminium strip having outstanding formability properties may be produced when the aluminium strip produced according to the invention undergoes a solution annealing process followed by a heat treatment process after it is produced, and has a uniform elongation A g greater than 25% with an yield point Rp0.2 from 80 to 140 MPa in the T4 state. As was noted previously, with this variant it is possible to produce an MgSi aluminium strip that is capable of rapid aging and at the same time has very good formability. The artificial aging process to create the T6 state may be carried out at 185° C. for 20 min. to achieve the required yield point enhancements.
[0067] If, as in a further embodiment, the aluminium strip has a uniform elongation A g greater than 25% in the direction of rolling, transversely to the direction of rolling and diagonally to the direction of rolling, a particularly isotropic formability is enabled.
[0068] The aluminium strips preferably have a thickness from 0.5 mm to 12 mm. Aluminium strips having thicknesses from 0.5 mm to 2 mm are preferably used for bodywork parts in the carbuilding industry for example, whereas aluminium strips of greater thickness from 2 to 4.5 mm may be suitable for applications in chassis parts in carbuilding, for example. Single components having a thickness of up to 6 mm may also be produced in the cold strip. Besides these, aluminium strips having thicknesses even up to 12 mm may be used in specific applications. These very thick aluminium strips are normally only produced by hot rolling.
[0069] According to a further embodiment of the aluminium strip according to the invention, the aluminium alloy of the aluminium strip is of alloy type AA6xxx, preferably AA6014, AA6016, AA6060, AA6111 or AA6181. With regard to the advantages of these aluminium alloys, reference is made to the explanations of the method according to the invention.
[0070] Due to the outstanding combination of good formability in state T4, high resistance to corrosion and high values for the yield point Rp0.2 in the application state (state T6), the object stated above is solved in accordance with a third teaching of the present invention by the use of a metal sheet produced from an aluminium strip according to the invention as a component, a chassis or structural part and panel in automotive, aircraft or railcar construction, particularly as a component, a chassis part, outer or inner panel in carbuilding, preferably as a bodywork structural element. Above all visible bodywork parts, for example bonnets, fenders etc., also outer skin panels of a railcar or aircraft benefit from the high yield points Rp0.2 and good surface properties even after forming with high degrees of deformation.
[0071] There are many possible ways in which to refine and develop the method according to the invention and the aluminium strip according to the invention as well as the use of a metal sheet created therefrom. To this end, reference is made both to the claims subordinate to patent claims 1 and 6 and to the description of exemplary embodiments in conjunction with the drawing.
BRIEF DESCRIPTION OF THE DRAWINGS
[0072] FIGS. 1 a - 1 c illustrate schematically an exemplary of embodiment of a method according to the teachings of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0073] In the drawing, the only FIG. 1 shows a schematic flowchart of an exemplary embodiment of the method according to the invention for producing a strip made from an MgSi aluminium alloy in steps a) producing and homogenizing the rolling ingot, b) hot rolling, c) cold rolling and d) solution annealing with quenching.
[0074] First a rolling ingot 1 is cast from an aluminium alloy having the following alloy components a percent by weight:
0.35%≦Mg≦0.6%, 0.3%≦Si≦0.6%, 0.1%≦Fe≦0.3%
[0078] Cu≦0.1%,
[0079] Mn≦0.1%,
[0080] Cr≦0.05%,
[0081] Zn≦0.1%,
[0082] Ti≦0.1% and
[0000] the remainder being Al and unavoidable impurities, constituting not more than 0.15% in total and not more than 0.05% individually.
[0083] The rolling ingot made in this way is homogenized in a furnace 2 at a homogenizing temperature of about 550° C. for 8 h so that the alloying components are distributed completely homogeneously throughout the rolling ingot FIG. 1 a ).
[0084] FIG. 1 b ) shows how rolling ingot 1 in the present embodiment of the method according to the invention is hot rolled by reversing through a hot rolling mill 3 , wherein the rolling ingot 1 reaches a temperature from 230 to 550° C. during the hot rolling. In this embodiment, hot strip 4 preferably has a temperature of at least 400° C. after it leaves hot roller 3 and before the penultimate hot rolling pass. The quenching of warm strip 4 preferably takes place at this hot strip temperature of at least 400° C. using a plate cooler 5 and the working rollers of hot rolling mill 3 . Plate cooler 5 , which is shown only diagrammatically, sprays hot strip 4 with cooling rolling emulsion and ensure that hot strip 4 cools down quickly. The working rollers of roller mill 3 are loaded with emulsion and cool hot strip 4 further. After the last rolling pass, at the exit from plate cooler 5 ′ in the present example, hot strip 4 has a temperature of just 95° C. and will then be coiled on recoiler 6 .
[0085] Since hot strip 4 has a temperature not above 130° C. or not above 100° C. immediately at the exit from the last hot rolling pass or is optionally cooled to a temperature not above 130° C. or not above 100° C. in the last two hot rolling passes by the use of plate cooler 5 and the working rollers of hot rolling mill 3 , the crystal microstructure of hot strip 4 is frozen, as it were, since no additional energy in the form of heat is available for subsequent precipitating steps. The hot strip, with a thickness of 3 to 12 mm, preferably 3.5 to 8 mm, is coiled on recoiler 6 . As was explained previously, the coiling temperature in the present embodiment is below 95° C.
[0086] In the method according to the invention, now no or very few coarse Mg 2 Si precipitates are able to form in the coiled hot strip 4 . Hot strip 4 has a crystalline state that lends itself very well to further processing and may be decoiled by decoiler 7 , fed to a cold rolling mill 9 , for example, and then coiled again on coiler 8 , FIG. 1 c ).
[0087] The resulting, cold rolled strip 11 is coiled. It is then transported to solution annealing and quenching 10 , FIG. 1 d ). For this purpose, it is decoiled again from coil 12 , solution annealed in a furnace 10 , quenched and returned to a coil 13 . Then, after natural aging at room temperature, aluminium strip may then in state T4 be shipped with maximum formability. Alternatively (not shown), the aluminium strip 11 may be separated into individual sheets, which will then be available in state T4 after natural aging.
[0088] With larger aluminium strip thicknesses, for example for chassis applications or components such as backing plates, alternatively piecewise annealing may be carried out and the sheets quenched directly afterwards.
[0089] In state T6, the aluminium strip, or the aluminium panel, is heated to 100° C. to 220° C. g in an artificial aging process in order to obtain maximum values for the yield point. For example, artificial aging may be performed at 205° C./30 min.
[0090] The aluminium strips produced in accordance with the embodiment presented have, for example, a thickness of 0.5 to 4.5 mm after natural aging. Strip thicknesses from 0.5 to 2 mm are typically used for bodywork applications and strip thicknesses from 2.0 mm to 4.5 mm are used for chassis parts in car manufacturing. In both application areas, the improved elongation values represent a decisive advantage in parts manufacturing, since most operations with the sheets involve extensive forming but at the same time high strengths in the application state (T6) of the end product are imperative.
[0091] Table 1 shows the alloy compositions of aluminium alloys from which aluminium strips have been produced by conventional or inventive methods. Besides the contents of alloy components shown, the remaining composition of the aluminium strips is made up of aluminium and impurities, which are present in individual quantities not exceeding 0.05% by weight and altogether in a quantity not exceeding 0.15% by weight.
[0000]
TABLE 1
Strips
Si %/wt
Fe %/wt
Cu %/wt
Mn %/wt
Mg %/wt
Cr %/wt
Zn %/wt
Ti %/wt
409
1.29
0.17
0.001
0.057
0.29
<0.0005
<0.001
0.02
410
1.30
0.17
0.001
0.056
0.29
<0.0005
<0.001
0.0172
491-1
1.39
0.18
0.002
0.062
0.30
0.0006
0.01
0.0158
491-11
1.40
0.18
0.002
0.063
0.31
0.0006
0.0104
0.0147
[0092] Strips (specimens) 409 and 410 were produced according to a method according to the invention in which in the last two hot rolling passes the hot strip was cooled from about 400° C. to 95° C. using a plate cooler and the hot rollers themselves and coiled. The measured values for this strips are marked “Inv.” in Table 2. They were then cold rolled to a final thickness of 1.04 mm.
[0093] The strips (specimens) 491-1 and 491-11 were produced using a conventional hot rolling and cold rolling method and are identified with the label “Conv.”.
[0094] The results of the mechanical properties presented in Table 2 clearly show the difference in achievable elongation values A 80 .
[0000]
TABLE 2
T6
T4
205° C./30 min.
Thickness
Rp0.2
R m
A g
A 80
Rp0.2
R m
A 80
ΔRp0.2
Strips
(mm)
(MPa)
(MPa)
(%)
(%)
(MPa)
(MPa)
(%)
(MPa)
409
Inv.
1.04
100
220
26.3
31.3
187
251
16.2
87
410
Inv.
1.04
98
217
25.6
30.3
195
256
15.5
97
491-1
Conv.
1.04
92
202
23.1
27.8
180
235
14.7
88
491-11
Conv.
1.04
88
196
23.0
27.4
179
232
14.3
91
[0095] In order to achieve the T4 state, the strips underwent solution annealing with subsequent quenching followed by natural aging at room temperature. The T6 state was achieved with artificial aging at 205° C. for 30 minutes.
[0096] It was found that the advantageous microstructure that was created in strips 409 and 410 via the method according to the invention, not only offered a higher yield point Rp0.2 and increased strength Rm but also enabled increased elongation A 80 . This microstructure results in a particularly advantageous combination of high breaking elongation A 80 of at least 30% or at least 30% with very high values for the yield point Rp0.2 from 80 to 140 MPa. In the state T6, the yield point may rise to more than 185 MPa, in which case the elongation A 80 still remains above 15%. The hardenability with a ΔRp0.2 of 87 or 97 MPa shows that the embodiments according to the invention exhibit a very good increase in the yield point of the artificially aged state T6 under artificial aging at 205° C./30 min. despite the increased elongation values of more than 15%.
[0097] A comparison of the uniform elongations A g of the strips according to the invention and of the conventional strips also shows that the uniform elongation A g , with values of more than 25%, the inventive strips 409 and 410 significantly outperform the conventional strips, for which values of 23% were measured. Table 2 shows the value for uniform elongation transversely to the direction of rolling. Values greater than 25% for uniform elongation A g also diagonally and in the direction of rolling were also recorded on strips, not listed in the Table 2, which were measured with the method according to the invention. These results underscore the exceptional formability of the strips according to invention.
[0098] Breaking elongation values A g and A 80 , the yield point values Rp0.2 and the tensile strength values Rm in the following tablew were measured according to DIN EN.
[0099] The measured values were verified in state T4 by means of measurements taken on other strips. The aluminium alloy of strips A and B had the following composition:
0.25%≦Mg≦0.6%, 1.0%≦Si≦1.5%,
[0102] Fe≦0.5%,
[0103] Cu≦0.2%,
[0104] Mn≦0.2%,
[0105] Cr≦0.1%,
[0106] Zn≦0.1%,
[0107] Ti≦0.1%
[0000] the remainder being Al and unavoidable impurities, constituting not more than 0.15% in total and not more than 0.05% individually.
[0108] Strips A and B underwent quenching of the hot strip to 95° C. by application of the method according to the invention during the last two reduction phases and were coiled and then cold rolled to final thicknesses of 1.0 mm and 3.0 mm respectively. In order to achieve state T4, strips A and B were solution annealed and then naturally aged following quenching.
[0109] The following measured values were determined for the two strips:
[0000]
TABLE 3
T4
Thickness
Rp0.2
R m
A 80
Strips
(mm)
(MPa)
(MPa)
(%)
A
1.0
107
221
31.1
B
3.0
108
212
32.0
[0110] The further increase in elongation values A 80 shows how ideally suited these aluminium strips are for producing components in which very high degrees of deformation in state T4 during manufacturing must be combined with maximum tensile strengths Rm and yield points Rp0.2 in state T6.
[0111] In addition, an examination was made of other aluminium strips that had undergone additional heat treatment, which was carried out on the aluminium strip preferably immediately after the product was produced, for example directly after the solution annealing and quenching. For this, the aluminium strips were briefly heated to above 100° C. and then coiled at a temperature above 85° C., in the present case 88° C., and aged naturally.
[0112] Table 4 shows the composition of strip 342, which underwent the additional heat treatment after solution annealing and quenching.
[0000]
TABLE 4
Strip
Si %/wt
Fe %/wt
Cu %/wt
Mn %/wt
Mg %/wt
Cr %/wt
Zn %/wt
Ti %/wt
342
1.3
0.17
0.00
0.06
0.3
≦0.0005
≦0.001
0.02
[0113] The heat treatment, called a pre-bake step, did lead to a worsening of the breaking elongation properties, since the breaking elongation A 80 was now below 30%. Surprisingly, the uniform elongation of aluminium strip P342 remained at over 25%, unchanged from the variant that did not undergo heat treatment, as is shown in Table 5. Uniform elongation is a very important factor in forming aluminium strip into a part, because improved uniform elongation enables higher degrees of deformation and thus either greater process reliability in manufacturing or fewer forming steps.
[0114] Table 5 shows various measured values. On the one hand, three measurements were taken at the start of the strip P342-BA and at the end of the strip P342-BE. The “State” column indicates that the strips were in state T4, that is to say they were solution annealed and quenched, and had undergone natural aging for 8 days at room temperature. The strips from the strip start and strip end were cut out and measured in the longitudinal direction (L),that is to say in the direction of rolling, transversely to the direction of rolling (Q), and diagonally to the direction of rolling (D). It was found that while there was a fall in breaking elongation values A 80 nm in some cases to below 30%, the uniform elongation A g still remained above 25% when measured in all directions and surprisingly was constant compared to the breaking elongation of the strip that had not under gone heat treatment.
[0000]
TABLE 5
Position
a o
R p0.2
R m
A g
A 80 mm
Strip
State
Pos
(mm)
(MPa)
(MPa)
%
%
P342-BA
T4
L
1.009
97
209
25.3
28.9
(8 d RT)
P342-BA
T4
Q
1.006
90
206
25.5
28.5
(8 d RT)
P342-BA
T4
D
1.005
92
207
25.6
29.1
(8 d RT)
P342-BE
T4
L
1.002
95
208
25.9
30.1
(8 d RT)
P342-BE
T4
Q
1.000
89
204
25.3
28.3
(8 d RT)
P342-BE
T4
D
1.000
90
205
25.7
29.8
(8 d RT)
[0115] In a subsequent artificial aging step, the state T6 was reached after 20 minutes at 185° C. Typical values for the tensile yield point measured in state T6 were higher than 140 MPa after artificial aging and higher than 165 MPa after artificial aging following by further stretching of 2%. The aluminium strip prepared according to the invention that also underwent heat treatment, therefore combines to important properties. In the T4 state it is very readily deformable because of its high uniform elongation, and at the same time it reaches the desired strength after artificial aging at 185° C. for 20 min. | The invention relates to a method for producing a strip made of an AlMgSi alloy in which a rolling ingot is cast of an AlMgSi alloy, the rolling ingot is subjected to homogenization, the rolling ingot which has been brought to rolling temperature is hot-rolled, and then is optionally cold-rolled to the final thickness thereof. The problem of providing a method for producing an aluminum strip made of an AlMgSi alloy and an aluminum strip, which has a higher breaking elongation with constant strength and therefore enables higher degrees of deformation in producing structured metal sheets, is solved in that the hot strip has a temperature of no more than 130° C. directly at the exit of the last rolling pass, preferably a temperature of no more than 100° C., and the hot strip is coiled at that or a lower temperature. | 1 |
FIELD OF THE INVENTION
This invention relates to a method and apparatus for controlling a shot-peening device, and, more particularly, to maximizing an impact of a collision of a stream of shot particles to be projected from a nozzle.
BACKGROUND OF THE INVENTION
In one conventional use of shot peening, a stream of shot, i.e., particles, is directed from a nozzle to the surface of a workpiece such that a collision occurs thereon. Although the impact of the collision of the stream of the shot particles can be readily controlled to be a suitable value that is needed for the workpiece, it is difficult to set such an impact for the optimal and most efficient conditions. Further, an approach to achieve such optimal and most efficient conditions of the impact causes the consumption of the energy for the shot-peening process to increase relatively.
Accordingly, there exists a need in the art for a method and apparatus for shot peening that maximizes the impact of a stream of shot, that is accurate, and that has a low consumption of energy.
SUMMARY OF THE INVENTION
Therefore, one object of the invention provides a method for controlling a shot-peening device having an enclosure in which are located a workpiece to be shot peened and at least one nozzle for projecting shot particles and for directing them onto the workpiece under specified conditions for projecting the shot particles. The conditions for projecting the shot particles are partly defined by a shot-peening process to be applied to the workpiece. The method comprises steps a) through g).
First, step a) is to acquire data for maximizing the anticipated shot-peening intensity at the workpiece based on the predetermined conditions for projecting the shot particles.
In step b), a shot-peening process to be applied to the workpiece is then selected.
In step c), the conditions for projecting the shot particles to maximize the anticipated shot-peening intensity at the workpiece are then determined based on the acquired data and the selected shot-peening process before the shot particles have been actually projected.
In step d), the shot particles are then projected and directed onto the workpiece from the nozzle under the determined conditions for projecting the shot particles.
In step e), the shot-peening intensity at the workpiece is then measured based on the actually projected shot particles.
In step f), at least some of the present conditions for projecting the shot particles to maximize the measured shot-peening intensity are controlled based on the acquired data.
In step g), the shot particles are projected and directed onto the workpiece from the nozzle under the controlled conditions for projecting the shot particles.
To increase the accuracy of the shot-peening process, steps e) through g) may be repeated a plurality of times after step g) is completed.
In one aspect of the invention, at least some of the conditions for projecting the shot particles include the mass-flow rate of the shot particles to be fed to the nozzle, and the pressure or flow rate of the compressed air to be used to project the shot particles from the nozzle.
As used herein, the term mass-flow rate of the shot particles refers to the flow rate of the mass of the shot particles.
Another object of the invention is to provide an apparatus for controlling a shot-peening device having an enclosure in which are located a support for supporting a target to be shot peened and at least one nozzle for projecting shot particles and for directing them onto the target under conditions for projecting the shot particles. The conditions for projecting the shot particles are partly defined by a shot-peening process to be applied to the target.
The apparatus comprises a) measuring means for measuring the shot-peening intensity by the actually projected shot particles at a position for measuring which is located at or near the target within the enclosure; b) storing means for storing data for maximizing the anticipated shot-peening intensity at the position for measuring based on the predetermined conditions for projecting the shot particles; means for determining the conditions for projecting the shot particles to maximize an anticipated shot-peening intensity at the position for measuring based on the stored data from the memory and a selected shot-peening process before the shot particles have been actually projected; means for operating the nozzle such that the nozzle projects the shot particles and directs them onto the target therefrom under the determined conditions for the operation thereof, and e) controlling means for controlling at least some of the present conditions for projecting the shot particles to maximize the measured shot-peening intensity based on the acquired data such that the nozzle projects the shot particles and directs them onto the target therefrom under the controlled conditions thereof.
In the embodiment of the invention the measuring means includes a sensor for sensing the kinetic energy or its equivalent of the actually projected shot particles at the position for measuring and for sending a sensing signal, and means for converting the sensing signal of the sensor into the corresponding shot-peening intensity.
The sensor may be located in the support near the target. In this case, the target is a workpiece to be shot peened.
Alternatively, the target may be a dummy workpiece in which the sensor is located.
BRIEF DESCRIPTION OF THE DRAWINGS
The accompanying drawings, which are incorporated in and constitute a part of the specification, schematically illustrate the preferred embodiment of the present invention, and together with the general description given above and the detailed description of the preferred embodiment given below serve to explain the principles of the invention.
FIG. 1 is a schematic, elevational and front view of the shot-peening system of the preferred embodiment of the present invention.
FIG. 2 is a schematic block diagram of the controller for the shot-peening system of FIG. 1 .
FIG. 3 shows graphs to indicate variations in impacts of a stream of shot based on variations in the proportion of the shot in relation to compressed air.
FIG. 4 is a flowchart that illustrates the steps of the shot-peening process to carry out the method of the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1 shows a shot-peening system 10 for controlling its shot-peening device according to the present invention.
The shot-peening device has a sealed enclosure 12 . Within the enclosure is a workpiece support 14 , which can be moved vertically and rotated by any known driving mechanism (none shown). A workpiece W to be shot peened is supported by the support 14 such that it can be moved with the support 14 . Within the enclosure 12 , a peening nozzle 16 is also located a variable distance from the surface of the supported workpiece W to be shot peened. The variable distance is adjusted by any known driving mechanism (none shown).
The shot-peening system 10 includes a measuring device 18 that is connected to a sensor, which sensor is embedded in the support 14 at the measuring point near the workpiece W. The sensor is omitted from FIG. 1, but shown in FIG. 2 as denoted by reference number 20 . The sensor 20 may convert an elastic wave that is generated when a shot particle strikes the sensor 20 to an electrical signal. Based on the electrical signals from the sensor 20 , the measuring device 18 measures the total peening energy. It is the product of the intensity, or kinetic energy, per the individual projected shot particle multiplied by the number of impacts of the projected shot particles on the sensor 20 per unit time.
The measuring device 18 and the sensor 20 may be ones like those disclosed in, e.g., Japanese Patent Early-Publication Nos. 07-214472 (Oota), and 04-019071 (Matsuura, et al.) or any similar devices. The corresponding applications of these publications are assigned to the assignee of the present application.
Immediately under the enclosure 12 , the system 10 includes a hopper 22 for storing the shot particles. The bottom of the hopper 22 has a vent opening. It communicates with one port (a receiving port) of a three-port flow regulator 24 for regulating the mass-flow rate of the shot particles from the hopper 22 . The three-port flow regulator 24 may be electric-mechanical, or an electric-magnetic mechanical regulator. Of the remaining two ports of the three-port flow regulator, one port communicates with a compressed gas source (typically, a compressed air source, but none is shown) via a pressure/flow valve 26 and a first piping 26 a , while the other port communicates with the peening nozzle 16 in the enclosure 12 via a second piping 30 . Between the first piping 26 a and the nozzle 16 , a pressure sensor 36 (it is omitted from FIG. 1, but shown in FIG. 2) is provided. The pressure/flow valve 26 may be replaced with a pressure valve or a flow valve.
Preferably, the shot-peening system 10 also includes a classifier 38 , such as the type having stacked rotating disks and disclosed in, e.g., Japanese Patent Early-Publication No. 2000-70863 (Oota, et al.), which was assigned to the assignee of the present application, or any similar devices. The classifier 38 classifies the shot particles by the ranges of the sizes (each range may include different size particles) and sphericities such that the workpiece W can be shot peened with a higher accuracy. The type of classifier 38 in Oota, et al., classifies the shot particles based on the friction factor between the upper surface of each rotating disk and each shot particle, and the differences in the speeds of rotation of the rotating disk between positions in the radial direction of it.
On the upper portion of the classifier 38 , its inlet communicates with the bottom of the enclosure 12 via a guiding conduit 40 such that the projected shot particles in the enclosure 12 partly flow into the classifier 38 , and thus are classified therein. In turn, a vent opening of the classifier 38 communicates with the enclosure 12 via a return conduit 42 for conveying the classified shot particles such that they return to the enclosure 12 .
In reference to FIG. 2, the shot-peening system 10 also includes a control panel 50 , which includes a main controller, such as a computer 52 . The computer 52 includes a memory 54 , a manual input device 56 , such as a keyboard, which a human operator can use to provide data or information to the computer 52 , a calculating circuitry or calculator 58 , a calibration circuitry or calibrator 60 , a driver 62 for controlling the three-port flow regulator 24 , and a driver 64 for controlling the pressure/flow valve 26 . The computer 52 may also include a display (not shown) for displaying any data or controlling parameters from the memory 54 , the manual input device 56 , the calculating circuitry 58 , and the calibration circuitry 60 .
The computer 52 shown herein is just an example. The diagram of it explains the invention. The calculating circuitry 58 and the calibration circuitry 60 may be a common processor or separate processors. The drivers 62 and 64 may include computer software.
The memory 54 stores correlation functions between predetermined conditions for projecting the shot particles and the ideal maximum values of the total peening energies based on the corresponding predetermined conditions. Examples of the correlation functions are shown in FIG. 3 .
FIG. 4 is a flowchart 100 that illustrates the steps of the shot-peening process in accordance with the method of the invention. The shot-peening system 10 or any similar device can be used in the steps as shown in the flowchart 100 .
As shown in step 110 of FIG. 4, the operator provides the computer 52 information that identifies conditions for processing the workpiece W to be processed via the manual input device 56 . The conditions for processing the workpiece W include the pressure of the compressed air for projecting the shot particles, the bore diameter of the nozzle 16 , and the diameter, the specific gravity, and the hardness of the individual shot particle to be projected. Further, the conditions for processing the workpiece W also include conditions for the system that are independent from the workpiece W, but dependent on the shot-peening system 10 . The conditions for the system include the type of the path or the conduit for conveying the shot particles.
The information can then be provided to the calculating circuitry 58 in step 120 . As shown in step 120 , the calculating circuitry 58 then calculates the ideal maximum value for the total peening energy for the workpiece W that is to be shot peened based on the information from the manual input device 56 and the correlation functions retrieved from the memory 54 .
To save the labor of the operator in step 110 , it is understood that at least some of the conditions for processing the workpiece W can be permanently stored in the memory 54 . The stored condition(s) is provided to the calculating circuitry 58 from the memory 54 in step 120 . In this case, the manual input device 56 may include, e.g., a switch or switches (none shown), which the operator can use to select the stored condition(s) in the memory 54 .
Once the ideal maximum value for the total peening energy is calculated, this result can then be provided to the driver 62 of the regulator 24 and the driver 64 of the pressure/flow valve 26 in step 130 . As shown in step 130 , the drivers 62 and 64 control the regulator 24 and the pressure/flow valve 26 based on the result calculated by the calculating circuitry 58 .
As shown in step 140 , the nozzle 32 then projects the shot particles under the conditions that are determined in step 130 .
Once the shot particles are projected, they strike the sensor 20 , and thus the measuring device 18 measures the total peening energy as shown in step (measuring step) 150 .
The measured total peening energy is then provided to the calibration circuitry 60 in step 160 . As shown in step 160 , the calibration circuitry 60 then calculates the target mass-flow rate of the shot particles and the target pressure or the target flow rate of the compressed air to maximize the total peening energy based on the measured total peening energy provided by the measuring device 18 and the correlation functions retrieved from the memory 54 .
Once the target mass-flow rate of the shot particles and the target pressure or the target flow rate of the compressed air that is necessary to maximize the total shot-peening energy are calculated, they can be used as calibration values to make feedback controls in step 170 . As shown in step 170 , the calibration values are provided to the corresponding drivers 62 and 64 from the calibration circuitry 60 . The drivers 62 and 64 then control the regulator 24 and the pressure/flow valve 26 based on the calibration values.
As shown in step 180 , the nozzle 32 then projects the shot particles under the control conditions that are determined in step 170 . Then the process returns to the measuring step 150 in order to measure the total peening energy again. Based on the new measured total peening energy, steps 160 - 180 are also carried out again. Then steps 150 - 180 are repeated many times in order to increase the reliability and accuracy for the maximum total peening energy generated in the shot-peening system 10 .
During the shot-peening process, some of the projected shot particles within the enclosure 12 that are projected from the nozzle 16 flow into the inlet of the classifier 36 via the guiding conduit 40 . The classifier 38 classifies the shot particles in the enclosure 12 and returns the classified shot particles to the enclosure 12 via the return conduit 40 .
It is assumed that the pressure of the compressed air is selected for the given diameter of the bore of the nozzle 16 , and the given diameter, the given specific gravity, and the given hardness of each individual shot particle in step 110 of FIG. 4 . It is also assumed that the shot particles are then projected when the distance between the tip of the nozzle 16 and the surface of the workpiece W to be shot peened is 150 mm. Under these conditions, it is can be seen from the graphs of FIG. 3 that a mixture rate by volume of the shot particles to the compressed air to maximize the total shot-peening energy is 1:3. If the distance between the tip of the nozzle 16 and the surface of the workpiece W is 220 mm, the total shot-peening energy can be maximized when the mixture rate by volume of the shot particles to the compressed air is 1:3. Thus, this mixture rate is the most efficient rate for the conditions for projecting the shot particles.
During the shot-peening process, it is possible that the pressure of the compressed air will be decreased due to a temporary over consumption of the air from the air source after the ideal maximum value of the total shot-peening energy is once calculated at step 120 . In such a case, the ideal maximum value may be recalculated based on the decreased pressure of the compressed air. The recalculated ideal maximum value can then be used as a new condition for projecting the shot particles. Therefore, the ideal maximum value of the total peening energy within a required range of the shot-peening intensity for the workpiece to be processed may be specified with a higher accuracy.
It is also possible that the pressure of the compressed air will be significantly decreased to a value that cannot satisfy the required range of the shot-peening intensity for the workpiece to be processed. To deal with such a case, the shot-peening system 10 may be configured so that the operator will notice such a condition, by the system 10 generating an alarm that indicates that an abnormal pressure has occurred.
It should be understood that various modifications and variations within the scope of this invention can be made by one of ordinary skill in the art without departing from the scope and sprit thereof as defined by the appended claims.
For example, in the above embodiment, the sensor 20 is embedded in the support 14 near the workpiece W. Alternatively, the sensor 20 may be embedded in a dummy workpiece (not shown) rather than in the support 14 . This dummy workpiece with the sensor 20 may be configured such that it can be detachably mounted on the support 14 and used at the step for detecting the shot-peening intensity so that the measuring point can be assumed to be positioned on the real workpiece to be shot peened. In this case, the sensor 20 detects the shot-peening energy at the position for measuring that is located at the dummy workpiece. Thus, the resulting shot-peening energy can be assumed to correspond to the peening energy on the real workpiece.
Although the embodiment employs the single nozzle 16 , a plurality of nozzles may be employed. | A system for shot peening that includes an enclosure in which are provided a workpiece W to be shot peened and a nozzle for projecting the shot particles. A memory stores data for maximizing the anticipated shot-peening intensity at the workpiece based on the predetermined conditions of the shot peening. Then a calculating circuitry determines the conditions of the shot peening to be carried out in the system to maximize an anticipated shot-peening intensity at the workpiece based on the stored data from the memory and the selected type of the shot-peening process to be applied to the workpiece before the shot particles have been actually projected. The nozzle is then actuated under the determined conditions such that it projects the shot particles and directs them onto the workpiece. The shot-peening intensity of the actually projected shot particles at the workpiece is measured by a measuring device. Then a calibration circuitry controls the mass-flow rate of the shot particles and the pressure or the flow rate of the compressed air to maximize the measured shot-peening intensity based on the stored data such that the nozzle projects the shot particles under the corrected and controlled conditions. | 1 |
BACKGROUND
The present disclosure relates to medical implants. More particularly, the present disclosure relates to medical implants having a mesh configuration that are useful in tissue repair.
Implantable meshes may be inserted into a patient's body during a surgical procedure to reinforce, at least temporarily, deficient musculo-aponeurotic substrates. For example, implantable meshes may be utilized to treat hernias, urinary incontinence, uterovaginal prolapses, and other similar injuries.
Implanted meshes may be produced from non-absorbable or absorbable materials and may be constructed of monofilament threads or multifilament yarns. Some commercially available implantable meshes are made of monofilaments threads, the resulting mesh having relatively small pores, in some cases less than about 1 mm, and almost all are relatively rigid. This rigidity results in a mechanical mismatch between the implant and the host tissues which, in turn, may result in irritation of the tissue at the site of the implant. This irritation, combined with a lack of porosity, may lead to the formation of a pseudo fibrous capsule around the mesh implant which may cause discomfort, chronic pain, and increase the risk of recurrence.
Recently, some monofilament polypropylene meshes have been demonstrated to be oxidized in vivo when infection or acute inflammation occurs, resulting in some degradation of the material which could also be responsible for mesh stiffening, impaired abdominal wall movement when used to repair a hernia, and chronic pain.
Multifilament meshes are usually softer and more compliant than monofilament meshes. A multifilament mesh may possess a larger, more developed surface, which could be beneficial with respect to tissue integration, but could be detrimental with respect to increased bacterial contamination.
One way to attempt to minimize the risk of infection associated with the use of meshes in vivo is to apply antimicrobial coatings thereto. For example, U.S. Patent Application Publication No. 2005/0085924 and U.S. Pat. No. 5,217,493 both disclose meshes with coatings possessing antimicrobial agents. However, while these meshes may exhibit an antibacterial effect on a local and diffuse basis by inhibiting bacterial adhesion and proliferation as a result of the antibiotics and antiseptics included in the coatings, they may also damage the cytocompatibility of the material, thereby inhibiting and/or delaying the integration of the mesh with tissue. This inhibition or delay of the integration of the mesh material may generate adverse effects such as local necrosis, seroma, pseudocapsule formation, secondary infection, and the like.
Meshes with long term biocompatibility and infection resistance remain desirable.
SUMMARY
The present disclosure provides mesh implants which are tissue-friendly, with an initial rigidity providing easy handling and positioning of the mesh. In embodiments, the mesh implants may possess biological active agents capable of providing the mesh with desirable properties during the key phase of tissue integration, while maintaining for the long term a minimal amount of material possessing suitable mechanical properties. The strands of the mesh may include monofilament threads or multifilament yarns.
In embodiments, a suitable medical implant may include a mesh having strands and pores, with a coating on at least a portion of the mesh. The coating on the mesh, in embodiments, may include at least one collagen in combination with at least one polysaccharide which, in turn, may include fucans, dextrans, dextran derivatives, chitosan, cellulose, oxidized cellulose, polyglucuronic acid, hyaluronic acid and combinations thereof.
In other embodiments, a medical implant of the present disclosure may include a mesh having strands and pores and a coating on at least a portion of the mesh, wherein the coating includes at least one collagen in combination with at least one fucan.
In some embodiments, the strands of the mesh may include a synthetic non-absorbable material such as polyethylene, polypropylene, copolymers of polyethylene and polypropylene, blends of polyethylene and polypropylene, polyethylene terephthalate, polyamides, aramides, expanded polytetrafluoroethylene, polyurethane, polyvinylidene difluoride, polybutester, copper alloy, silver alloy, platinum, medical grade stainless steel, and combinations thereof.
Methods for forming such meshes and uses thereof are also provided.
BRIEF DESCRIPTION OF THE DRAWINGS
Various embodiments of the present disclosure will be described herein below with reference to the figures wherein:
FIG. 1 is a graph of the results of HPLC analysis depicting the amount of fucan released from a collagen film in accordance with the present disclosure;
FIG. 2 is a graph depicting the adhesion of S. aureus on collagen and collagen-fucan films in accordance with the present disclosure (a), and adhesion of S. aureus on polypropylene (PP, T′), collagen films, and collagen-fucan films in the presence of an extract obtained from a collagen-fucan film in accordance with the present disclosure (b);
FIG. 3 is a graph depicting the growth of fibroblasts on polypropylene (PP), polyethylene terephthalate (PET), collagen films with varying concentrations of fucan, and collagen films with varying concentrations of fucan on a textile;
FIG. 4 is a depiction of a Boyden Chamber Assay utilized to test coated implants of the present disclosure;
FIG. 5 is a graph depicting the chemotactic response of fucans on fibroblasts (varying concentrations of fucan in collagen films, with and without textile, with polypropylene and polyethylene terephthalate as a control);
FIG. 6 is a graph depicting the anti-complement activity of heparin, fucan precursor P240 RED, and fucan TH90RED A2 0305 PUF 30 in solution; and
FIG. 7 are histological pictures obtained after intraperitoneal implantation of implants of the present disclosure in rats at various times after explantation.
DETAILED DESCRIPTION
According to the present disclosure there is provided a surgical mesh implant made of a biocompatible material. The mesh implants of the present disclosure may be suitable for soft tissue repair, for example when a permanent reinforcement is necessary. The implants of the present disclosure can also be used as an in-vitro support for biological evaluations, for example, cell cultures, microbiological assays, anticomplement and anticoagulant activity assays, and the like.
To support tissue ingrowth, it may be desirable to minimize the invasiveness of a mesh implant. At the same time, while it may be desirable for the implant to possess mechanical properties as close as possible to those of healthy tissue, the stiffer the mesh, the easier for the surgeon it is to handle the mesh, to spread it homogeneously on the defect, and adhere the mesh to the defect, thus decreasing the time required for a surgical procedure to repair a defect. Thus, a suitable mesh implant in accordance with the present disclosure may possess large pores, a limited amount of permanent, non-absorbable material, and isoelastic behavior. The mesh of the present disclosure may also, in embodiments, possess a coating which enhances its integration in vivo while at the same time minimizing bacterial colonization of the mesh. Such a coating may also, in embodiments, provide a stiffness to the mesh thereby facilitating its handling by a surgeon during implantation.
The mesh implant of the present disclosure may be made of strands which, in turn, may be made of filaments of any suitable biocompatible material. Suitable materials from which the mesh can be made should have the following characteristics: biocompatibility; sufficient tensile strength; sufficiently inert to avoid foreign body reactions when retained in the human body for long periods of time; exhibit minimal allergic and/or inflammatory response; non-carcinogenic; easily sterilized to prevent the introduction of infection when the mesh is implanted in the human body; minimal elasticity; minimal shrinkage; and easy handling characteristics for placement in the desired location in the body. Meshes of the present disclosure may be of monofilament or multi-filament in construction.
In some embodiments the filaments may be made of a plastic or similar synthetic non-absorbable material. Some examples of suitable non-absorbable materials which may be utilized include polyolefins, such as polyethylene, polypropylene, copolymers of polyethylene and polypropylene, and blends of polyethylene and polypropylene. Other non-absorbable materials which may be utilized include polyesters such as polyethylene terephthalate (PET), polyamides, aramides, expanded polytetrafluoroethylene, polyurethane, polyvinylidene difluoride (PVDF), polybutester, copper alloy, silver alloy, platinum, medical grade stainless steels such as 316L medical grade stainless steel, combinations thereof, and the like. Examples of commercially available polypropylene-based textile supports which may be utilized include those sold under the brand name PARIETENE® from Sofradim, and examples of commercially available PET-based textile supports which may be utilized include those sold under the brand name PARIETEX® from Sofradim.
In other embodiment the filaments of the mesh may be made of an absorbable material. Suitable absorbable materials include, but are not limited to, trimethylene carbonate, caprolactone, dioxanone, glycolic acid, lactic acid, glycolide, lactide, homopolymers thereof, copolymers thereof, and combinations thereof. Specific absorbable materials which may be suitable include, for example chitosan, cellulose, oxidized cellulose, combinations thereof, and the like.
In embodiments, the filaments described above may be utilized to form strands which, in turn, may be utilized to form a mesh implant of the present disclosure. For example, the strands may be warp knit or woven into a variety of different mesh shapes. Thus, the mesh may include strands, with pores formed between the strands. In some embodiments the strands may be arranged to form a net mesh which has isotropic or near isotropic tensile strength and elasticity.
The monofilaments utilized to produce the strands of the mesh implant may have a diameter of from about 0.07 mm to about 0.1 mm, in embodiments from about 0.08 mm to about 0.09 mm.
In embodiments, a mesh implant of the present disclosure may possess large hexagonal pores of more than about 1.5 mm in size, in embodiments from about 1.5 mm to about 4 mm in size. In some embodiments, the pores in a mesh implant in accordance with the present disclosure may be square in shape having dimensions of from about 1.2 mm to about 2.5 mm in size, in embodiments about 1.5 mm×1.5 mm in size.
A yarn in accordance with the present disclosure may possess a mass in grams per 10,000 meters (decitex or dtex) of from about 33 dtex to about 76 dtex, in embodiments from about 35 dtex to about 50 dtex.
As would be apparent to one of skill in the art, the surface density of a mesh can be decreased while maintaining its mechanical properties in an adequate range by selecting a monofilament thread having the right size and strength. For example, for a thread having the same diameter, a PET monofilament thread may have better mechanical properties compared to a polypropylene monofilament, so a smaller diameter PET monofilament thread can be used to obtain similar mechanical properties as the polypropylene monofilament, thus decreasing the amount of material implanted and enlarging pore sizes. Similarly, in other embodiments a PET monofilament thread having the same diameter as a polypropylene monofilament can be used with a more open textile structure to get similar mechanical properties as the polypropylene monofilament, thus decreasing the amount of material implanted and enlarging pore sizes. In both cases the surface density may not be lower because the PET specific weight is higher than the polypropylene specific weight. However, the developed surface will be lower and the pore size greater, thereby enhancing tissue ingrowth.
Moreover, for the same yarn count, a high tenacity polyester multifilament yarn may have better mechanical properties than a standard polyester multifilament yarn, so a thinner high tenacity polyester such as a high tenacity PET multifilament yarn could be used to obtain similar mechanical properties, thus decreasing the mesh surface density. A same count high tenacity PET multifilament yarn can be combined with a more open textile structure to get similar mechanical properties, thus decreasing the mesh surface density. In both cases the surface density will be lower, thereby limiting foreign body implantation and promoting mesh integration.
Mesh implants of the present disclosure may have a surface density of less than about 50 g/m 2 , in embodiments from about 20 g/m 2 to about 50 g/m 2 , in other embodiments from about 25 g/m 2 to about 35 g/m 2 .
Mesh implants may also possess compliance and mechanical properties matching or very similar to native tissues, for example from about 10% to about 50% of elongation under a force of about 20 N of load in warp and weft direction, in embodiments from about 10% to about 40% of elongation under a force of about 20 N in warp direction and from about 20% to about 50% of elongation under a force of about 20 N in weft direction. Thus, in embodiments, a mesh of the disclosure may possess isoelastic behavior wherein the ratio of longitudinal elastic properties to transverse elastic properties is from about 0.7:1 to about 1.3:1, in embodiments of about 0.75:1 under a force of about 20 Newtons of load.
The pattern and the density of the strands forming the mesh provide the mesh implant with its necessary strength. Mesh implants in accordance with the present disclosure may possess a tensile strength of more than about 80 Newtons, in embodiments from about 80 Newtons to about 200 Newtons, in other embodiments from about 90 Newtons to about 150 Newtons, as determined according to ISO 13934-1 in both the warp and weft direction.
The shape of the mesh implant of the present disclosure may be varied depending upon the condition to be treated with the mesh implant. Mesh implants of the present disclosure may be circular, rectangular, trapezoidal, and the like. Due to the variability in patient morphology and anatomy, the implant may be of any suitable size. The mesh implant may have a width from about 50 mm to about 500 mm, in embodiments from about 75 mm to about 200 mm, and a length from about 50 mm to about 500 mm, in embodiments from about 90 mm to about 250 mm.
The thickness of the surgical mesh of the present disclosure may also vary, but may be less than about 5 mm. In some embodiments, the thickness of the mesh can be from about 0.05 mm to about 0.8 mm.
In embodiments a mesh may be formed utilizing a polyester monofilament, of a diameter of from about 0.07 mm to about 0.1 mm. In other embodiments, a multifilament polyester may be utilized to form a mesh, with a mass of about 49 dtex. In other embodiments, a multifilament high tenacity polyester, for example, a high tenacity PET, may be utilized to form a mesh, with a mass of about 49 dtex. In either embodiment, the mesh may have a low surface density of from about 20 g/m 2 to about 35 g/m 2 .
Methods and apparatus suitable for forming meshes are within the purview of those skilled in the art. Suitable apparatus and methods include, for example, those disclosed in U.S. Pat. Nos. 6,408,656 and 6,478,727, the entire disclosures of each of which are incorporated by reference herein. In embodiments, a suitable mesh may be formed utilizing a tricot warp knitting machine or Rachel warp knitting machine with 2 or 3 guide bars. The gauge of needles utilized to form these meshes may be from about E22 to about E28 (i.e., about 22 to about 28 needles/inch), in embodiments from about E22 to about E24, in some embodiments about E24. In some embodiments, a mesh may be formed with two half threaded guide bars, being moved symmetrically for forming an open mesh according to the following graphics/bar movement.
In embodiments, to obtain pores with no specific shape and several pore sizes:
Guide-bar BI: 5.4/4.3/2.1/0.1/1.2/3.41//
Guide-bar BII: 0.1/1.2/3.4/5.4/4.3/2.1//
or
Guide-bar BI: 3.2/2.1/0.1//
Guide-bar BII: 0.1/1.2/3.2//
In some embodiments, a mesh may be formed with several guide bars using adequate threading diagrams and adequate bar movement to form an open mesh according to the following graphics.
In embodiments, to obtain single size square pores:
Guide-bar BI: 1.0/0.1//
Guide-bar BII: 6.6/0.0/2.2/0.0/6.6/4.4//
Guide-bar BIII: 0.0/6.6/4.4/6.6/0.0/2.2//
In other embodiments, to obtain single size hexagonal pores:
Guide-bar BI: 1.0/0.1/1.0/2.3/3.2/2.3//
Guide-bar BII: 0.0/1.1/0.0/3.3/2.2/3.3//
In embodiments, it may be desirable for a mesh to possess single size hexagonal pores, but any configuration of pores, or multiple pore configurations, may be utilized.
In order to facilitate handling by a surgeon during implantation, the meshes of the present disclosure may possess a coating thereon. Suitable coatings include, but are not limited to, collagens, chitosan, polyethylene glycol (PEG), polyglycolic acid (PGA), oxidized cellulose, polyarylates, polysiloxanes, combinations thereof, and the like.
In embodiments, a suitable coating may include collagen. The term “collagen” as used herein refers to all forms of collagen from any source including, but not limited to, collagen extracted from tissue or produced recombinantly, collagen analogues, collagen derivatives, modified collagens, and denatured collagens such as gelatin. For example, collagen may be extracted and purified from animal tissue including human or other mammalian sources, such as bovine or porcine corium and human placenta, or may be recombinantly or otherwise produced. The preparation of purified, substantially non-antigenic collagen in solution from animal sources such as bovine and porcine sources is within the purview of those skilled in the art. For example, collagen, including Type I collagen, may be extracted from pig dermis via an acid pH solubilization or via a pepsin digestion and purified with saline precipitations, utilizing processes within the purview of those skilled in the art. Moreover, U.S. Pat. No. 5,428,022 discloses methods of extracting and purifying collagen from the human placenta, and U.S. Pat. No. 5,667,839 discloses methods of producing recombinant human collagen in the milk of transgenic animals, including transgenic cows. Non-transgenic, recombinant collagen expression in yeast and other cell lines is described in U.S. Pat. Nos. 6,413,742, 6,428,978, and 6,653,450.
Collagen of any type, including, but not limited to, types I, II, III, IV, or any combination thereof, may be used in the coating of a mesh implant of the present disclosure. Either atelopeptide or telopeptide-containing collagen may be used; however, when collagen from a xenogenic source, such as bovine collagen or porcine collagen, is used, atelopeptide collagen may be suitable because of its reduced immunogenicity compared to telopeptide-containing collagen.
Collagen that has not been previously crosslinked by methods such as heat, irradiation, or chemical crosslinking agents may be utilized in some embodiments; in other embodiments previously crosslinked collagen may be used.
Collagens for use in coatings of mesh implants of the present disclosure may generally be in aqueous suspensions at a concentration of from about 20 mg/ml to about 120 mg/ml, in embodiments from about 30 mg/ml to about 90 mg/ml.
Collagen for use in forming a coating on a mesh implant of the present disclosure may be fibrillar or nonfibrillar. Collagens for use in the compositions of the present invention may start out in fibrillar form, then can be rendered nonfibrillar by the addition of one or more fiber disassembly agent(s). Where utilized, a fiber disassembly agent may be present in an amount sufficient to render the collagen substantially nonfibrillar at a pH of about 7. Suitable fiber disassembly agents include, without limitation, various biocompatible alcohols, amino acids, inorganic salts, and carbohydrates. Suitable biocompatible alcohols include glycerol and propylene glycol. Suitable amino acids include arginine. Suitable inorganic salts include sodium chloride and potassium chloride.
In embodiments, collagen type I and/or collagen type III, the main molecules of native extracellular matrix (ECM), may be utilized as the coating. Collagen types I and III are known to facilitate cellular adhesion, proliferation and differentiation.
The collagen coating leaves the pores empty for rapid colonization of the macrostructure of the mesh. Hence, the coating of the present disclosure should provide a better handling of the mesh and will also hide the main part of the surface of the synthetic yarns utilized to construct the mesh during the early integration phase.
In some embodiments, in addition to the collagen described above, a coating on a mesh implant of the present disclosure may also include additional absorbable materials. Such additional absorbable materials are within the purview of those skilled in the art and include, but are not limited to, trimethylene carbonate, caprolactone, dioxanone, glycolic acid, lactic acid, glycolide, lactide, polysaccharides including but not limited to, chitosan, polyglucuronic acid, hyaluronic acid, homopolymers thereof, copolymers thereof, and combinations thereof. When present, such absorbable materials may be present in a coating in an amount from about 20% to about 80% by weight of the coating, in embodiments from about 40% to about 60% by weight of the coating.
The coating of the present disclosure, in embodiments, may also include a bioactive molecule, such as a natural vegetal or synthetic polysaccharide. Suitable natural or synthetic polysaccharides include fucans, also called fucoidans, dextrans, dextran derivatives, cellulose, oxidized cellulose, chitosan, polyglucuronic acid, hyaluronic acid, combinations thereof, and the like.
In embodiments, a fucan may be utilized as the polysaccharide in the coating of a mesh implant of the present disclosure. As used herein, “fucan” includes any natural fucoidans, including those produced by recombinant techniques, as well as any fucoidan precursors, fucoidan derivatives or modified fucoidans and fucoidan derivatives, and depolymerized fucans. “Fucan” and “fucoidan” are used interchangeably herein. Sulfated fucans, also referred to simply as fucans, include natural sulfated polysaccharides extracted from the cell wall of brown algae, or the egg jelly coat of sea urchins, or from the body wall of sea cucumbers. Fucoidans are mainly absent from green algae ( Chlorophyceae ), red algae ( Rhodophyceae ), golden algae ( Xanthophyceae ) and from fresh water algae and terrestrial plants. In embodiments, suitable fucans may be extracted from brown algae. Suitable fucans include, for example, TH90RED A2 0305 PUF30 (extracted from Ascophyllum Nodosum brown algae) which is a low molecular weight fucan of about 17,000 g/mol with a polydispersity index of about 1.78.
Methods for extracting fucans from natural vegetal sources, including brown algae, are within the purview of those skilled in the art. Once obtained, the fucan may then be combined with collagen as described above to form a coating on a mesh implant of the present disclosure.
The addition of a fucan as part of a coating may permit quicker integration of the mesh in host tissue by enhancing fibroblastic and mesothelial cell proliferation and migration (respectively an increase of about 45% to 70% and about 50% to 80% of stimulation), inhibiting bacterial adhesion proliferation (about 20% to 40% of inhibition) and generating a favorable environment after implantation as evidenced by reduced anticomplement, limiting the immune response of the host, reducing anticoagulant activity, and enhancing the integration of the mesh without generating any adverse hemophilic effect. Biological properties of the fucans may be increased with a low molecular weight, low polydispersity index and a high sulfate rate.
A coating of the present disclosure may possess collagen in an amount from about 2% to about 5% by weight of the coating solution, in embodiments from about 2.5% to about 3.2% by weight of the coating solution, with a polysaccharide like a fucan present in the coating in an amount from about 0.001% to about 1% by weight of the coating solution, in embodiments from about 0.005% to about 0.05% by weight of the coating solution.
As noted above, in embodiments the collagen may be in a suspension. The polysaccharide described above may be added to this suspension which, in turn, may then be applied to a mesh implant. In other embodiments the collagen and polysaccharide may be placed into a solvent to form a solution, which may then be applied to a mesh. Any biocompatible solvent may be used to form such a solution. In embodiments, suitable solvents include, but are not limited to, methylene chloride, hexane, ethanol acetone, combinations thereof, and the like.
The coating may encapsulate an entire filament, strand or mesh. Alternatively, the coating may be applied to one or more sides of a filament, strand or mesh. Such a coating may improve the desired therapeutic characteristics of the mesh.
The coating may be applied to the mesh implant utilizing any suitable method known to those skilled in the art. Some examples include, but are not limited to, spraying, dipping, layering, calendaring, etc.
In some embodiments, the coating may add bulk to the mesh such that it is easier to handle. As the coating includes collagen and a polysaccharide, the coating should be released into the body after implantation and therefore should not contribute to the foreign body mass retained in the body. Thus, the advantages of a surgical implant having minimal mass may be retained.
The coating may be released into the body within a period of time from about 0 days to about 28 days following implantation, in embodiments from about 1 day to about 5 days following implantation.
As noted above, in embodiments a mesh implant in accordance with the present disclosure may possess initial handling properties which facilitate surgeon use, including use through a laparoscopic approach. Such handling properties may include, for example, initial memory, relative stiffness, surface smoothness, and combinations thereof.
Mesh implants of the present disclosure may also possess a tissue friendly surface capable of enhancing quick cellular adhesion, proliferation and connective tissue differentiation, while minimizing foreign body inflammation and decreasing the risk of bacterial adhesion and proliferation.
In embodiments, the mesh implant of the present disclosure may possess additional bioactive agents in its coatings. The term “bioactive agent”, as used herein, is used in its broadest sense and includes any substance or mixture of substances that have clinical use. Consequently, bioactive agents may or may not have pharmacological activity per se, e.g., a dye. Alternatively, a bioactive agent could be any agent which provides a therapeutic or prophylactic effect; a compound that affects or participates in tissue growth, cell growth, and/or cell differentiation; a compound that may be able to invoke a biological action such as an immune response; or a compound that could play any other role in one or more biological processes.
Any agent which may produce therapeutic benefits, i.e., tissue repair, cell proliferation, limit the risk of sepsis, may be added in the coating formulation. Such agents include, for example, fucans, dextrans, dextran derivatives, carrageenan, alginate, hyaluronic acid, keratin sulfate, keratan sulfate, dermatan sulfate, chitin, chitosan, combinations thereof, and the like. For example, chitosan is biodegradable, has good biocompatibility, has been demonstrated to be hemostatic and bacteriostatic, and it also plays an important role in cell proliferation and tissue regeneration.
Examples of classes of bioactive agents which may be utilized in accordance with the present disclosure include antimicrobials, analgesics, antiadhesive agents, antipyretics, anesthetics, antiepileptics, antihistamines, anti-inflammatories, cardiovascular drugs, diagnostic agents, sympathomimetics, cholinomimetics, antimuscarinics, antispasmodics, hormones, growth factors, muscle relaxants, adrenergic neuron blockers, antineoplastics, immunogenic agents, immunosuppressants, gastrointestinal drugs, diuretics, steroids, lipids, lipopolysaccharides, polysaccharides, and enzymes. It is also intended that combinations of bioactive agents may be used.
Suitable antimicrobial agents which may be included as a bioactive agent in the coating include quaternary ammonium, including triclosan also known as 2,4,4′-trichloro-2′-hydroxydiphenyl ether, diallyldimethylaminocarbonate (also known as DADMAC), chlorhexidine and its salts, including chlorhexidine acetate, chlorhexidine gluconate, chlorhexidine hydrochloride, and chlorhexidine sulfate, silver and its salts, including silver acetate, silver benzoate, silver carbonate, silver citrate, silver iodate, silver iodide, silver lactate, silver laurate, silver nitrate, silver oxide, silver palmitate, silver protein, and silver sulfadiazine, polymyxin, tetracycline, aminoglycosides, such as tobramycin and gentamicin, rifampicin, bacitracin, neomycin, chloramphenicol, miconazole, quinolones such as oxolinic acid, norfloxacin, nalidixic acid, pefloxacin, enoxacin and ciprofloxacin, penicillins such as oxacillin and pipracil, nonoxynol 9, fusidic acid, cephalosporins, and combinations thereof. In addition, antimicrobial proteins and peptides such as bovine lactoferrin and lactoferricin B may be included as a bioactive agent in the coating.
Other bioactive agents which may be included in the coating of a mesh implant of the present disclosure include: local anesthetics; non-steroidal antifertility agents; parasympathomimetic agents; psychotherapeutic agents; tranquilizers; decongestants; sedative hypnotics; steroids; sulfonamides; sympathomimetic agents; vaccines; vitamins; antimalarials; anti-migraine agents; anti-parkinson agents such as L-dopa; anti-spasmodics; anticholinergic agents (e.g. oxybutynin); antitussives; bronchodilators; cardiovascular agents such as coronary vasodilators and nitroglycerin; alkaloids; analgesics; narcotics such as codeine, dihydrocodeinone, meperidine, morphine and the like; non-narcotics such as salicylates, aspirin, acetaminophen, d-propoxyphene and the like; opioid receptor antagonists, such as naltrexone and naloxone; anti-cancer agents; anti-convulsants; anti-emetics; antihistamines; anti-inflammatory agents such as honnonal agents, hydrocortisone, prednisolone, prednisone, non-hormonal agents, allopurinol, indomethacin, phenylbutazone and the like; prostaglandins and cytotoxic drugs; estrogens; antibacterials; antibiotics; anti-fungals; anti-virals; anticoagulants; anticonvulsants; antidepressants; antihistamines; and immunological agents.
Other examples of suitable bioactive agents which may be included in the coating of a mesh implant of the present disclosure include viruses and cells, peptides, polypeptides and proteins, analogs, muteins, and active fragments thereof, such as immunoglobulins, antibodies, beta glycans, cytokines (e.g. lymphokines, monokines, chemokines), blood clotting factors, hemopoietic factors, interleukins (IL-2, IL-3, IL-4, IL-6), interferons (β-IFN, (α-IFN and γ-IFN), erythropoietin, nucleases, tumor necrosis factor, colony stimulating factors (e.g., GCSF, GM-CSF, MCSF), insulin, anti-tumor agents and tumor suppressors, blood proteins, gonadotropins (e.g., FSH, LH, CG, etc.), hormones and hormone analogs (e.g., growth hormnone), vaccines (e.g., tumoral, bacterial and viral antigens); somatostatin; antigens; blood coagulation factors; growth factors (e.g., nerve growth factor, insulin-like growth factor); protein inhibitors, protein antagonists, and protein agonists; nucleic acids, such as antisense molecules, DNA and RNA; oligonucleotides; and ribozymes.
Any combination of bioactive agents may be utilized as part of a coating of the mesh implant of the present disclosure.
A coating may be applied to the mesh as a composition containing one or more bioactive agents, or bioactive agent(s) dispersed in a suitable biocompatible solvent.
Suitable solvents for particular bioactive agents are within the purview of those skilled in the art.
The rate of release of a bioactive agent from the coating on a mesh of the present disclosure can be controlled by any means within the purview of one skilled in the art. Some examples include, but are not limited to, the depth of the bioactive agent from the surface of the coating; the size of the bioactive agent; the hydrophilicty of the bioactive agent; and the strength of physical and physical-chemical interaction between the bioactive agent, the coating and/or the mesh material. By properly controlling some of these factors, a controlled release of a bioactive agent from the mesh of the present disclosure can be achieved.
In embodiments, filaments utilized to produce the strands of the mesh implant of the present disclosure may be made of bicomponent microfibers. Bicomponent microfibers typically include a core material and a surface material. In embodiments, the bicomponent microfibers may include a non-absorbable or long lasting absorbable core and a shorter lasting absorbable surface material. The surface material of the bicomponent microfiber may be absorbed by the body within a number of hours, such that only the core portion is left in the body for an extended period of time, typically for a long enough period of time to enable tissue ingrowth. Although a variety of materials may be used in forming these bicomponent microfibers, suitable materials include polypropylene for the core and polylactic acid or polyglycolic acid for the surface material. In another embodiment, the bicomponent microfibers may be made of a core material which may be rapidly absorbed by the body and a surface material which is not rapidly absorbed, but instead is absorbed for a longer period of time than the core.
In embodiments, the surface material of the bicomponent microfibers may provide the mesh implant with enhanced characteristics required for surgical handling. After insertion in the body, the surface material of the bicomponent microfiber may be absorbed by the body leaving behind the reduced mass of the core material as the strands of the mesh. For example, suitable bicomponent microfibers include a polypropylene non-absorbable portion as the core and a polylactic acid absorbable portion as the surface. The surface material is present during the surgical procedure when the mesh is being inserted and located in the patient, and provides the mesh with characteristics desirable for surgical handling. Following a period of insertion in the body, typically a few hours, the surface material is absorbed into the body leaving only the core material of the filaments in the body.
It may be desirable to provide a variety of implants having different sizes and dimensions so that a surgeon can select an implant of suitable size to treat a particular patient. This allows implants to be completely formed before delivery, ensuring that the smooth edge of the implant is properly formed under the control of the manufacturer. The surgeon would thus have a variety of differently sized and/or shaped implants to select the appropriate implant to use after assessment of the patient.
Methods of reducing fraying of the filaments to maintain a smooth edge of the mesh implant are within the purview of those skilled in the art and include, but are not limited to, heat treatment, laser treatment, combinations thereof, and the like. In some embodiments a heat treatment may be desirable, as such a treatment may promote adhesion of the strands forming the mesh, thereby facilitating removal of the mesh implant if required for any reason.
In another embodiment the mesh can be cut to any desired size. The cutting may be carried out by a surgeon or nurse under sterile conditions such that the surgeon need not have many differently sized implants on hand, but can simply cut a mesh to the desired size of the implant after assessment of the patient. In other words, the implant may be supplied in a large size and be capable of being cut to a smaller size, as desired.
Even where the cutting of the mesh causes an unfinished edge of the mesh to be produced, this unfinished mesh is not likely to cause the same problems as the rough and jagged edges of implants of the prior art, due to the coating, which protects the tissue from the mesh during the surgical procedure when damage to the tissue is most likely to occur.
Medical implants of the disclosure may include, but are not limited to, incontinence tapes and slings, and meshes, patches and/or implants for use in fascial repair, hernia repair, prolapse repair, and the like. Different shapes are suitable for repairing different defects. Thus, by providing a mesh implant which can be cut to a range of shapes, a wide range of defects, including those found in fascial tissue, can be treated.
In some embodiments, it may be desirable to secure the mesh in place once it has been suitably located in the patient. The mesh implant can be secured in any manner within the purview of those skilled in the art. Some examples include suturing the mesh to strong lateral tissue, gluing the mesh in place using a biocompatible glue, using a surgical fastener, or combinations thereof.
Any biocompatible glue within the purview of one skilled in the art may be used. In embodiments useful glues include fibrin glues, cyanoacrylate glues, combinations thereof, and the like. In other embodiments, the mesh implant of the present disclosure may be secured to tissue using a surgical fastener such as a surgical tack. Other surgical fasteners which may be used are within the purview of one skilled in the art, including staples, clips, helical fasteners, tissue anchors, suture anchors, bone anchors, hooks, combinations thereof, and the like.
Surgical fasteners useful with the mesh implant herein may be made from bioabsorbable materials, non-bioabsorbable materials, and combinations thereof. Examples of suitable absorbable materials which may be utilized to form a fastener include trimethylene carbonate, caprolactone, dioxanone, glycolic acid, lactic acid, glycolide, lactide, homopolymers thereof, copolymers thereof, and combinations thereof. Examples of non-absorbable materials which may be utilized to form a fastener include stainless steel, titanium, nickel, chrome alloys, and other biocompatible implantable metals. In embodiments, a shape memory alloy, such as nitinol, may be utilized as a fastener.
Surgical fasteners utilized with the mesh implant of the present disclosure may be made into any size or shape to enhance their use depending on the size, shape and type of tissue located at the repair site for attachment of the mesh implant. The surgical fasteners, e.g., tacks, may be used alone or in combination with other fastening methods described herein to secure the mesh to the repair site. For example, the mesh implant may be tacked and glued, sutured and tacked, or only tacked, into place.
The surgical fasteners may be attached to the mesh implant in various ways. In embodiments, the ends of the mesh may be directly attached to the fastener(s). In other embodiments, the mesh may be curled around the fastener(s) prior to implantation. In yet another embodiment, the fastener may be placed inside the outer edge of the mesh and implanted in a manner which pinches the mesh up against the fastener and into the site of the injury.
A mesh in accordance with the present disclosure possesses several desirable characteristics. In embodiments, where a non-absorbable material is utilized to form the strands of the mesh, the low surface density of a mesh of the present disclosure enhances the integration of the mesh with tissue, especially upon implantation in vivo. The collagen component of the coating minimizes the formation of adhesions and reduces the inflammation response to the mesh, while also improving the handling characteristics of the mesh for implantation by providing the mesh with stiffness. Moreover, the bioactive agent, in embodiments a fucan polysaccharide, may confer desirable properties to the mesh, for example the enhancement of cell proliferation and migration for enhanced and faster integration, antibacterial properties including the inhibition of both gram positive and gram negative bacteria, and the inhibition of inflammation, as evidenced by a decrease in complement activity. The bioactive agent, in embodiments a polysaccharide such as a fucoidan, may be released by the collagen coating immediately upon implantation, as well as for an extended period over several days.
A variety of different surgical approaches are contemplated herein for introducing the mesh implant of the present disclosure into a patient, including through an incision, laparoscopically, or through a natural approach such as, for example, vaginal approach, and the like.
The following Examples are being submitted to illustrate embodiments of the present disclosure. These Examples are intended to be illustrative only and are not intended to limit the scope of the present disclosure. Also, parts and percentages are by weight unless otherwise indicated.
EXAMPLES
Example 1
A mesh was prepared with the following parameters. A high tenacity PET multifilament yarn, about 49 dtex was utilized to form the mesh. A tricot warp knitting machine utilizing gauge E24 needles (i.e., 24 needles/inch) was utilized. The mesh included hexagonal pores, which were formed using 2 guide-bars, with the following bar movement:
Guide-bar BI: 1.0/0.1/1.0/2.3/3.2/2.3//
Guide-bar BII: 0.0/1.1/0.0/3.3/2.2/3.3//
The resulting mesh had a low surface density of from about 20 g/m 2 to about 35 g/m 2 , large pores of about 1.5 mm×1.5 mm, a ratio of longitudinal elastic properties/transversal elastic properties of from about 0.7:1 to about 1.3:1, and a breaking strength measured according to ISO 13934-1 in warp and weft direction of from about 80 Newtons to about 150 Newtons.
Example 2
The high tenacity PET mesh produced in Example 1 above was coated with a porcine collagen solution (about 0.8% m/V), which was a Type I collagen extracted from pig dermis. Dried collagen fibers were used, obtained after precipitation of an acid collagen solution and adjunction of NaCl, followed by washings and dryings of the resulting precipitate with acetone aqueous solution with concentrations of from about 80% up to about 100%.
The mesh was coated by immersion in the solution, followed by wringing and drying the textile under a laminar air flow. At the end of the enduction process, the collagen coating on the textile was reticulated by an aqueous solution of glutaraldehyde at about 0.5% m/V (Fluka, Glutaraldehyde about 25%), at pH about 6.5 to about 7.5, over a period of about 2 hours. A reduction with sodium borohydrate was then performed. The reagents in excess were washed several times with water and rinsed.
Example 3
The molecular weight, polydispersity and structure of the fucan TH90 RED A2 0305 PUF30, was physicochemically characterized via Gel Permeation Chromatography (GPC, on a Column Zorbax G-F450 associated with a column TSK G2000 SW XL), Infra Red analysis (FTIR, on a Perkin Elmer 1600) and elemental analysis. This fucan had a low molecular weight (M n about 12,000 to 17,000 g/mol), and a polydispersity index of about 1.78. The FTIR showed that the extraction process was reproducible and stable. Elemental analysis indicated that the sulfate content was about 25%. Furthermore, the final depyrogenation process utilized to obtain a pharmaceutical grade fucan did not alter the main molecule, as confirmed with GPC, FTIR and elemental analysis.
Example 4
In order to use the fucan with a mesh, the fucan of Example 3 was mixed with the collagen solution of Example 2 prior to application to the mesh of Example 1. Two concentrations of fucan were incorporated in the collagen solution: about 0.1% (m/V), sometimes referred to herein as “High Dose”, and about 0.01% (m/V), sometimes referred to herein as “Low Dose”. The coating of the yarns was performed as described above in Example 2.
In vitro assays were conducted in which about 1.5 mm diameter collagen-fucan disc shaped samples were prepared as models. The collagen-fucan films at a fucan concentration of about 0.1% contained about 250 μg of fucan, while the films at a fucan concentration of about 0.01% contained about 25 μg of fucan.
Fucan leaching from the collagen film was studied using High Pressure Liquid Chromatography (HPLC on a Dionex Carbo Pac 100).
Measurements were performed on the extracts of the collagen in combination with the collagen-fucan Low Dose after several hydration times of from about 20 minutes to about 96 hours in PBS buffer solution (Na 2 HPO 4 , 7H 2 O at about 0.726 g/L, NaCl at about 9 g/L, KH 2 PO 4 t about 0.21 g/L, [PBS Gibco, Invitrogen ref 20012-019] from Gibco, Life Sciences), at about 37° C. The results are set forth in FIG. 1 .
As can be seen in FIG. 1 , about 50% and about 70% of the incorporated fucan was released during the first 24 and 48 hours, respectively, of hydration in the PBS medium.
From these results, it can be seen that the fucan on the mesh may possess both local and diffuse effects during the first phase of implantation, which is the critical phase, in terms of immune and adverse reaction due to the surgery.
Moreover, incorporation of the fucan in a collagen film did not significantly alter its physico-chemical properties, in the case of fucan concentrations of less than about 0.1% (m/V).
Example 5
A mediated bacterial adhesion assay involving the fucan in collagen as described above in Example 4 was conducted. Cultures of the bacterial strain S. aureus (ATCC 6538; Gram+) were prepared by incubating a well-isolated representative colony selected from an agar plate in about 1 ml of broth at about 37° C. overnight.
Bacteria were harvested from this saturated bacterial suspension by centrifugation at about 3500 revolutions per minute (rpm) for about 15 minutes. After discarding the supernatant, the bacterial pellet, about 10 7 colony forming units (cfu)/ml, was suspended in about 1 ml of fresh broth and about 100 μL of tritiated thymidine (from Amersham, activity about 1 mCi/ml) was added. The resulting bacterial suspensions were incubated for about 3 hours at about 37° C. to obtain bacteria in the exponential growth phase. After the incubation period, the bacterial suspension was harvested twice at about 3500 rpm for about 15 minutes to remove the excess unbound radioactive thymidine.
A solution of PBS with Ca ++ and Mg ++ was then added to the bacterial pellet to obtain suitable bacterial dilutions (about 10 6 -10 7 cfu/ml) and the bacterial suspension was homogenized using a vortex-mixer.
Collagen from Example 2 and collagen-fucan Low Dose samples from Example 4 were utilized to prepare films. The films were first coated with plasma constituents and then incubated with about 500 μl of PBS for about 50 hours under stirring.
About 500 μl of the washed-log phase radiolabeled bacterial suspension (about 10 6 -10 7 cfu/ml) described above was then added to the films. The bacterial suspension on the film was incubated for about 3 hours at about 37° C. After about 5 washings with PBS buffer, each sample was transferred to counting vials; about 10 ml of scintillation fluid (Optiphase Hisahe, EG and G) were added; the amount of bacteria which adhered onto the implants was measured using an automatic β-liquid scintillation analyser model (Tri CARB 2100 TR (Packard IND 1401)).
In order to check that the investigated bacteriophobic activity was due to the fucan, additional collagen films (with and without fucan) were first coated with plasma constituents and incubated with a mixture of about 500 μl of the above washed-log phase radiolabeled bacterial suspension (about 10 6 -10 7 cfu/ml) in combination with about 500 μl of a solution of collagen-fucan Low Dose implant extracts obtained after about 50 hours of incubation in PBS buffer at about 37° C. The resulting mixture was incubated for about 3 hours at about 37° C. After about 5 washings with PBS buffer, each sample was transferred to counting vials; about 10 ml of scintillation fluid (Optiphase Hisahe, EG and G) were added; the amount of bacteria which adhered onto the implants was measured using an automatic β-liquid scintillation analyser model Tri CARB 2100 TR (Packard IND 1401).
The results are set forth in FIG. 2 , which shows the bacterial adhesion on collagen and collagen-fucan films. In FIG. 2 , the two bar graphs for (a) demonstrate the adhesion of S. aureus on collagen (C) and collagen-fucan Low Dose (CF) films; the three bar graphs for (b) demonstrate the adhesion of S. aureus on a control of porous polypropylene (T′), collagen films (C′) and collagen-fucan Low Dose films (CF′) in the presence of collagen-fucan Low Dose extracts.
As can be seen in FIG. 2 , the bacterial adhesion was more prevalent on the control and was statistically different than bacterial adhesion obtained on collagen films. Moreover, as can be seen in FIG. 2( a ), films possessing fucan incorporated into collagen demonstrated a decrease in bacterial adhesion. The inhibition rate reached an average value of about 37% (after a period of incubation of about 50 hours in buffer).
In the case of the extract diffusion, an inhibition of bacterial adhesion on the three types of implants was observed (see FIG. 2( b )). Bacterial adhesion inhibition reached an average value of about 40%, which was nearly equal the rate obtained for the first experiment (about 37%). The bacterial inhibition obtained on T′ (textile alone) was less (about 31% inhibition) as compared to the one observed on C′ (collagen film) and CF′ (Low Dose film).
The above results demonstrate that the fucan was released from the collagen-fucan Low Dose film during the first 50 hours, and was responsible for the inhibition of adhesion.
Example 6
In vivo experiments were conducted to check the antibacterial properties of a collagen-fucan implant in a rat contaminated model.
About 2.5×3.5 cm shaped composite implants were constructed with the two-dimensional non biodegradable textile of Example 1. Multiple implants were prepared; some possessed a collagen film coating as described in Example 2, while others possessed a collagen-fucan film coating as described in Example 4. The implants were implanted in rat peritoneal cavities at the site of a preformed 1.5×2.5 cm parietal defect. The implants were sutured with 6 points and the surgery was ended with suture strand. High virulence E. coli bacteria were inoculated (10 9 bacteria in 2 mL of phosphate buffer Na 2 HPO 4 , 7H 2 O; 0.1M; pH 7.2 [PBS, Invitrogen 20012-068]) by means of a percutaneous injection in the region of the implant/defect.
After time periods of about 2 days and about 30 days, the rats were sacrificed and the meshes explanted. The proliferated bacteria were detached from the explants and cultured on agar gelose before being counted. Immunohistology was also performed in order to identify the bacteria.
Fucan, at high dose, inhibited bacterial proliferation after 30 days (2 logs of inhibition). No significant effect was observed after 2 days of incubation. The results are summarized in Table 1 below.
TABLE 1
# of Rats
Mesh reference
Timing
E. Coli
7
Textile*
J2
5.43E+08
7
Textile High Dose**
J2
2.73E+08
7
Textile Low Dose***
J2
5.17E+08
7
Textile*
J30
9.43E+10
7
Textile High Dose**
J30
1.74E+09
5
Textile Low Dose***
J30
8.28E+10
J2 = rats sacrificed after 2 days
J30 = rats sacrificed after 30 days
*Textile - mesh with collagen coating
**Textile High Dose = mesh with collagen and High Dose fucan coating
***Textile Low Dose = mesh with collagen and collagen-fucan Low Dose coating
Example 7
In-vitro cell culture characterization. The effects of fucans, incorporated in the collagen films as described above in Example 4, were analyzed at several concentrations on several different cells and their effects on cell proliferation were studied. The cells tested included fibroblasts, mesothelial cells, mesenchymal stem cells, urothelial cells, endothelial cells and smooth muscle cells (SMCs).
Normal human dermal fibroblasts (NHDF, Cambrex CC2511) were cultured in Dulbecco's Modified Eagle's Medium (DMEM, Cambrex CC3132) supplemented with about 10% fetal calf serum (FCS, Fischer 10270106), about 1% Fungizone (Fischer 15290026) and about 1% Penicillin/Streptomycin (Fischer 15140122). Cells were maintained in a controlled atmosphere (about 37° C., about 95% relative humidity and about 5% CO 2 ). All the experiments were carried out using cells with passage numbers of less than about 25 (passage=treatment with trypsin-ethylenediamine tetraacetic acid (EDTA)).
NHDF were grown onto the collagen-fucan film of Example 4, which included a collagen based gel associated with different concentrations of fucan, optionally associated with a 2D textile of Example 1. Cell growth was studied for about 7 days. Each experiment was repeated 3 times. The results of this experiment are set forth in FIG. 3 , which shows the fibroblast growth on collagen-fucan TH90 RED A2 0305 PUF 30. As depicted in FIG. 3 , G0, G0.01, G0.05 were collagen film without textile containing respectively about 0%, about 0.01%, and about 0.05% (m/V) of fucan; T0, T0.01, T0.05 were composite collagen films/2D textiles containing respectively about 0%, about 0.01%, and about 0.05% (m/V) of fucan.
The fibroblasts demonstrated an affinity for the collagen-fucan surfaces (see FIG. 3 ). The optimal concentration was evaluated at about 0.01% (m/V) of fucan in the collagen solution, i.e., a non degrading concentration for the physical integrity of the film.
The presence of the textile reduced the cell adhesion and proliferation rate. This may be due to the surface properties (e.g., planarity) induced by the presence of the textile, as well as differences in the degradation rate of the film and its impact on the cell adhesion and proliferation.
Example 8
Cell migration is a major process in tissue repair and wound healing. Cell migration was studied using a Boyden chamber assay through inserts with 8 μm pores. A depiction of a Boyden chamber is set forth in FIG. 4 .
Cells were suspended in culture medium and added to the upper chamber of the assay wells. Migration assays were performed in the presence of fucan matrices (T0, T0.01, G0, G0.01 as described above in Example 7), polypropylene (PP) or polyethylene terephthalate (PET) in the lower chamber. The chemotactic response to fucan was determined for fibroblasts. Positive controls were performed (migration in presence of about 20% fetal calf serum (FCS, Fischer 10270106)).
The results are presented in FIG. 5 , which demonstrates the chemotactic response of fucans on fibroblasts. As can be seen in FIG. 5 , the migration of fibroblasts was stimulated in presence of fucans (comparison between G0.01 and G0 and between T0.01 and T0). The same effect was observed when fucan was released from the matrix including polypropylene and collagen (T0.01) or from the sole collagen matrix (G0.01), and reached about 60%.
No statistical difference was observed when the fibroblasts or mesothelial cells migrated in the presence of PP or PET matrices in the medium.
Example 9
The anti-complement activity of fucans was tested via a CH50 test, a standard hemolytic assay in total human serum.
Complement activation in human serum was induced by the introduction of sheep erythrocytes coated with rabbit antibodies and then recognized as foreign elements. This led to the activation of the classical pathway of the complement system, and hence to the lysis of erythrocytes.
The amount of released hemoglobin was then determined by an optical density (OD) measurement at about 414 nm. The human serum dilution was adjusted for a known amount of erythrocytes, in order to lyse about 50% of the red blood cells (CH50).
In order to check the impact of the fucan on the complement activation in solution, the fucan was added with the sheep erythrocytes. A decrease in cell lysis, as evidenced by a decrease of the OD at about 414 nm, demonstrated that the fucan inhibited the complement activation.
Heparin (heparin H108 173 UI/mg, Choay-Sanofi) and fucan P240 RED synthesized in the Laboratoire de Recherche sur les Macromolecules (LRM, CNRS UMR 7540, France) were also tested instead of fucan.
The results are set forth in FIG. 6 , which depicts the anti-complement activity of heparin H108, P240 RED and fucan TH90RED A2 0305 PUF 30 in solution.
As can be seen in FIG. 6 , the fucan TH90RED A2 0305 PUF30 like its precursor P240 RED, presented dose-dependent anti-complement activity; both had an IC50 (median inhibition concentration) of about 4 μg/mL, evidencing a strong anti-complement activity as compared with the reference heparin H108 (IC50 about 30 μg/mL as measured in this test).
Example 10
In order to check the in-vivo integration of composite implants made of a 3D non biodegradable textile (PET) associated with a collagen film and collagen-fucan film, an intraperitoneal implantation in rat peritoneal cavity was performed. 2 sites in 25 rats were implanted with 3 kinds of implants: collagen/textile implant, as a control; collagen-fucan Low Dose/textile implant; and collagen-fucan High Dose/textile implant.
The mesh integration and associated adherences were observed after about 3 days, about 5 days, about 7 days, and about 6 weeks, by both macroscopic and immunohistological observations.
The results of the histological analysis of explanted composite implants is set forth in FIG. 7 which depicts images of tissue obtained by histological observation. As can be seen in FIG. 7 , after 3 days of implantation better integration of the mesh associated with the collagen-fucan Low Dose was observed compared with the composite control. The mesh containing the collagen-fucan Low Dose (0.01% (m/V)) showed multiple layers of fibroblastic cells after about 3 days of implantation. Statistical differences were observed for tissue integration between the collagen-fucan Low Dose and control.
The following days (see day 5 data and day 7 data on FIG. 7 ) presented a faster integration of the mesh associated with the collagen-fucan Low Dose compared to the composite control, with comparable inflammatory reactions. Integration of all the meshes was observed about 7 days after implantation. The moderate inflammatory reactions observed did not prevent the final integration of the mesh.
No data were available for the collagen-fucan Low Dose implant at 6 weeks, because the rat died during the experiment. This death was not due to the experiment.
While the above description contains many specifics, these specifics should not be construed as limitations on the scope of the disclosure herein but merely as exemplifications of particularly useful embodiments thereof. Those skilled in the art will envision many other possibilities within the scope and spirit of the disclosure as defined by the claims appended hereto. | A mesh implant is disclosed which may be utilized for treating urinary incontinence, hernias, uterovaginal prolapses and other related injuries. | 0 |
FIELD OF THE INVENTION
[0001] The invention relates generally to carabiner-type attachment devices, and more particularly, to a carabiner-type attachment device having further use as a standard tool, such as, but not limited to, a tape measure or a screwdriver/allan wrench.
BACKGROUND OF THE INVENTION
[0002] Carabiners have long been in use for providing a means for attaching articles to each other. Such devices have numerous applications, such as for example enabling articles to be quickly and easily secured to a backpack, purse, handbag, key chain, belt loop, utility belt, or the like. U.S. Pat. No. 5,005,266 discloses a typical carabiner-type attachment device.
[0003] It is also known that combination tools are useful. For example, the Swiss Army knife concept of taking a known item, such as a knife, and enhancing it through the incorporation of various types of other tools, such as, screwdrivers, combs, toothpicks, scissors, tweezers, eating utensils, can openers, and the like has been around for years. In some instances it has even been known to combine specific types of tools, such as knives and flashlights, as part of the standard construction of a carabiner; i.e., as one of the three legs of the carabiner body (see U.S. Pat. Nos. 5,270,909 and 6,223,372 and www.demstore.com and www.branders.com). It has further been known to combine a carabiner attachment device with standard items used everyday by individuals, such as radios (see U.S. Design Pat. No. D459,338), compasses (see www.advantageindustries.com), and watches and chronometers (see U.S. Pat. No. 6,527,434 and U.S. Design Pat. No. D469,023 and www.promoplace.com).
[0004] Such prior art, while useful in their own right for achieving their specific purposes, are simply not what is disclosed in the subject invention, and so have no adverse bearing thereon.
[0005] As it is thus desirable to have the above types of items/tools made easily attachable/detachable to other items through the use of a carabiner-type construction, it would also be desirable to have items/tools such as a tape measure and an interchangeable head screwdriver/allan wrench made easily attachable/detachable through use of a carabiner-type attachment mechanism.
SUMMARY OF THE INVENTION
[0006] In accordance with the invention, a carabiner tool assembly is provided. The tool assembly comprises in one embodiment a body portion for storing a tool having a longitudinal length and a carabiner assembly. The body portion comprises an outside shell forming an interior chamber and an opening extending through the outside shell through to the interior chamber, the opening being sized to be only slightly larger than needed to pass the tool through in a direction along the longitudinal length of the tool. The carabiner assembly comprises a first leg having a selectively openable gate assembly, the first leg extending from a first section of the body portion. A second leg extends from a second section of the body portion and a third leg extends between and connects the first and second legs, wherein the first, second and third legs of the carabiner assembly define another opening. The carabiner assembly can also have only two legs.
[0007] It is an object of the present invention to provide an improved tool assembly.
[0008] It is another object of the present invention to provide an improved tool assembly having a carabiner-type attaching mechanism.
[0009] It is yet another object of the present invention to provide an improved tool assembly wherein the tool is a screwdriver having a carabiner-type handle assembly.
[0010] Still a further object of the present invention is to provide an improved tool assembly wherein the screwdriver comprises a plurality of interchangeable screwdriver heads, and/or allan wrench-type bit heads.
[0011] It is still an additional object of the invention to provide an improved tool assembly wherein the tool is a tape measure having a carabiner-type handle assembly.
[0012] Other objects of the invention will in part be obvious and will in part be apparent from the following description.
[0013] The invention accordingly comprises assemblies possessing the features, properties and the relation of components which will be exemplified in the products hereinafter described, and the scope of the invention will be indicated in the claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] For a fuller understanding of the invention, reference is made to the following description, taken in connection with the accompanying drawings, in which:
[0015] FIG. 1 is a side elevational view of a first embodiment of the tool assembly of the present invention, showing in cut out the plurality of screwdriver heads in the body;
[0016] FIG. 2 is a bottom plan view of the tool assembly of FIG. 1 ;
[0017] FIG. 3 is a side elevational view of a second embodiment of the tool assembly of the present invention, showing in cut out the measuring tape in the body; and
[0018] FIG. 4 is a bottom plan view of the tool assembly of FIG. 3 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0019] In the following description, for purposes of explanation, specific numbers, materials and configurations are set forth in order to provide a better understanding of the invention. It will be apparent, however, to one having ordinary skill in the art that the invention may be practiced without these specific details. In some instances, well-known features may be omitted or simplified so as not to obscure the present invention. Furthermore, reference in the specification to “one embodiment” or “an embodiment” means that a particular feature, structure or characteristic described in connection with the embodiment is included in at least one embodiment of the invention. The appearances of the phrase “in one embodiment,” if any, in various places in the specification are not necessarily all referring to the same embodiment.
[0020] Referring now to the figures, it is seen in FIGS. 1 and 2 that a tool assembly 10 is provided. Tool assembly 10 is comprised of body section 20 and carabiner-type handle section 50 .
[0021] Body section 20 is of a cylindrical/bulbous shape, which shape allows it to store therein a tool 80 . Tool 80 in the embodiment shown in FIGS. 1 and 2 comprises a plurality of screwdriver heads. In a preferred embodiment, the plurality of screwdriver heads is four (4) screwdriver heads 82 , 84 , 86 and 88 (hereinafter “ 82 - 88 ”), with two of these heads being flat head screwdrivers and the other two being philips head screwdrivers. For purposes of the figures, it makes no difference which of heads 82 - 88 are flat and which are philips. It is further to be understood that of the two flat head screwdrivers and two philips head screwdrivers, one will be smaller while the other is larger. This “size” differentiation between the screwdriver heads 82 - 88 does not refer to the length of the screwdriver head, and also does not refer to the width of the screwdriver head, but instead refers to the size of the tips of the flat and philips head portions, so that different size screw heads are more easily accommodated. In another embodiment heads 82 - 88 may comprise allan wrench-type tips or other tips known in the art, and/or a combination of screwdriver heads and allan wrench-type bit heads.
[0022] Body 20 also has an opening 90 extending therethrough from its outside surface to the inner chamber thereof. For purposes of interchangeable placement into opening 90 of body 20 , heads 82 - 88 are all of substantially the same longitudinal length L and width W. In this way, head 82 may be placed into opening 90 of body 20 for use in attending to insertion or removal of a screw, and then once the screw is all the way in or all the way out, head 82 can be removed from opening 90 and head 86 can substitute therefore, when, for example, a larger or smaller thread size is needed for a larger or smaller threaded screw, or if one needs to switch from a philips/flat head to a flat/philips head, or to an allan wrench-type head.
[0023] Heads 82 - 88 are held within opening 90 in manners known in the art; for example, by octagonal or hexagonally shaping the width W of these heads to correspond to the walls of opening 90 having a similar receiving shape (not shown). Raised nubs 92 may be placed on one, or multiple, of the flat surfaces of the longitudinal length of the portion of heads 82 - 88 that go into opening 90 , in order to retain the heads within opening 90 , as is also known in the art.
[0024] Finally regarding body 20 of tool assembly 10 of the embodiment of FIGS. 1 and 2 , plurality of heads 80 may be received onto/into a slidable drawer 94 . Drawer 94 is designed to hold all of the plurality of heads 80 , and is able to be selectively slid into and out of body 20 for secure holding within body 20 of the heads, or for removal of the heads from body 20 for use in opening 90 , respectively. It is to be understood that the invention is also meant to cover other manners of storing plurality of heads 80 within body 20 of tool assembly 10 . Such other types of constructions might consist of providing a pivotable door that opens outwardly (not shown) from one side of body 20 for access into the interior chamber of body 20 where heads 80 are stored between their various usages. Yet another type of construction for access into the interior chamber of body 20 to remove and/or replace heads 80 would be to use a sliding door (not shown) on one, or both, sides of body 20 . Other similar types of constructions are anticipated herein.
[0025] It is also to be understood herein that the tool may be comprised solely of one tool bit received within opening 90 . In this regard, if the tool is a screwdriver head, it can be either a flat or philips head bit, or a dual-head screwdriver bit having screwdriver heads on either side, as for example, two flat heads or two philips heads or even a flat head on one side and a philips head on the other side. The tool can even be in the form of an allan wrench-type bit head, or a dual-sided allan wrench-type bit head. In such an embodiment, no storage component is anticipated, although one might exist.
[0026] Turning now to the embodiment of FIGS. 3 and 4 , we are again faced with tool assembly 10 having a body portion 20 and a carabiner-type handle portion 50 . In this embodiment, however, tool 80 ′ is a measuring tape. Measuring tape 80 ′ is located within body 20 in the inner chamber and is preferably rotatably mounted around a dowel 96 .
[0027] In this embodiment of tool assembly 10 , it is anticipated that the assembly operate as a typical tape measure, whereby the spool of measuring tape 80 ′ has a leading edge 100 extending out from an opening 90 in body 20 and that a user of assembly 10 will simply need to pull on leading edge 100 in the normal use of a tape measure. In this embodiment, opening 90 is sized so as to just allow the longitudinal length of measuring tape 80 ′ to extend therethrough, yet being smaller in size than the size of an end cap 102 on leading edge 100 . In this way, end cap 102 acts as a full retraction prevention device since it prevents leading edge 100 from automatically retracting all the way into the inner chamber of body 20 once measuring tape 80 ′ is released.
[0028] It is further understood herein that tool assembly 10 may comprise another retraction prevention device 94 located along an outside surface of body 20 which, as is known in the art, will exert pressure onto/against measuring tape 80 ′ to prevent it from automatically retracting around dowel 96 when tape 80 ′ is released by a user. Other constructions of a standard operating tape measure are anticipated herein.
[0029] It is also anticipated herein that tool assembly 10 can be made of any of the well known standard materials for making the same, including metal, metal alloys, rigid plastics, and/or other such known materials.
[0030] It is also to be understood herein that assembly 10 will in its normal construction be made from two separate halves 12 and 14 that are adhered together in manners known in the art for adhering such materials as metals and/plastics; such as, but not limited to, using adhesives and/or screws. While body 20 may be so sealed together, it is understood that opening 90 is not sealed, and instead allows receipt of tools 80 and 80 ′ therethrough.
[0031] Turning now to a discussion of carabiner-type handle assembly 50 , it will be seen that carabiner 50 in a preferred embodiment has a first leg 60 , a second leg 70 , and a third leg 74 . First leg 60 has gate assembly 62 extending therealong as an integral part thereof. Gate 62 is constructed in the known ways of making carabiner gates which are automatically closable upon release, including using spring-loaded mechanisms or a flexible gate construction. If using a flexible gate construction, arm 61 of gate 62 is molded of a flexible material having a “memory” for its starting position, so that after arm 61 is bent and gate 62 is opened, arm 61 will return to the closed position after it is released by the user. In these particular embodiments, pivot element 64 of gate assembly 62 is on portions of first leg 60 closer to body 20 than to third leg 74 . In this manner, gate assembly 62 opens closer to third leg 74 allowing for easier attachment of assembly 10 onto such items as belt loops, utility belts, handbags, etc., as well as removal thereof.
[0032] Unless otherwise expressly indicated, when used throughout this document the term “substantially” shall have the meaning, “being largely but not wholly that which is specified.” See, Webster's Ninth New Collegiate Dictionary, Merriam-Webster Inc., 1989. Hence, applicant is not using the term “substantially” to denote “considerable quantity” or “significantly large,” but is instead using the term as a qualifier/minimizer of a term. For example, in the phrase “the head portion is substantially above the body portion,” “substantially above” is meant to indicate that most of the head portion is located above the body portion, but there might be some of the head portion located in planes with the body portion, or even below parts of the body portion. As a further example, the phrase “substantially hollow,” is meant to indicate that the item is almost totally hollow, but there might be small areas where it is not. These examples are meant to be illustrative of the meaning to be attributed to the term “substantially” as used throughout this document, even if these particular phrases are not found herein.
[0033] It is also to be understood that when used throughout this document the phrase “at least one” is meant to mean one or more.
[0034] It will thus be seen that the objects set forth above, among those made apparent from the preceding description, are efficiently attained, and since certain changes may be made in the above constructions without departing from the spirit and scope of the invention, it is intended that all matter contained in the above description and shown in the accompanying drawings shall be interpreted as illustrative and not in a limiting sense.
[0035] It is also to be understood that the following claims are intended to cover all of the generic and specific features of the invention herein described and all statements of the scope of the invention, which, as a matter of language, might be said to fall therebetween. | A carabiner tool assembly is provided. The tool assembly comprises in one embodiment a body portion for storing a tool having a longitudinal length and a carabiner assembly. The body portion comprises an outside shell forming an interior chamber and an opening extending through the outside shell through to the interior chamber, the opening being sized to be only slightly larger than needed to pass the tool through in a direction along the longitudinal length of the tool. The carabiner assembly comprises a first leg having a selectively openable gate assembly, the first leg extending from a first section of the body portion. A second leg extends from a second section of the body portion and a third leg extends between and connects the first and second legs, wherein the first, second and third legs of the carabiner assembly define another opening. The carabiner assembly can also have only two legs. | 5 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to forming an executable program using a linker, and in particular to the use of symbol attributes when forming an executable program.
2. Description of the Related Art
Linkers for producing executable programs are known. Generally speaking, a linker acts to link a number of object code modules to form a single executable program. Object code modules are usually generated from program source code modules, these modules being written in a high level language. An assembler/compiler reads each source code module and assembles and/or compiles the high level language of the source code module to produce an object code module. The assembler also generates a number of relocations which are used to combine the object code modules at link time in a linker.
The ELF (executable linking format) standard defines a convention for naming relocation sections belonging to a given section, e.g., rela.abc is relocation section of section .abc. Standard relocations under the ELF format allow an offset in section data to be defined where patching is to occur and a symbol whose value is to be patched. A type field also exists which is used to describe the appropriate method of encoding the value of the symbol into the instruction or data of the section data being patched. According to the existing arrangements, the relocation type definitions are usually created on an ad hoc basis for each instruction set targeted. The 32-bit ELF standard allows only 256 distinct relocation types, so the same types are reascribed to different semantics for each instruction set.
SUMMARY OF THE INVENTION
The disclosed embodiments of the present invention provide a method of linking a plurality of object code modules to form an executable program, each object code module including section data, a set of relocation instructions and one or more symbols, each symbol having a plurality of attributes associated therewith, wherein the relocation instructions include a data retrieval instruction having a symbol field identifying a symbol and an attribute field identifying a symbol attribute associated with the identified symbol to be retrieved, the method including: reading at least one relocation instruction from the set of relocation instructions and where the relocation instruction is a data retrieval instruction, determining the symbol identified by the symbol field and retrieving one of the plurality of symbol attributes associated with the symbol in dependence on the contents of the symbol attributes field of the instruction.
There is also provided a method of linking a plurality of object code modules to form an executable program, each object code module including section data, a set of relocation instructions and one or more symbols, each symbol having a plurality of symbol attributes associated therewith, the symbol attributes including the symbol value, wherein the relocation instructions include a data retrieval instruction having a symbol field identifying one of the symbols and an attribute field identifying one of the plurality of symbol attributes associated with the identified symbol to be retrieved, the method including: reading at least one relocation instruction from the set of relocations; recording a pass value indicative of the number of times the set of relocation instructions have been read; where the relocation instruction is a data retrieval instruction, identifying the symbol identified by the symbol field, determining if the associated symbol value has been retrieved by a further data retrieval instruction during the current or previous repetition of the set of relocation instructions, and responsive to the determination, placing a predetermined value in a store.
There is additionally provided a computer program product for linking a plurality of object code modules to form an executable program, the computer program product including program code having section data, a set of relocation instructions and one or more symbols, each symbol having a plurality of attributes associated therewith, wherein the relocation instructions include a data retrieval instruction having a symbol field identifying a symbol and an attribute field identifying a symbol attribute associated with the identified symbol to be retrieved, the program code arranged so that, when run on a computer, the steps of the method defined herein are performed.
There is further provided a computer program product for linking a plurality of object code modules to form an executable program, the computer program product including program code having section data, a set of relocation instructions and one or more symbols, each symbol having a plurality of symbol attributes associated therewith, the symbol attributes including the symbol value, wherein the relocation instructions include a data retrieval instruction having a symbol field identifying one of the symbols and an attribute field identifying one of the plurality of symbol attributes associated with the identified symbol to be retrieved, the program code arranged so that, when run on a computer, the steps of the method defined herein are performed.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
For a better understanding of the present invention and to show how the same may be carried into effect, reference will now be made by way of example to the accompanying drawings.
FIG. 1 is a block diagram illustrating the context of the invention;
FIG. 2 is a sketch showing the layout of bit and non-bit relocations;
FIG. 3 is a block diagram of a linker for use with embodiments of the present invention;
FIG. 4 is a schematic diagram illustrating one example of the use of relocations to retrieve symbol attributes;
FIG. 5 is a schematic diagram illustrating one example of storing a variable value when a symbol attribute is retrieved; and
FIG. 6 is a schematic diagram illustrating an example of examining a symbol attribute and placing a value on a store in dependence of the outcome of the examination.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring initially to FIG. 1 , a system for linking a number of program modules to form a single executable program is shown schematically. A number of program source code modules 1 a, 1 b, each module written in a high level language, is provided. The particular high level language used for each source code module may vary from module to module, or alternatively all of the program source code modules may be written in the same high-level language. Each source code module 1 a, 1 b, is input to a respective assembler/compiler 2 a, 2 b which assembles and/or compiles the high level language of the source code module to produce an object code module 3 a, 3 b. Each object code module 3 a, 3 b is the low level language equivalent to each respective source code module 1 a, 1 b, the low level language being a language which is directly executable by a target microprocessor into which the final resulting single executable program is to be loaded. It will be appreciated that a single assembler/compiler could be used to sequentially convert a number of source code modules to respective object code modules.
Each object code module 3 a, 3 b is passed to a linker 4 . Object code modules may be stored in libraries, such as the library 6 in FIG. 1 , placed under the control of an archive tool 7 . The linker combines all of the respective object code modules 3 a, 3 b to produced single executable programs, still in the low level language suitable for the target processor into which the program is to be loaded.
For a given architecture there are often different instruction sequences for achieving the same objective depending on the values of the operands that are being handled. For example, “load a function address into a register” may be achieved in various ways depending on the address in question. When the operand is unknown before link time there is scope for re-writing the code at link time depending on the value of the operand. This re-writing of the code is a form of optimization termed herein “linker relaxation.” In United Kingdom Patent Application No 9920905.8 in the name of the present applicant, a scheme is described for an achieving linker relaxation based on information written in assembler files and passed to the linker as special relocations, which is incorporated herein by reference in its entirety. The special relocations are also used for rewriting particular instruction sequences as one of a set of known alternatives.
Each assembler generates an object code module that includes sets of section data, each set of section data having a set of relocations generated by the assembler to describe how the section data is to be patched so as to render it compatible with other section data to form the program 5 . These relocations are generated by the assembler. The section data includes a plurality of code sequences executable in the final program and data values to be accessed by the executing program.
In particular a set of “relocations” to enable link time optimization of code is described. Conventionally a relocation describes the patching of section data or instructions with (encoded versions of) symbols. Such relocations are referred to herein as “bit relocations.” In addition a number of so-called “special relocations” are discussed in GB 9920905.8 which are sometimes referred to in the following as “non-bit” relocations to distinguish from conventional “bit” relocations.
In particular, in GB 9920905.8 a “macro-call” relocation is defined that allows section data (code sequences) to be inserted from a special section (“.macro” section) written to contain frequently used idioms. Section data that is to be selectively inserted into a section being optimized by the linker can be thought of as a “link time macro.” It is parameterized by symbols with the substitution of the values for the parameters being performed by the linker.
One use of the macro-call relocation is to conditionally introduce selected instruction sequences from a number of alternatives into the executable program. The alternative instruction sequences are written as alternative sequences in the special macro section in the object code modules and a macro call is inserted at the point in the ordinary section wherein one or more of them may be needed. As mentioned above, the object code modules can be user defined or retrieved by the linker 4 from a library 6 as object files containing template code for insertion in the executable program wherever it is needed.
For the sake of completeness there follows the bit relocations and non-bit relocations, which are discussed in the earlier application previously referred to and which have application in embodiments of the present invention.
It is assumed that a skilled reader is familiar with the ELF format and so only a very brief description will be given here prior to describing the special relocations.
The ELF (executable and linking format) standard defines a convention for naming relocation sections belonging to a given section. For a section of name .xxx the standard prescribes relocation sections .rel.xxx and .rela.xxx. The structure of these sections is defined and a partial semantic associated with them. Specifically an entry in .rel.xxx has,
an offset field—the offset in the xxx section where the patching is to occur, a symbol field—the symbol whose value is to be patched, and a type field—an otherwise undefined type.
It is the type field that is used to describe the appropriate method of encoding the symbol value into the instruction or data of the .xxx section.
The .rela.xxx section is similarly defined but has an extra field (the addend) with the semantic that the addend is to be added to the symbol value before patching in.
In order to support the special relocations described herein, a new type of relocation section is defined, with the naming convention .relo.xxx which is specifically intended to support optimizing at link time. In this way the .rel and .rela sections are left free to be used for conventional bit relocations.
The format of an entry in the .relo section is given in Annex 1 (it should be read in the context of the 32-bit ELF standard). It is illustrated in FIG. 2 .
The underlying structure of the new type has an address field AF (r_offset), a 1 byte classification field CF (r_class), 3 information fields which are labeled reltype, S 1 , S 2 (1 byte each) for non-bit NB relocations and bit, bitstart, bytes for bit (B) relocations, and two one word arguments (r_arg 1 ; r_arg 2 ).
r offset
The location at which to apply the relocation action. (That is, if this is the .relo.xxx section, then r_offset is the offset in the .xxx section where the relocation applies.)
r class
The classification byte indicates the type of relocation (bit or non-bit), and also conveys information about the use of the remaining fields.
In the classification byte, bit 7 RT_BIT indicates a bit relocation if set (in which case the B fields apply) or non-bit relocation if clear (in which case the NB fields apply). Bits 3 – 6 specify whether the r_arg 1 , 2 fields are a symbol index or a value. Table 1 defines how the bits specify the interpretation of the r_arg 1 , 2 fields.
r_arg 1 , 2
The interpretation of these fields depend on bits 3 – 6 of the r_class field. Two bits RC_ARG 1 , RC_ARG 2 are associated with each of r_arg 1 and r_arg 2 . For bit relocations these two fields are normally used as symbol and addend.
For non-bit relocations the fields r_arg 1 , 2 hold constant data being passed with a non-bit relocation. As with bit relocations bits 6 and 5 say whether they hold a symbol index or a value. The actual use of any symbol or value passed with a non-bit relocation depends on the nonbit.reltype field. This may be an absolute value representing things such as alignment, register numbers etc. The semantics are given in the table of relocation types in Annex 2 .
The bit (B) type fields:
r.bit.bits
The number of bits that are to be patched. A lower case “b” is used to indicate this quantity in the name of a relocation.
r.bit.bitstart
The least significant bit to be patched. A lower case “s” is used to indicate this quantity in the name of a relocation.
r.bit.bytes
The size of the object being patched. This is needed for big endian targets in order to find which byte the least significant bit is to be found in, and where the higher order bits are. An upper case “B” is used to indicate this quantity in the name of a relocation.
Note that the following notation is used to name the bit relocations:
R_b<val>s<val>B<val>
where <oval>'s represent the number of bits, start bit and number of bytes as specified by the r-bits, r.bitstart, r.bytes fields. For example R_b16s0B4 will patch the least significant two bytes of a four-byte object. This will be the bytes at offsets 0,1 or 4,3 depending on the target endianness.
The non-bit (NB) type fields:
r.nonbit.reltype
This field describes what sort of action the linker must perform. These include such things as executing an operation on the linker's internal stack of values, storing parameters to macros, conditionally deleting section data etc, as described in more detail later.
r.nonbit.subtype 1 , 2 (S 1 ,S 2 )
These fields hold values whose interpretation depends on the reltype field, and bits 3 to 6 of the classification field.
TABLE 1
Name
RC_ARG1
Meaning
RC_PARAM
3
r_arg1 is param
RC_VAL
2
r_arg1 is value
RC_SYM
1
r_arg1 is symbol
RC_UNUSED
0
r_arg1 is unused
The new type of relocation section described in GB 9920905.8 supports a number of special relocations that allow a number of different functions to be performed by the linker. FIG. 3 is a block diagram of components of the linker which will be used to describe these additional functions. It will be appreciated that in practice the linker can be constituted by a suitably programmed microprocessor. It will be understood therefore that the schematic blocks shown in FIG. 3 are for the purposes of explaining the functionality of the linker.
The linker comprises a module reader 10 which reads a set of incoming object files as user written code modules and library object files from the library 6 . A relocation module 12 reads the relocations in the object code module. A section data module 14 holds section data from the object code module and allows patching to take place in response to relocation instructions in the object code module interpreted by the relocation module 12 . The relocation module can also interpret special relocations and apply these to the section data held in the section data module 14 . A program former 20 receives sequences from the section data module 14 and/or the library 6 depending on the actions taken by the relocation module 12 and forms the executable program 5 which is output from the linker 4 . The linker also includes a condition evaluator 22 that operates in conjunction with a stack-type store 24 . The condition evaluator reads the value of the top entry of the stack 24 .
The linker also implements three arrays or tables as follows, a parameter array 16 , a symbol table 17 , and a condition array 26 .
A number of the non-bit relocations allow code sequences to be conditionally included in a final executable program where all the possible alternative sequences are included in the section data of the object code module that the linker is currently examining. The code sequences that are not required are deleted at link time. The following are the non-bit relocations used to support conditional section data deletions, which are issued by the assembler responsive to special conditional Assembler Directives.
R IF
Causes the top entry to be popped from the linker's stack of values. When the value is zero, then section data is skipped and the succeeding relocations are ignored until R_ELSE/R_ENDIF is encountered. When the value is non-zero, then relocations are processed and instructions are not deleted until R_ELSE/R_ENDIF is encountered.
R ENDIF
Defines the end of the relocations subject to the R_IF relocations and of section data to be conditionally deleted subject to the R_IF relocation.
R ELSE
If this is encountered while section data is being taken, then section data is skipped and the succeeding relocations are ignored until R_EN_DIF is encountered. If encountered while skipped due to R_IF, then relocations are processed and instructions are no longer deleted until R_EN_DIF is encountered.
R STORE index
A value is popped from the linker's stack of values. It is put in a conditional array in the linker kept by the linker for this purpose. The value is stored at the index passed with the relocation. This relocation avoids the overhead of passing the same calculation to the linker many times over.
R FETCH index
A value is pushed on the linker's stack of values. The value pushed is the value in the condition array 26 at the index passed with the relocation.
A further set of non-bit relocations is defined for implementing macros.
R START MACRO
The linker seeks this relocation at the offset labeled by the macro name (relocations prior to this one are not processed). It is an error if the linker encounters this instruction except on entry to a macro.
R GET PARAM index
The relocation conveys an index for accessing a parameter array in the linker. The linker reads the index'th parameter from the parameter array. If the parameter is an index in the symbol table 17 of the linker, the symbol's value is pushed on to the linker's stack of values. Otherwise the value itself is pushed.
R EXIT MACRO
The linker stops inserting bytes/processing relocations from the .macro section. It discards the parameter array and then the macro invocation terminates.
Further non-bit relocations for Ordinary Sections include:
R PUT PARAM index
An index is passed to the linker and the value is stored by the linker in the parameter array at this index. The linker also stores the value of this relocation along with the parameter. This enables the linker to perform type checking when R_GET_PARAM is encountered.
R MACRO CALL symbol
The symbol specifies an offset in the macro section. The relocations in.relo.macro are traversed from the R START MACRO at the offset until R EXIT MACRO is processed. Section data from the macro section are inserted in the section at the location of the R MACRO CALL relocation.
In embodiments of the present invention described hereinafter a further special relocation type is described that allows arbitrary calculations to be passed to the linker by way of a number of special relocations that are defined by the reltype field of the new relocation format ELF 32 _relo and also allows various parameters to be pushed onto the linker stack.
To place the value of a constant onto the stack the following relocation may be used:
R-PUSH value
Equally the value of a symbol held in the symbol table 17 may be placed onto the stack by the use of the relocation:
R-PUSH symbol
The above relocations are implemented as described in the following with reference to FIGS. 3 and 4 . The relocation module considers the first relocation read by the module reader 10 , in this case R-PUSH symbol and reads the required value of the identified symbol from the symbol table 17 and pushes the value onto the top of the stack. The next bit relocation R-b16s0B2 patches the symbol value from the top of the stack into the 16-bit target integer.
The set of the special relocation types listed in Annex 2 allow the linker to support a general-purpose stack based calculator. These relocations allow the value of symbols and constants to be pushed on the stack 24 and a designated manipulation to be performed. With the bits RC_ARG 1 in the class field CF set to RC_UNUSED (see Table 1), binary operators act on the top two stack entries. Otherwise, the value passed and the top of stack (tos) entry are used. Unary operators operate on the top of the stack 24 (tos). Both pop their operands and place the result on the top of the stack. The full definition of the relocation types to support this is given in Annex 2 .
The following description describes a further novel Relocation Instruction, R_ATTRIB which allows other symbol attributes to be pushed onto the stack. The format of this further relocation is as follows:
R_ATTRIB symbol_attribute
This relocation pushes a specified attribute of the specified symbol onto the stack of the Linker. Each symbol in the symbol table may have a number of attributes associated with it which are held in separate symbol fields of the symbol definition in the symbol table. These associated attributes include:
i) The value of the symbol. To push the value of a symbol onto the stack the R_ATTRIB relocation is expressed as R_ATTRIB symbol_value. This achieves the same results as the R_PUSH value relocation. ii) The symbol itself. To push a symbol itself as a pointer to the symbol in the symbol table, the R_ATTRIB relocation is expressed as R_ATTRIB symbol_self. iii) The Binding of the symbol. This is held in a field BIND of the attribute relocation R_ATTRIB symbol_bind. Multiple definitions of a symbol may be generated, only one of which is selected at link time. The binding of a symbol may be either WEAK or STRONG and it is the symbol binding that allows one definition to be selected in preference to the other. The binding of a symbol may be generated by each assembler/compiler when each source code module is assembled/compiled. When multiple definitions are generated they may be given the WEAK binding attribute, indicating to the linker that if no STRONG definition is found any one of the WEAK symbol definitions may be chosen and all further references to that symbol point to the selected one. This particular use of the symbol binding may be referred to as a ranking determinator, although the binding field is also used for other purposes as well. The binding of the selected symbol is changed to the STRONG binding.
It will be appreciated by those skilled in the art that the binding attribute itself is already known and therefore requires no additional functionality to the linker described in FIG. 3 . It will also be appreciated that the further bindings LOCAL and GLOBAL also exist, allowing the following binding combinations to be given to symbol definitions;
i. WEAK/GLOBAL ii. WEAK/LOCAL iii. STRONG/GLOBAL iv. STRONG/LOCAL
The LOCAL/GLOBAL binding is used to indicate whether the symbol ‘fred’, for example, in object module 1 is the same symbol as the symbol ‘fred’ in object module 2 —to be considered the same they must both be GLOBAL.
The selection of the symbol definition in accordance with its binding is a further function provided by embodiments of the present invention and is performed by the linker. All the symbol definitions from the object code module are examined and where multiple definitions occur for the same symbol the following conditions are applied:
i. If more than definition has a STRONG binding a fatal error is deemed to have occurred and the link process is halted. ii. If all the definitions have a WEAK binding any one is selected on a substantially arbitrary basis, and its binding changed to STRONG. iii. If only one definition has a STRONG binding it is the definition that is selected.
The relocation R_ATTRIB symbol_bind pushes the binding of the symbol onto the stack.
iv. The REFERENCED symbol attribute. The corresponding R_ATTRIB relocation has the format R_ATTRIB symbol_referenced and causes the linker to push a 1 onto the stack if the symbol referred to has been previously referred to in an R_ATTRIB symbol_value instruction during either the current or previous pass of the linker. Otherwise a 0 is pushed onto the stack. How this is achieved is explained below.
As is known in the art, the linker may execute the linking and relocation process on the object code modules a number of times before the output target executable is in the optimum form. In embodiments of the prevent invention, the state of certain variables may be recorded during each linker pass.
Two such variables are LS-PASS and LS-CHANGE. LS-PASS is the number of times all of the relocation instructions in the object code modules have been executed, i.e., the number of passes the linker has made. It is incremented by 1 by the linker at each pass. LS-CHANGE is a flag and is set FALSE by the linker at the start of each pass and becomes TRUE if a symbol that refers to a set of section data changes its value. This indicates that the target executable program has changed. The variables LS PASS and LS CHANGE are updated by the linker 4 and are stored in the variable modules LS PASS 51 and LS CHANGE 52 , shown in FIG. 3 . These variables can be used as stack values by other relocations instructions to allow state variable based conditions to be determined.
A further function of an R_ATTRIB symbol_value relocation is to store the current value of the state variable LS_PASS in a further symbol field in the symbol table whenever the R_ATTRIB relocation is executed, as is shown schematically in FIG. 5 . The value of variable LS-PASS is fetched from the LS-PASS variable store 51 and placed in the pass number symbol field in the symbol table whenever an R-ATTRIB symbol_value instruction is executed. It is to be noted that in embodiments of the present invention the further symbol field SF-PASS is generated by the Linker in the symbol table 17 and that no additional information is stored in the object modules over standard ELF modules of the prior art.
With reference to the REFERENCED symbol attribute, when, an R_ATTRIB symbol_referenced instruction is subsequently executed the value of LS_PASS stored in the symbol field SF_PASS is retrieved, together with the current value of the state variable LS_PASS from the state variable module LS_PASS 51 . This is shown schematically in FIG. 6 . The relocation module 12 determines if the value of the symbol field SF_PASS is equal to or only one less than the value of the state variable LS_PASS and if so pushes a 1 onto the stack. Otherwise a zero is pushed onto the stack.
The inclusion of a symbol field which holds information relating to the number of passes executed by the Linker when the symbol's value was last read via the R_ATTRIB_symbol value relocation provides further advantages. In addition to allowing selected attributes to be pushed onto to the stack, the R_ATTRIB instruction and associated symbol fields allow section data labeled by unreferenced symbols to be eliminated at link time.
If it transpires that during linking a symbol is not accessed by a R_ATTRIB symbol value instruction, the value of the SF_PASS symbol field will remain at zero. Because of this such symbols will evaluate R_ATTRIB_symbol referenced as zero in subsequent passes. Consequently the user can instruct the linker to remove the section data that the symbol labels by using a conditional R_IF instruction as follows:
If it transpires that during linking a symbol is not accessed by a R_ATTRIB symbol value instruction, the value of the SF_PASS symbol field will remain at zero. Because of this such symbols will evaluate R_ATTRIB_symbol referenced as zero in subsequent passes. Consequently the user can instruct the linker to remove the section data that the symbol labels by using a conditional R_IF instruction as follows:
R_ATTRIB_-symbol=reference fred
R_INV
R_IF
.
.
{the section data labelled by fred}
.
.
R_END IF
If ‘fred’ is not referenced, the section data will not be included in the final program. (R_INV reverses 10 on the top of the stack.)
As mentioned above in connection with the symbol field BIND, multiple definitions of a symbol may be generated, only one of which is selected at link time. The remaining definitions are called Orphans and should ideally be deleted. However, even if the user instructs the linker to remove the duplicate definitions by writing R_ATTRIB_symbol_referenced and R_INV,R_IF as described above, the definitions will not be removed because the R_ATTRIB_symbol_referenced will have become a reference to the nominated symbol definition, not the duplicate definitions. To avoid this, when the Linker resolves the symbol references prior to actually linking the individual object code modules the symbols referenced in R_ATTRIB_symbol_refd instructions are treated specially: the original binding of a symbol is compared by the Linker with the binding of any selected symbol which is pointed to. If the binding differs, the R_ATTRIB symbol refd instruction referring to the orphan symbol is replaced by an instruction which pushes a 0 onto the stack, so that the definition associated with an orphan symbol may be deleted as described above.
From the foregoing it will be appreciated that, although specific embodiments of the invention have been described herein for purposes of illustration, various modifications may be made without deviating from the spirit and scope of the invention. Accordingly, the invention is not limited except as by the appended claims and the equivalents thereof.
Annex 1
typedef struct {
Elf32_Addr r_offset;
unsigned char r_class;
union {
struct {
unsigned char bits;
unsigned char bitstart;
unsigned char bytes;
} bit;
struct {
unsigned char reltype;
unsigned char subtype1;
unsigned char subtype 2;
} nonbit;
} r;
Elf32_Word r_arg1;
ELF32_Word r_arg2;
} Elf32_Relo;
Annex 2
Relocation Type Name
reltyp
Meaning (C syntax is assumed)
R_NONE
1
No action is performed.
R_NOOPTIMISE
2
Optimization will be turned off from r —
offset
R OPTIMISE
3
Optimization will be turned on from r —
offset
R_PROC
4
Marks start of PROC. One marker byte is
inserted at r_offset
R_ENDPROC
5
Marks end of PROC
R_MAX (signed)
6
tos=(arg1>arg2?arg1:arg2)
R_OR
7
tos=(arg1|arg2)
R_XOR
8
tos=(arg1{circumflex over ( )}arg2)
R_AND
9
tos=(arg1&arg2)
R_EQ
10
tos=(arg1==arg2)
R_NE
11
tos=(arg1!=arg2)
R_GT
12
tos=(arg1>arg2)
R_GE
13
tos=(arg1>=arg2)
R_LT
14
tos=(arg1<arg2)
R_LE
15
tos=(arg1<=arg2)
R_SHR
16
tos=(arg1>>arg2) note: arithmetic shift
R_SHL
17
tos=(arg1<<arg2)
R_ADD
18
tos=(arg1+arg2)
R_SUB
19
tos=(arg1−arg2)
R_MUL
20
tos=(arg1*arg2)
R_DIV
21
tos=(arg2/arg2) note: undefined if
arg2==0
R_REM
22
tos=(arg1%arg2) note: undefined if
arg2==0
R_PC
23
tos<−P
R_NEG
24
toss=−tos
R_INV
25
toss=~tos
R_REL
26
tos<−O
R_SIZE
27
tos<Sz section size
R_PUSH
28
tos<−symbol attribute or value. s1 holds
flag saying which symbol attribute value
to be pushed.
R_DUP
29
tos<−tos (duplicates the top of stack)
R_IF
30
if (!tos) section data is skipped
R_IF_FIXED
31
Worst case branch (only for .macro).
R_ELSE
32
see R_IF (not supported in .macro).
R_ENDIF
33
see R_IF
R_START MACRO
34
Informational, for error checking.
R_EXIT_MACRO
35
Linker stops inserting section data at r —
offset
R_PUT_PARAM
36
s1 holds index, s2 holds type information;
the linker associates r_arg with these
R_GET_PARAM
37
s1 holds index, s2 holds type information;
the linker retrieves the value associated
with these
R_STORE
38
s1 holds index; the linker associates the
value r_arg with the index for retrieval
via R_FETCH
R_FETCH
39
s1 holds index; the linker retrieves the
value associated with the index
R_MACRO_ALL
40
r_arg is a symbol in .macro section
whence to insert section data. One marker
byte is present at r_offset
Key
s1,s2 Mean the r.nonbit .subtype1,2 field of the relocation.
S Means the sum of r_arg1 and r_arg2 after interpreting them as symbol values or constant values according to RC_ARG1/2.
So The value of symbol's st_other field.
O Means the offset, relative to the base of the containing section, of the relocation entry symbol.
P The absolute address of the relocation entry, r_offset (i.e., the PC).
Sz Means the size of the relocation entry symbol's defining section.
tos Top-of-stack, the value at the top of the internal linker stack.
tos <− Pushes a 32-bit signed value onto the internal linker stack
tos=arg1 op arg2 If both RC_ARG1 and RC_ARG2 are RC_UNUSED then both the arguments are assumed to be on the stack (with arg1 pushed first). Otherwise arg1 is S (i.e., the symbol value + addend) and arg2 is tos. The argument(s) on the stack are popped and the operation indicated as op is performed. Finally the result is pushed on the stack. | A method of linking a plurality of object code modules to form an executable program, each object code module having section data, a set of relocation instructions and one or more symbols, each symbol having a plurality of attributes associated therewith, wherein the relocation instructions include a data retrieval instruction having a symbol field identifying a symbol and an attribute field identifying a symbol attribute associated with the identified symbol to be retrieved, the method including reading at least one relocation instruction from the set of relocation instructions and where the relocation instruction is a data retrieval instruction, determining the symbol identified by the symbol field and retrieving one of the plurality of symbol attributes associated with the symbol in dependence on the contents of the symbol attributes field of the instruction. | 6 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention:
[0002] The invention relates to a method for identifying an integrated circuit in which a digital identification word is provided in order to program programmable elements that are disposed on the integrated circuit.
[0003] Integrated circuits are provided with an individual identification in order to be identifiable. For example, semiconductor memories, in particular dynamic random access memories (DRAMs) are programmed with what is referred to as a chip ID so that the individual chip can be unambiguously identified during subsequent tests in the quality control system or in the application system when there are questions. The chip ID contains a multiplicity of bits in order to permanently provide information, for example, on the number of the manufacturing batch, the factory in which the chip was manufactured, electrical classifications and a serial number, on the integrated circuit itself. A chip ID can easily contain sixty or even more bits.
[0004] Programmable elements, also referred to as fuses or antifuses, are used to program the chip ID. The fuses and antifuses can be programmed by a laser pulse. Before the chip has been cast in the housing, the bits, which are intended to represent, for example, a logic “1” of the chip ID, are programmed with the laser and the other bits which are intended to represent a logic “0” are not programmed. A fuse has a low impedance or is conductive in the initial state and has high impedance or is not conductive in the programmed state. An antifuse is not conductive in the initial state and is conductive after the programming. The laser programming of the fuses and the antifuses can be carried out in a relatively reliable and stable fashion but has the disadvantage that a laser must be made available at a high cost and the programming can only be carried out before the encapsulation of the integrated circuit in a housing.
[0005] There have therefore been efforts to replace laser-programmable fuses and antifuses with electrically programmable fuses and antifuses. Such E-fuses and E-antifuses are programmed by electrical energy pulses, that is to say by impressing a sufficient current pulse given a correspondingly high programming voltage. The E-fuses and E-antifuses can also be programmed in chips that are already housed. The programming can be handled more flexibly by virtue of the completely electrical actuation of E-fuses/antifuses.
[0006] A disadvantage with the use of E-fuses/antifuses is however that an E-fuse still has a residual resistance after programming and an E-antifuse has only limited conductivity after programming. After programming E-fuses/antifuses a wide distribution of the conductivity values is therefore to be expected. Furthermore, it is disadvantageous that, owing to the aging of the semiconductor chip, the programmed conductivity changes in the course of time in the direction of the original initial state. The high impedance of a programmed E-fuse or the low impedance of a programmed E-antifuse decreases in the course of time. Therefore, there is the problem when electrically programmable fuses and antifuses are used for programming the chip ID that, on the one hand, the programming operation does not run with sufficient reliability and, on the other hand, the programming heals in the course of the operating time and its re-detection is consequently faulty.
SUMMARY OF THE INVENTION
[0007] It is accordingly an object of the invention to provide a method for identifying an integrated circuit and an integrated circuit which overcome the above-mentioned disadvantages of the prior art methods and devices of this general type, in which the programming can be reliably read and re-detected.
[0008] With the foregoing and other objects in view there is provided, in accordance with the invention, a method for identifying an integrated circuit. The method includes the steps of providing a digital identification word containing a first number of bits, calculating an expanded identification word containing a second number of bits being larger than the first number of bits and has a fault-correcting redundancy for the digital identification word, and programming programmable elements disposed on the integrated circuit in dependence on the expanded identification word.
[0009] An integrated circuit which is particularly suitable for carrying out the method contains a configuration of programmable elements which are connected, on the one hand, to a terminal for a supply potential and, on the other hand, to a circuit node for reading out the conductivity state of the respective programmable element.
[0010] According to the invention, the original, uniquely defined chip ID is provided with redundant bits. The chip ID that is expanded with redundancy therefore has more bits than the original chip ID. The additional bits that are obtained by the redundancy can be added to the original chip ID at the edge or mixed with the original bits. By the additional redundancy it is possible to correct faultily programmed bits or bits of the chip ID that have become faulty owing to aging effects. Depending on the redundancy method used, the chip ID that is expanded with redundancy ensures the detection of a faulty chip ID per se and ensures the possibility of correcting one or more of the faulty bits. A precondition for this is that, during the reading-out operation, the redundancy-forming method is known and can be correspondingly decoded. In order to form redundancy and decode redundancy, a large number of methods in the technology are known per se. In principle, any redundancy-forming method can be applied.
[0011] The invention can be used particularly advantageously if elements that can be programmed electrically are used to program the bits of the chip ID. As explained at the beginning, with such E-fuses or E-antifuses, on the one hand, the programming operation becomes faulty and subject to tolerances and, on the other hand, healing effects during the course of the operation ensure that the programming automatically cancels itself out. When E-fuses/antifuses are used, the addition of redundancy to the chip ID has the particular advantage that these inherent disadvantages are compensated and corrected with relatively little expenditure.
[0012] One bit of the chip ID containing the redundancy is expediently assigned to a programmable element, that is to say a fuse or antifuse. In a first logic state, the fuse is preferably programmed by impressing a current and in the other logic state it is not programmed and retains the original state. In the case of a fuse, a programming device is provided that can change the conductivity from an originally low impedance to a high impedance. In the case of an antifuse, programming results in that the conductivity is changed from an originally high impedance to a low impedance.
[0013] For programming, the uniquely defined chip ID is made available in the automatic test equipment. The chip ID is fed to a redundancy algorithm that adds additional bits to the original chip ID in order to output a chip ID that has been expanded with redundancy. The chip ID is transmitted by the automatic test equipment to the integrated circuit. The electrical programming of the fuses/antifuses assigned to the bits of the chip ID takes place after this or together with the transmission of the expanded chip ID. To program the electrically programmable fuses/antifuses, a corresponding programming voltage is supplied which generates a sufficiently high current pulse inside the chip so that the desired change of the conductivity of the fuses/antifuses is brought about. To read out the chip ID it is necessary for the bits of the programmed chip ID to be read out and the redundant elements to be supplied within the scope of redundancy decoding for fault detection and fault correction in order to calculate the original uniquely defined chip ID.
[0014] The fuses/antifuses are connected, on the one hand, to a terminal for a supply potential, for example reference potential or ground, and, on the other hand, to a circuit node via which, on the one hand, the fuse is programmed and, on the other hand, the programmed state is read out. For reading out, the circuit node is preloaded and subsequently evaluated. A conductive fuse draws the node to the reference potential, and a non-conductive fuse leaves the node at the predefined potential. In this way, the programmed state of a logic “1” or logic “0” can be read out again. The circuit nodes are connected, for example to the inputs of a register that can be accessed from the outside for reading out.
[0015] As explained at the beginning, there is, in particular in the case of semiconductor memories, the requirement for a chip ID that can be reliably recognized again.
[0016] In accordance with an added mode of the invention, there is the step of forming the expanded identification word to contain all the bits of the digital identification word and further bits which are determined from the bits of the digital identification word by a redundancy calculation.
[0017] In accordance with another mode of the invention, there is the step of forming the programmable elements to initially have a high impedance and, if a respective bit has the first logic state, an associated one of the programmable elements assigned to the respective bit is changed to a low-impedance state by impressing an electric current pulse.
[0018] In accordance with a further mode of the invention, there is the step of forming the programmable elements to initially have a low impedance and, if a respective bit has the first logic state, an associated one of the programmable elements assigned to the respective bit is changed into a high impedance state by impressing an electrical current pulse.
[0019] Other features which are considered as characteristic for the invention are set forth in the appended claims.
[0020] Although the invention is illustrated and described herein as embodied in a method for identifying an integrated circuit and an integrated circuit, 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.
[0021] The construction and method of operation of the invention, however, together with additional objects and advantages thereof will be best understood from the following description of specific embodiments when read in connection with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0022] [0022]FIG. 1 is a basic circuit diagram for a method sequence for programming an identification of an integrated circuit; and
[0023] [0023]FIG. 2 is a block diagram of a fuse bank that is disposed on an integrated circuit.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0024] Referring now to the figures of the drawing in detail and first, particularly, to FIG. 1 thereof, there is shown a chip ID 10 which uniquely identifies an integrated circuit, in particular a DRAM. It contains six bits “101010”. For reasons of clarity, the chip ID 10 is kept short. In practice, it can contain up to sixty bits. Each of the bits of the chip ID 10 is assigned a fuse on the integrated semiconductor circuit. The assignment of one antifuse in each case is also conceivable. If a bit of the chip ID 10 is a logic “1”, the fuse is, for example, not programmed and retains the original, conductive state. If a bit of the chip ID 10 is a logic “0”, the fuse is electrically programmed with high impedance by a current pulse.
[0025] The chip ID 10 is subjected in the automatic test equipment to which the semiconductor memory is connected to a redundancy calculation 11 that generates a chip ID 20 that is expanded with redundancy. The chip ID 20 contains the original bits of the chip ID “101010” and a portion “001” that contains redundancy in accordance with the redundancy calculation 11 . The automatic test equipment accordingly actuates the terminals of the semiconductor memory in such a way that the fuses provided for the chip ID are electrically programmed in accordance with the expanded chip ID 20 .
[0026] The programming state of the fuse bank storing the chip ID 20 that comes about on the semiconductor chip after several years of service life is represented by a reference numeral 30 . It is apparent that, instead of the original logic value “0”, the bit place 31 now has a logic “1”. It may either be the case that the programming of the E-fuse has already been carried out faultily or else the programming state has gradually changed from “0” to “1” owing to aging effects. When the chip ID 30 is read out, a redundancy decoding device 12 , which evaluates the redundancy added in the redundancy calculation 11 , is carried out. The redundant bits “001” permit the fault at the bit place 31 to be detected and even corrected in order to obtain the original chip ID 10 during reading out. Depending on the redundancy coding method 11 used and the number of redundant bits 22 , it is possible either just to detect that there is a fault in the chip ID or else one or more faults can be corrected.
[0027] [0027]FIG. 2 shows a fuse bank 40 in which a programming state of the fuses is shown corresponding to the chip ID 30 . A logic “1” of the chip ID 30 is represented by a conductive fuse, and the logic state “0” is represented by a fuse which is programmed with a high impedance. Each of the fuses, for example a fuse 41 , is connected by one terminal to a reference potential VSS. Another terminal of the fuse 41 is connected to a circuit node 42 . The fuse 41 is read out dynamically. For this purpose, the circuit node 42 is preloaded to a high potential. The conductive fuse 41 draws the potential to ground VSS. The potential is buffered at a bit place 46 of a register 50 . The register 50 is embodied as a shift register so that all the bits of the stored chip ID 30 can be read out serially and fed to the decoding algorithm 12 . At a bit place 47 , the fuse 43 is programmed with a high impedance and constitutes a no-load operation at the terminal 44 . When the terminal 44 is preloaded to the high potential, the potential is maintained and is stored as a logic “0” at the bit place of the shift register 50 .
[0028] The fuse 43 was programmed electrically by impressing a correspondingly high current pulse during programming and the originally conductive fuse was subsequently destroyed and thus changed from the originally low-impedance state to the high-impedance state represented. The current pulse is generated by a voltage generator 45 that makes available a high programming voltage VP that is above the normal operating voltage. | In order to identify an integrated circuit, the bits of the chip ID are programmed by fuses or antifuses. Programming errors and aging errors can be detected and corrected by adding redundant bits. This can be applied in particular when electrically programmable fuses/antifuses are used in order to make the re-detection of a faulty chip ID more reliable. | 6 |
CROSS-REFERENCES TO RELATED APPLICATIONS
[0001] This application is a continuation of prior filed copending U.S. application Ser. No. 10/524,719, filed Feb. 15, 2005, the priority of which is hereby claimed under 35 U.S.C. §120 and which in turn is the U.S. national stage of PCT International application no. PCT/EP2003/009132, filed Aug. 18, 2003, which designated the United States and has been published but not in English as International Publication No. WO 2004/018271 and which claims the priority of German Patent Applications, Serial Nos. 102 37 446.5, filed Aug. 16, 2002 and 103 33 272.3, filed Jul. 21, 2003, pursuant to 35 U.S.C. 119(a)-(d).
[0002] The content of U.S. application Ser. No. 10/524,719 is incorporated herein by reference in its entirety as if fully set forth herein.
BACKGROUND OF THE INVENTION
[0003] The invention relates to a spring element, in particular a spring rail for wipers, as are used for the generally curved windshields of motor vehicles, rail-borne vehicles, ships and aircraft.
[0004] Wipers usually comprise a wiper lever with a wiper blade composed of a spring rail and a wiper strip which is pressed onto the screen to be cleaned with the aid of spring forces. To achieve the necessary cleaning action, it is necessary for elastomeric wiper strip always to bear tightly against the screen surface irrespective of the curvature of the screen. This is ensured by spring elements arranged between the wiper lever and the wiper strip, in particular including the spring rail, the length of which substantially corresponds to that of the elastomeric wiper strip.
[0005] However, high driving speeds and/or wind speeds give rise to turbulence and vibrations, with the result that the wiper strip does not bear uniformly and with sufficient force against the screen over its entire length and/or throughout its entire reciprocating motion, with the result that films of water and dirt adhering to the screen are not reliably removed.
[0006] Modern wipers comprise a main bracket which is arranged in articulated fashion on a motor-driven wiper lever and has a claw bracket articulatedly secured to each of its two ends. The claw brackets are articulatedly connected at one end to a spring rail and at the other end to claws, the two ends of which are in each case connected, via joints, to the spring rail. The spring rail is embedded in the elastomeric wiper strip over its entire length.
[0007] The spring system, which in total comprises five brackets and a spring rail, is intended to ensure that the wiper strip bears uniformly against the screen. To achieve this, and in particular to suppress rattling vibrations, the distances between the two claw brackets and the length of the latter have to be matched to the screen geometry. Further criteria are the size of the screen surface to be covered, the length of the wiper blades, the orientation of the reciprocating-motion axis of the wiper arm with respect to the screen surface and in particular the spring force and the width and thickness of the spring rail. It is scarcely possible to record these parameters by calculation; consequently, the nature of the claw brackets and their position with respect to the wiper blade are generally based on practical experience.
[0008] Despite all efforts, it has only to a certain extent been possible to avoid rattling and the occurrence of vibrations at high driving speeds and/or wind speeds. Accordingly, the result of wiping is unsatisfactory and, moreover, there is extensive abrasion to the wiping edge of the wiper strip, as well as disruptive operating noise, and furthermore the service life of the wiper strip is shortened.
[0009] To reduce the noise, European laid-open specification 1 288 089 A2 proposes reducing the coefficient of friction of a wiper strip with a special profile with the aid of a polymer coating. However, this is not only highly complex but also makes it easier for vibrations to occur as a result of the lower coefficient of friction. Furthermore, PCT laid-open specification WO 01/58732 A1 proposes using two spring rails running parallel to one another but with different resonant frequencies instead of a single spring rail extending over virtually the entire length of the wiper strip, in order to suppress the occurrence of wiper blade vibrations. However, different resonant frequencies require spring rails which differ in terms of their cross section and/or material, and therefore entail additional outlay both on production and on stock-holding and in terms of spare parts. An additional factor is that it is only possible to avoid vibrations by using two spring rails with different resonant frequencies within a relatively narrow frequency window, and therefore it is not possible to cover all operating or vibration states which occur in practise.
[0010] The material used for spring elements and spring rails is usually alloyed steels, since pure carbon steels have poor damping properties and therefore do not break down disruptive vibrations sufficiently quickly. This is because scarcely any energy-consuming processes take place within the microstructure.
SUMMARY OF THE INVENTION
[0011] In view of this background, the problem on which the invention is based is to improve the vibration properties of spring elements, for example the wiping performance of wipers having a spring rail.
[0012] To this end, the invention proposes that the material used for spring elements, in particular spring rails, be a ferritic chromium steel comprising 0.03 to 0.12% of carbon, 0.2 to 0.9% of silicon, 0.3 to 1% of manganese, 13 to 20% of chromium, 0.1 to 2.0% of molybdenum, 0.05 to 1.0% of copper, 0.02 to 0.05% of nitrogen, less than 0.01% of titanium, 0.01 to 0.10% of niobium and 0.02 to 0.25% of vanadium, remainder iron.
[0013] The steel may contain at most 0.1% of carbon, at most 1.5% of molybdenum and 0.1% of copper up to 0.5%, and at least 0.03% of nitrogen, individually or in combination with one another.
[0014] A steel containing 0.06 to 0.1% of carbon, 15 to 18% of chromium and 0.8 to 1.5% of molybdenum has proven particularly suitable.
[0015] The spring element according to the invention has a coercive force H C of from 190 to 240 A/cm and a saturation magnetization J ma of from 1.45 to 1.75 T, which corresponds to a ferrite content in the microstructure of approximately 10% or 55%.
[0016] This data can be achieved, for example, by cold strip or flat wire formed from the alloy according to the invention being cold-formed and then solution-annealed and cooled in air or quenched with water, so as to set a magnetizable microstructure having the abovementioned magnetic saturation. Then, the desired coercive force can be set, if appropriate in steps, with the aid of at least one further cold-forming operation.
[0017] To improve the mechanical and/or optical properties, the starting material or the spring element (spring rail) may be provided with a preferably 50 to 150 μm thick coating of a thermosetting powder coating. The coating is produced under the action of heat and is therefore inevitably associated with advantageous tempering of the material.
[0018] The spring elements according to the invention are distinguished by a high spring force and a high resistance to weathering, and in particular by a spring magneto-mechanical vibration damping. The advantageous damping performance makes it possible to dispense with the complex claws and if appropriate also the claw bracket, and therefore provides a wiper in which the wiper arm acts directly on the spring rail via the main bracket.
[0019] The microstructure consisting of ferrite and martensite with nonmagnetic fine precipitations, such as nitrides and carbonitrides, ensures high initial damping, the cause of which is stress-induced domain boundary formation of the microstructural constituents. This involves internal changes in the magnetization, such as stress-induced inelastic domain boundary movements, which lead to eddy current losses and thereby consume vibration energy.
BRIEF DESCRIPTION OF THE DRAWING
[0020] The invention is explained in more detail below on the basis of drawings in combination with exemplary embodiments. In the drawings:
[0021] FIG. 1 shows the structure of a conventional wiper arm,
[0022] FIG. 2 shows a measuring apparatus for determining the vibration performance of spring rails,
[0023] FIG. 3 shows a graph illustrating the vibration performance of conventional spring rails,
[0024] FIG. 4 shows a graph illustrating the vibration performance of a spring rail according to the invention compared to two spring rails made from conventional steels.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0025] According to the illustration shown in FIG. 1 , a conventional wiper comprises a wiper arm 1 , the end of which is articulatedly connected to a main bracket 2 . In each case one claw bracket 3 , 4 is articulatedly mounted at both ends of the main bracket. The ends 5 , 6 of the longer limbs of the claw brackets 3 , 4 engage in an articulated manner on a spring rail 7 which, together with an elastomeric wiper strip 8 , serves as wiper blade for removing water and dirt from a vehicle screen.
[0026] The shorter limbs of the claw brackets 3 , 4 , by contrast, are each connected, via joints 10 , 11 , to a claw 12 , 13 , the ends of which act in an articulated manner on the spring rail 7 .
[0027] The use of a spring rail according to the invention makes it possible, in a wiper of the type presented, to dispense with the two claw brackets 3 , 4 or also with the claws 12 , 13 . This reduces the assembly costs for the wiper by approximately 50%. This is true irrespective of the cross-sectional profile of the spring rail, the advantageous damping properties of which manifest themselves for various profiles.
[0028] The invention is explained in more detail below on the basis of exemplary embodiments and comparative alloys.
[0029] Table I below gives the compositions for five chromium steels according to the invention E1 to E5 and seven comparative steels C6 to C12.
[0000]
TABLE I
Steel
% C
% Si
% Mn
% Cr
% Ni
% Mo
% Cu
% N
E1
0.06
0.50
0.65
17.3
0.26
0.15
0.21
0.030
E2
0.07
0.52
0.48
17.0
0.32
0.14
0.15
0.045
E3
0.08
0.48
0.52
16.2
0.35
0.10
0.12
0.040
E4
0.10
0.65
0.61
17.6
0.40
0.07
0.15
0.035
E5
0.06
0.44
0.92
16.8
0.30
0.82
0.35
0.035
C6
0.03
0.58
0.49
17.1
0.32
0.10
0.12
0.040
C7
0.35
0.62
0.69
14.1
0.18
0.08
0.17
0.030
C8
0.07
0.45
0.98
18.0
6.12
0.12
0.09
0.360
C9
0.10
0.86
1.22
17.4
8.15
0.36
0.19
0.020
C10
0.47
0.25
0.55
Traces
Traces
Traces
Traces
Traces
C11
0.55
0.48
0.94
0.95
Traces
Traces
Traces
Traces
C12
0.79
0.18
0.78
Traces
Traces
Traces
Traces
Traces
The tensile strength R m
coercive force H C
saturation magnetization J
damping as a percentage amplitude after 15 seconds
damping as a percentage amplitude after 25 seconds
of the steels were tested.
[0035] To produce a spring rail, the alloys E1 to E6 according to the invention with a cross section of 28 mm 2 were used in the soft-annealed state. After initial cold-forming, the specimens were exposed to solution-annealing at 1050° C. for 12 minutes, followed by rapid cooling and further cold-forming until a final cross section of 6 mm 2 was produced. These processing steps resulted in a total deformation of 78%. The specimens, in order to be prepared for a coating or tempering treatment, were then cleaned in an ultrasound bath, heated to 350° C. and coated with a powder coating. The coating was applied during the cooling phase of the tempering treatment in order to utilize the process heat of the spring rail to harden the powder coating.
[0036] One of the specimens formed from alloy E4 was additionally pre-deformed prior to the abovementioned first cold-forming, then annealed and then treated further in the same way as the other specimens (cf. Test 8).
[0037] The test results are compiled in Table II below, which in addition to the layer thickness also gives the hardening temperature or the coating temperature; it effects tempering and leads to an increase in the tensile strength, as demonstrated by the damping properties of Test 5, which relates to a specimen of alloy E1 without coating and accordingly also without tempering during the coating operation. This reveals the importance of the tempering for the increase in strength.
[0000]
TABLE II
Coating
% Residual
thickness/
Saturation
amplitude
hardening
Test
Steel
Coercive force
magnetization
Tensile strength
after
temperature
Assessment
Assessment
No.
HC (A/cm)
J (T)
Rm (MPa)
0.15 s
0.25 s
mm
° C.
Strength
Damping
1
E1
217
1.65
1682
39.0
15.0
none
340
+
good
2
E1
216
1.67
1695
31.0
14.0
0.8
340
+
good
3
E1
219
1.52
1774
36.0
12.5
0.8
340
+
very good
4
E1
192
1.82
1685
54.0
35.0
0.8
340
+
poor
5
E2
225
1.76
1851
35.0
12.0
0.8
340
+
very good
6
E3
215
1.72
1712
35.0
12.5
0.8
340
+
very good
7
E4
198
1.62
1849
34.5
10.0
0.8
340
+
very good
8
E4
205
1.63
1670
35.0
11.0
0.8
340
+
very good
9
E5
230
1.53
1716
34.0
11.0
0.8
340
+
very good
10
E5
232
1.55
1728
33.0
10.0
0.8
340
+
very good
11
C6
38
1.54
535
n.d.
n.d.
0.8
340
−
12
C6
47
1.48
726
n.d.
n.d.
0.8
340
−
13
C6
49
1.43
980
n.d.
n.d.
none
—
−
14
C7
382
1.58
1682
60.0
39.0
0.8
340
+
average
15
C8
936
0.32
1640
55.0
34.0
0.8
340
+
poor
16
C9
914
0.36
1728
54.5
34.0
0.8
340
+
poor
17
C9
973
0.31
1620
57.0
35.0
0.8
340
+
insufficient
18
C9
766
0.22
1452
n.d.
n.d.
0.8
340
−
19
C10
123
1.83
1820
60.0
39.0
none
—
+
poor
20
C10
125
1.82
1845
59.0
38.0
0.8
340
+
poor
21
C11
129
1.84
1960
61.0
38.0
none
—
+
poor
22
C11
131
1.91
1986
59.0
37.0
0.8
340
+
poor
23
C12
122
1.97
2020
63.0
42.0
none
—
+
insufficient
24
C12
122
1.97
2022
62.0
40.0
0.8
340
+
insufficient
[0038] Tests 11 to 13 and 18 relate to steels which are too soft and do not have sufficient spring properties. Therefore, there was little sense in determining the spring damping. Accordingly, no residual amplitude is given for these tests in Table II (n.d.).
[0039] In general with regard to the residual amplitude, it is the case that the lower the residual amplitude given, the better the vibration damping.
[0040] The vibration performance was determined with the aid of the measurement apparatus illustrated in FIG. 2 . During the tests, one side of the specimens 14 was clamped in a pedestal 15 , then the specimens were made to deviate laterally over a distance of D=11 mm and then let go. The vibrations of the freely vibrating specimens as a function of time were recorded with the aid of a sensor, the amplified signal was fed to a PC measurement card and stored with a time resolution of 4400 measured values per second as a vibration diagram. The envelope of this vibration diagram was determined, and the percentage residual amplitude compared to the starting amplitude at instant zero (100%) was in each case determined on the basis of the resulting envelope curve or damping curve 16 after 0.15 and 0.25 second.
[0041] The magnetic characteristic values of the specimens were determined with the aid of a hysteresis curve from which the values for the coercive force H C and the saturation magnetization J max were taken in accordance with DIN 50460.
[0042] FIG. 3 illustrates the typical vibration performance of conventional spring rails. The profile of the envelope or damping curve 16 follows an exponential function. This can be explained by the fact that during the vibration of a leaf spring, a compressive stress or a tensile stress occur alternately at the leaf surface after deflection. A vibration of this type is generally described by a differential equation. The calculations of a vibration are usually based on a linear force relationship. The result of this linear force relationship is that the vibration can be described very successfully by an exponentially decreasing vibration curve. However, if, as in the case of the alloy according to the invention, there are magneto-mechanical interactions in the microstructure, the condition for the linear force relationship is no longer satisfied and a mechanical hysteresis occurs during vibration. This is stronger at high amplitudes or excursions than at low ones, since the energy loss is dependent on the surface area of the hysteresis curve. In such a situation, an exponentially decreasing damping curve is not attained. Rather, there is very strong initial damping (cf. Hornbogen, Metallkunde, 2nd edition).
[0043] As shown in FIG. 4 , the two damping curves 17 , 18 for the spring rails formed from comparison steels C9 and C10 in Tables I and II behave similarly; these follow Hooke's law. By contrast, curve 19 for the spring rail according to the invention formed from steel E1 in Table I or test 2 in Table II behaves differently. The profile of the curve 19 , on account of its relatively steep drop, reveals high initial damping, which can be explained by a nonlinear deviation from Hooke's law, caused by the abovementioned stress-induced domain wall movements as occur within the field of values according to the invention for coercive force and magnetic saturation.
[0044] In principle, a mechanical stress a in a material causes a change in the atomic spacing, which in practise manifests itself as strain ε. The known relationship or modulus of elasticity E is derived from this in accordance with the following formula:
[0000]
E
=
E
G
=
σ
1
ɛ
G
[0000] (the index G indicates that the modulus of elasticity is dependent on the lattice strain).
[0045] In the case of magnetically coupled microstructural constituents, such as ferrite and martensite, however, a stress, in addition to the lattice strain, also causes a change in the domain arrangement, for which reason an additional strain ε MM has to be taken into account in the equation. This results in the following relationship
[0000]
E
=
E
G
+
E
MM
=
σ
(
1
ɛ
G
+
1
ɛ
MM
)
[0000] εm MM represents a combination of all magnetically induced strains and additional strains; it is composed of three component strains and also encompasses the volume magnetostriction and its analogous strain component.
[0046] Therefore, the magneto-mechanical damping is produced by the fact that a mechanical stress not only changes the atom spacing (lattice strain) but also gives rise to the changes caused by the stress-induced domain wall movements.
[0047] The favorable vibration performance is explained by strong magneto-mechanical damping. This is formed on account of the fact that in the event of vibration the domain arrangements are changed, in the form of an imposed volume magnetostriction, as a result of changes in the mechanical stress over the course of time.
[0048] Since the stress-induced domain wall movement is associated with inelastic and eddy current losses, in the event of vibrating loads a mechanical hysteresis occurs, i.e. there is a nonlinear deviation from Hooke's law.
[0049] In this context, of course, the strength of the obstacles of the domain wall movements (i.e. the wall energy and therefore the H C value) also plays a major role, since they are ultimately responsible for the extent of damping. Optimum magneto-mechanical damping by stress-induced domain wall movements is accordingly only possible within a certain field of values for J (magnetic polarization) and HC (coercive force).
[0050] The damping can be improved further by coating with the aid of a thermosetting powder coating. A coating of this type has a number of advantageous effects: it increases the resistance to corrosion and the tensile strength and allows a coefficient of friction which is favorable for introduction of a spring rail into the wiper strip and also makes it possible to adapt the surface structure and the appearance to the appearance of the rubber wiper strip.
[0051] The excellent damping performance of the spring elements according to the invention (spring rail) is caused by the microstructure, which is composed of soft-magnetic ferrite and in relative terms comparatively hard-magnetic martensite with nonmagnetic fine precipitations of carbides and/or carbonitrides, as well as the volume proportions of the two magnetic phases ferrite and martensite. The ferrite has a high magnetic polarization, i.e. a very strong internal magnetization compared to the saturation magnetization of pure iron at 2.2 T or 22000 Gauss. This results in slight remagnetization, i.e. the ferrite is magnetically soft, which manifests itself by a low coercive force or a low wall energy. Although martensite has a lower magnetizability or a significantly lower magnetic polarization, compared to ferrite, its magnetic domains are more strongly fixed in energy terms on account of the fine precipitations, but also on account of alloying elements dissolved in the crystal lattice. Compared to ferrite, the martensite is more difficult to remagnetize, which means that it is magnetically harder and accordingly has a higher HC value.
[0052] The magnetic domains are magnetizable regions which are delimited by what are known as Bloch walls. The stability of the magnetic domains is expressed in what is known as the wall energy. The wall energies of ferrite are generally low and therefore give rise to easy remagnetization or a low coercive force below approximately 1 A/cm.
[0053] The damping performance can be set or optimized with the aid of the proportion by volume of the two magnetizable microstructure constituents ferrite and martensite (preferably 30% ferrite, remainder martensite including small amounts of nonmagnetic precipitations) and the resultant magnetic hardness. This is done with the aid of solution annealing with a duration of from 0.5 to 60 min at 900 to 1100° C. and cold-forming with a total degree of deformation of over 65%. In this way, it is possible to achieve a magnetic saturation, as a total value for the two magnetizable phases ferrite (10 to 55%, remainder substantially martensite) and martensite, of the order of magnitude of from 1.45 to 1.75 T.
[0054] To set the magnetic hardness, the cold-forming may be followed by a tempering treatment, for example with a duration of from 0.1 to 1 min at a temperature of from 200 to 380° C. in order to achieve a coercive force of from 190 to 320 A/cm. The tempering treatment can be carried out at the same time as the coating with a hot-hardening powder coating or coating. | Spring element, in particular spring rail for wipers, in particular of motor vehicles, with a low tendency to vibrate or a high attenuation, made from a ferritic chromium steel comprising 0.03 to 0.12% of carbon, 0.2 to 0.9% of silicon, 0.3 to 1% of manganese, 13 to 20% of chromium, 0.1 to 2.0% of molybdenum, 0.05 to 1.0% of copper, 0.02 to 0.05% of nitrogen, less than 0.01% of titanium, 0.01 to 0.10% of niobium and 0.02 to 0.25% of vanadium, remainder iron. | 2 |
FIELD OF THE INVENTION
The present invention relates to a tool for servicing refrigeration systems and, more particularly, to a pump down tool having an inflatable balloon for blocking the liquid line of a refrigeration system during a pump down procedure, thereby allowing the system refrigerant to be captured and isolated within the condenser of the refrigeration system.
BACKGROUND OF THE INVENTION
In a refrigeration system that utilizes a compressible evaporative refrigerant to transfer heat, the refrigerant must oftentimes be removed prior to a servicing of the system, and subsequently recharged after any necessary repairs have been completed.
In the past, refrigerants were typically vented directly into the atmosphere during the servicing of a refrigeration system. Recently, due primarily to the refrigerant actuated depletion of the ozone layer, a plethora of governmental regulations have been established to prevent the deleterious atmospheric release of refrigerants, especially those refrigerants containing chlorofluorocarbons (CFCs) and hydrochlorofluorocarbons (HCFCs). In compliance with such regulations, many complex refrigerant reclamation and recharging systems have been developed to temporarily remove the refrigerant from a refrigeration system under service. Unfortunately, to avoid the expensive and time consuming process of refrigerant reclamation, unscrupulous refrigeration technicians may discharge the refrigerant from a refrigeration system directly into the atmosphere, illegally circumventing the required reclamation process.
SUMMARY OF THE INVENTION
In order to avoid the disadvantages of the prior art, the present invention provides a pump down tool for blocking the liquid refrigerant line of a refrigeration system, advantageously resulting in the capture of the refrigerant within the condenser of the refrigeration system and obviating the expensive and time consuming refrigerant reclamation and recharging process.
The pump down tool of the present invention is a Schrader core removal tool, such as those disclosed in U.S. Pat. Nos. 3,840,967, 3,875,756 and 3,935,713, incorporated herein by reference, which has been modified to additionally insert an inflatable pump down head into the liquid refrigerant line of a refrigeration system through a conventional Schrader valve. The pump down tool includes a body member having a cylindrical, longitudinal passageway extending therethrough, a coupling nut for removably securing a first end portion of the body member to a Schrader valve disposed on the liquid line service port of a refrigeration system, a control knob assembly for displacing a removable, longitudinally displaceable, hollow operating shaft along the longitudinal passageway within the body member, and a tool service port, disposed on the control knob assembly, for directing an external source of a gas through the hollow operating shaft into the inflatable pump down head.
A valve core engaging chuck or an inflatable pump down head may be interchangeably attached to a first end portion of the hollow operating shaft during the servicing of a refrigeration system. Initially, to access the interior of the liquid line of the refrigeration system under service, the body member of the pump down tool is suitably coupled to the Schrader valve on the liquid line service port. After shutting off the refrigeration system and securing the valve core engaging chuck to the distal end of the removable, longitudinally displaceable, hollow operating shaft, the core of the Schrader valve is engaged and removed in a conventional manner. To prevent any unwanted depressurization of the refrigeration system after the successful removal of the valve core, a shut-off valve assembly is utilized to block the longitudinal passageway disposed within the body member of the pump down tool. Following the removal of the Schrader valve core, the control knob assembly is utilized to withdraw the hollow operating shaft from the longitudinal passageway of the body member, and the core engaging chuck is removed from the end of the hollow operating shaft and subsequently replaced with the inflatable pump down head.
A pump down procedure is initiated by introducing the inflatable pump down head into the liquid line of the refrigeration system. More specifically, the hollow operating shaft and attached inflatable pump down head are inserted into the longitudinal passageway of the body member using the control knob assembly. After reattaching the control knob assembly to the body member of the pump down tool, the shut-off valve assembly is suitably manipulated to reopen the longitudinal passageway within the body member, and the inflatable pump down head is inserted through the longitudinal passageway into the liquid line of the refrigeration system. Once inserted, an external source of a gas such as nitrogen or the like is attached to the tool service port on the control knob assembly. After opening a flow valve on the external source of gas, the inflatable pump down head is inflated as the gas flows therein through the hollow operating shaft, thereby closing off the liquid line of the refrigeration system. The system refrigerant is captured within the condenser of the refrigeration system in response to the inflation of the pump down head and the subsequent activation of the refrigeration system. Advantageously, the isolation of the refrigerant within the condenser of the refrigeration system allows a service technician to access, repair and/or replace many of the components of the refrigeration system, without having to perform the time consuming and expensive processes of refrigerant reclamation and recharging. Further, the pump down procedure allows the service technician to easily determine whether the compressor valves are in proper operating condition; if the system will not pump down, the compressor should be repaired or replaced.
BRIEF DESCRIPTION OF THE DRAWINGS
These and other features of the present invention will become readily apparent upon reading the following detailed description and upon reference to the drawings in which:
FIG. 1 is a cross-sectional view of a preferred embodiment of the present invention during a valve core removal procedure, illustrating the initial engagement of the valve core engaging chuck and the core of a Schrader valve disposed on the liquid line service port of a refrigeration system;
FIG. 2 is a cross-sectional view similar to FIG. 1, illustrating the withdrawal of the valve core through the longitudinal passageway of the pump down tool, and the subsequent closure of the shut-off valve assembly to prevent the release of refrigerant through the tool;
FIG. 3 is a cross-sectional view similar to FIG. 2, illustrating the complete removal of the valve core;
FIG. 4 is a schematic view of a residential refrigeration system with the pump down tool of the present invention attached to the liquid line service port of the refrigeration system;
FIG. 5 is an enlarged view of the liquid line and suction line service ports of the refrigeration system illustrated in FIG. 4;
FIG. 6 is an enlarged view of an inflatable pump down head in accordance with a preferred embodiment of the present invention;
FIG. 7 is an exploded, cross-sectional view of the inflatable pump down head of FIG. 6;
FIG. 8 is a partial enlarged view of the inflatable balloon member illustrated in FIG. 7;
FIG. 9 is a cross-sectional view of the hollow operating shaft with the inflatable pump down head interchangeably attached to an end portion thereof, prior to the insertion of the inflatable pump down head into the longitudinal passageway of the pump down tool;
FIG. 10 is a cross-sectional view similar to FIG. 9, illustrating the initial insertion of the inflatable pump down head into the longitudinal passageway of the pump down tool; and
FIG. 11 is a cross-sectional view of the pump down tool with the inflatable pump down head inserted and inflated within the liquid line of the refrigeration system.
DETAILED DESCRIPTION OF THE INVENTION
Referring now specifically to the drawings, there is illustrated a pump down tool, generally designated as 10, in accordance with a preferred embodiment of the present invention, wherein like reference numerals refer to like components throughout the drawings.
As illustrated throughout the drawings, the pump down tool 10 of the present invention includes a body member 12 having a first end portion 14, a second end portion 16, and a longitudinal passageway 18 passing completely therethrough.
A coupling nut 20, for removably securing the pump down tool 10 about a conventional Schrader valve 22 on the liquid line service port 24 of a refrigeration (air conditioning) system 26 (FIGS. 4-5), includes a snap ring 28 and flange members 30 for rotatably engaging a circumferential groove 32 formed about the outer periphery of the first end portion 14 of the pump down tool. The coupling nut 20 further includes a gasket 34, formed of rubber or the like, and internal threads 36 for receiving the external threads 38 of the Schrader valve 22.
An internally threaded access cap 40 is threadedly secured to the external threads 42 formed on the outer periphery of the second end portion 16 of the body member 12. The access cap 40 includes a bore 44 formed coaxially with the longitudinal passageway 18, and an annular retainer 46.
A removable, longitudinally displaceable, hollow operating shaft 48, having a cylindrically shaped outer periphery, extends through the bore 44 and the annular retainer 46. As illustrated most clearly in FIGS. 1 and 9, and as described in further detail hereinbelow, the bore 50 of the hollow operating shaft extends along the entire length of the shaft, thereby providing an unobstructed passageway for the passage of gas during the inflation of a pump down head 52 (FIGS. 9-11) during a pump down procedure. A first end portion 54 of the hollow operating shaft 48 is longitudinally displaceable within the longitudinal passageway 18. A control knob assembly 56 is fixedly secured about a second end portion 58 of the hollow operating shaft via set screw 60, with the bore 50 of the hollow operating shaft 48 extending completely therethrough. O-rings 62 form a fluid-tight seal between the access cap 40 and the hollow operating shaft 48. Analogously, O-ring 64 provides a fluid-tight seal between the access cap 40 and the second end portion 16 of the body member 12.
An external source of gas (not shown) is removably attached to the pump down tool 10 during a pump down procedure via tool service port 66. As detailed in FIG. 1, the tool service port 66 preferably includes a Schrader valve incorporating a conventional valve core 68 therein. A first, externally threaded end portion 70 of the tool service port 68 is threadedly secured to an internally threaded portion 72 of the control knob assembly 56. A second end portion 74 of the tool service port 66 includes external threads 76 for receiving a hose (not shown) attached to the external source of gas.
As illustrated in FIG. 1, the first end portion 54 of the hollow operating shaft 48 includes a reduced, hollow section 78 which is removably received within a valve core engaging chuck 80, and suitably secured therein with set screw 82. The reduced, hollow section 78 incorporates a bore 84 for receiving the outwardly extending head of the Schrader valve core 86 being engaged by the valve core engaging chuck 80. A transverse slot 88 is formed in the valve core engaging chuck 80 for receiving the rectangular portion of the valve core 86 therein during the threading or unthreading of the valve core from its fitting within the Schrader valve 22.
A shut-off valve assembly 90, such as that described in U.S. Pat. No. 3,935,713, is utilized to selectively block the longitudinal passageway 18 in the body member 12 of the pump down tool. Generally, the shut-off valve assembly 90 includes a control knob 92 and valve stem 94 for axially displacing a cylindrically shaped resilient valve member 96 within a lateral bore 98. FIG. 1 illustrates the shut-off assembly 90 in the open position with the resilient valve member 96 fully retracted within the lateral bore 98. Correspondingly, FIG. 2 illustrates the shut-off assembly 90 in the closed position with the resilient valve member 96 blocking the longitudinal passageway 18.
In accordance with the preferred embodiment of the present invention, the pump down tool 10 is utilized to sequentially remove the valve core from the Schrader valve on the liquid line service port of a refrigeration system, insert and inflate an inflatable pump down head within the liquid line (FIGS. 9-11) to initiate and perform a pump down procedure, and reinsert the valve core after completion of the pump down procedure.
Removal of Schrader Valve Core
The Schrader valve core 86 is removed in a conventional manner as illustrated in FIGS. 1-3. Referring first to FIG. 1, the coupling nut 20 is rotatably employed, after turning off the power to the refrigeration system 26, to secure the pump down tool 10 about the Schrader valve 22. With the shut-off valve assembly 90 in the open position, the control knob assembly 56 is actuated to insert the hollow operating shaft 48 and the attached valve core engaging chuck 80 into and through the longitudinal passageway 18 to engage the valve core 86. After the rectangular portion of the valve core 86 is appropriately seated within the transverse slot 88 in the valve core engaging chuck 80, the valve core is unthreaded by turning the control knob assembly 56 counterclockwise. Following the complete unthreading of the valve core 86, the control knob assembly 56 is withdrawn as far as possible as illustrated in FIG. 2. The shut-off valve assembly 90 is then suitably manipulated to block the longitudinal passageway 18, thereby preventing the release of system refrigerant through the pump down tool. Finally, as shown in FIG. 3, the access cap 40 is unthreaded from the second end portion 16 of the body member 12, and the access cap 40, control knob assembly 56, hollow operating shaft 48, valve core engaging chuck 80 and valve core 86 are fully detached and withdrawn from the body member 12 of the pump down tool 10.
Referring now specifically to FIG. 4, there is illustrated a generic residential refrigeration (air conditioning) system 26 with the pump down tool 10 of the present invention attached thereto, wherein the refrigeration system 26 generally includes a condensing unit 100 incorporating a compressor 102 therein, a liquid line 104, a suction line 106 and an indoor coil 108 (evaporator). As indicated by a series of directional arrows, the system refrigerant flows through the liquid line 104 from the condensing unit 100 to the indoor coil 108, with the liquid line 104 typically passing through a foundation wall 110. After exiting the indoor coil 108, the refrigerant is subsequently drawn into the low pressure side of the condensing unit 100 through the suction line 106. As illustrated in the enlarged view provided by FIG. 5, the liquid line service port 24 is disposed between the condensing unit 100 and the liquid line 104. Similarly, a suction line service port 112, having a conventional Schrader valve 114, is positioned between the condensing unit 100 and the suction line 106. The pump down tool 10 is attached to the liquid line service port 24 of the refrigeration system as illustrated in FIG. 5.
Pump Down Procedure
A pump down procedure is performed by inserting an inflatable pump down head 52 into the liquid line 104 of the refrigeration system 26. As illustrated in FIGS. 9-11, the pump down head 52 is inserted into the liquid line 104 through the Schrader valve 22 on the liquid line service port 24 using the pump down tool 10 of the present invention.
The pump down head 52 is illustrated in detail in FIGS. 6-8. The pump down head 52 includes a hollow shaft 116, a retainer 118, a set screw 120 for removably securing the retainer 118 about the reduced, hollow end section 78 of the hollow operating shaft 48, a reduced, hollow, externally threaded end portion 122 for receiving a coupling nut 124 thereover, and an inflatable balloon member 126. A conduit for the passage of gas, comprising bores 128 and 130, extends along the entire length of the pump down head 52.
The inflatable balloon member 126 comprises an inner inflatable balloon 132 for blocking the liquid line 104 during a pump down procedure, and an outer protective sac 134 for enclosing and protecting the balloon 132 when inserted into the liquid line 104 or during insertion therein through the pump down tool 10 and Schrader core 22. If a rupture should occur, the outer sac 134 is adapted to prevent pieces of the balloon 132 from entering the liquid line 104 and potentially damaging the refrigeration system. The inner inflatable balloon 132 may be formed from any expandable material which is robust enough to withstand the external refrigerant fluid pressure exerted thereagainst when the balloon is inserted and inflated within the liquid line 104 during a pump down procedure. Analogously, the outer sac 134 is preferably formed from a strong, tear resistant nylon mesh fabric or the like. As shown in FIG. 8, the inner inflatable balloon 132 is preferably freely movable within the outer protective sac 134. Alternately, the inner inflatable balloon 132 may be integrally formed with an expandable, protective outer covering.
An exploded view of a preferred embodiment of the pump down head 52 is presented in FIG. 7. As illustrated, the reduced, hollow, externally threaded end portion 122 of the hollow shaft 116 is inserted and suitably secured within the internally threaded coupling nut 124, after the base 136 of the inflatable balloon member 126 and enclosed hollow bushing 138 have been inserted through the coupling nut 124 and ferrule 140.
In anticipation of the pumping down of the refrigeration system, the retainer 118 of the pump down head 52 is secured and tightened about the end section 78 of the hollow operating shaft 48 using the set screw 120. When coupled, a composite bore extends from the tool service port 66 into the interior of the inner inflatable balloon 132, thereby allowing the balloon 132 to be inflated by an external source of gas applied to the tool service port 66. After the pump down head 52 is appropriately secured to the operating shaft 48 (FIG. 9), and with the resilient valve member 96 of the shut-off valve assembly 90 remaining in the closed position, the pump down head 52 is guided as far as possible into the longitudinal passageway 18 of the body member 12 (FIG. 10). Following the insertion of the pump down head 52, the access cap is secured over the second end portion 16 of the body member 12. The inflatable balloon member 126 is subsequently inserted into the liquid line 104 through the decored Schrader valve 22 after the resilient valve member 96 is withdrawn from the longitudinal passageway (FIG. 11). It should be noted that the inflatable balloon member 126 remains in a deflated state at this point in the pump down procedure.
The inflatable balloon member 126 is inflated by connecting an external source of gas to the second end portion 74 of the tool service port 66. When the supply valve on the source of gas is opened, gas flows into the inflatable balloon member 126 after passing through the bores 50 and 128 of the hollow operating shaft 48 and the pump down head 52, respectively, thereby inflating the inflatable balloon member 126 and closing off the liquid line 104. Following the closure of the liquid line 104, the power to the refrigeration system 26 is turned on, and the refrigerant within the liquid line 104, indoor coil 108 and suction line 106, downstream from the now inflated balloon member 126, is pumped down into the condensing unit 100.
The compressor actuated evacuation of the liquid line 104, indoor coil 108 and suction line 108 is continued until the refrigerant pressure therein reaches zero, indicating that all of the refrigerant within this section of the refrigeration system has been captured within the condensing unit 100. Thereafter, the power to the refrigeration system is again disconnected, confining the refrigerant within the condensing unit 100, thereby allowing a service technician to access and repair the line set and indoor coil without any deleterious loss of refrigerant.
Upon completion of any necessary repairs, any contaminants within the liquid line 104, suction line 106 and indoor coil 108 are evacuated by applying a vacuum pump to the Schrader valve 114 disposed on the suction line port 112. The balloon member 126 is subsequently deflated, allowing refrigerant to once again flow through the entire refrigeration system, by removing the external source of gas from the second end portion 74 of the tool service port 66. Finally, the refrigeration system is reactivated by sequentially removing the balloon member 126, reinstalling the Schrader core 86, removing the pump down tool 10, and reestablishing system power.
The foregoing description of the preferred embodiments of the invention has been presented for purposes of illustration and description. It is not intended to be exhaustive or to limit the invention to the precise form disclosed, and obviously many modifications and variations are possible in light of the above teaching. Such modifications and variations that may be apparent to a person skilled in the art are intended to be included within the scope of this invention as defined by the accompanying claims. | A pump down tool for facilitating the servicing of a refrigeration system. The tool utilizes a pump down head having an inflatable balloon member for blocking the liquid line of the refrigeration system, thereby isolating the system refrigerant within the condenser of the refrigeration system. | 5 |
CROSS REFERENCE TO RELATED APPLICATION
[0001] This application is a continuation-in-part of U.S. patent application Ser. Nos. 10/366,854, filed Feb. 14, 2003 and 10/915,512 filed Aug. 9, 2004.
BACKGROUND OF THE INVENTION
[0002] This invention relates to golf clubs and particularly to the continual adjustment of their shaft flex to match the dynamic characteristics of a player on a given day which we will refer to as tuning the shaft This is accomplished by the addition of a rigid tubular insert with a compressible outer surface which provides enough friction and compressibility to hold it in place when inserted within a golf club shaft so as provide a method of adjusting the overall shaft flex by changing its penetration within the shaft. The penetration can be changed at any time although the rules governing competitive golf forbid making such changes during a round
[0003] It is the object of this invention to provide the means to tune the shaft of a dynamically swung golf club, but not a putter which require adjustments other than flex, to match a player's tempo over a range.
[0004] It is a further object of this invention to compensate for misalignment of the spine of a shaft or at least not to add to the detrimental effects of said misalignment.
[0005] Technical specifications commonly used to describe golf clubs include: total weight, swing weight, length, loft angle, lie angle, head size and weight, grip diameter, and shaft flex. But the proper selection of the latter is generally acknowledged to be most important when fitting clubs to a golfer. Moreover, recent studies have shown that it is very important for custom golf club fitters to find the optimum flex for each player for improved shot control and greater distance. But finding the optimum flex has perplexed most teachers, club fitters and golfers.
[0006] Three methods for finding the best flex before club assembly presently dominate the market for custom clubs. In the first fitting method, the player swings one dub several times and the average club head speed measured and a formula used to calculate the flex for the entire club set The second approach relies on matching one club or a set of clubs to a players favorite club. In the third method, a player hits several shots with each of many calibrated test clubs, finally selecting the best of the lot judged by one of several radar devices that measure several parameters. The best club then serves as a model for his entire set, which can be matched to it. But once the clubs are constructed after fitting by any method, only minor adjustments of swing weight are possible until another set is purchased, in many cases by the golfer's belief that a better fit is probable.
[0007] Many factors such as club head speed, swing time duration, and acceleration, effect the choice of optimum flex for each player. So while it is generally accepted that there is a best flex for every player, the best flex on one day will not be the best flex for all days, since weather temperature and muscle tone change over the seasons. This suggests that a method for altering the flex of a golf club after it is constructed, even if it was fitted accurately to the conditions on the fitting day, would be a tremendous benefit For example, many of the touring pros bring with more than one driver to tournaments, choosing the one that works best on the driving range the same day of each tournament round. One famous pro, preceding his US Open win, warmed up before the last round, and choose one driver to play with over his two others that were separated by only one seventh of a flex each. The present invention allows flex adjustments over an entire flex and would eliminate the need to carry multiple drivers.
[0008] More recently, several leading club manufacturers began offering drivers with two or three quick-connect shafts in an effort to find a better flex fit. While one shaft is bound to be better than another, they are nevertheless separated by a whole flex and would yield the best flex only by chance. This conclusion is supported by tests on hundreds of players and proved that at least twenty test clubs separated by one seventh of a flex, or 3 CPM, are required to cover the range of flexes that prove to be best for 95 percent of golfers. To cover the same range with quick-connect shafts, the manufacturers would need to provide same number of shafts, or 20 shafts, instead of only three, each separated by only one seventh of a flex or 3 CPM. The cost of this approach would be prohibitive. But here comes this invention to help bridge the fine adjustments of flexes between the coarser steps allowed by only a few quick-connect shafts, which would need to be separated by only one whole flex, at a much lower overall cost.
[0009] To understand why adjusting the shaft flex of a golf club is critical for good play, one must understand the role of the shaft which is to deliver the club head to the ball at the best attitude and phase angle of the various oscillations occurring in the Swing Plane, Toe Plane and Torque Axis. For the ball to be struck solidly, the sum of these angles must compensate for the errors in that player's swing path and timing.
[0010] For maximum energy transfer and therefore the longest shots, the center of gravity of the club head should strike the ball. But for straighter shots for a golfer with an average swing, it may be better for ball contact to occur slightly off-center to compensate for player-induced errors in the swing plane or torque deflection errors caused by club head and shaft characteristics. Although hard to fix in practice, player-induced errors are easy to identify using photography. Errors in directional control due to shaft oscillation phase angle are much more difficult to measure. Shaft flex oscillation in the Swing, Toe and Torque Planes are measured during player swings using strain gauges mechanically attached to the shaft and electrically connected to a computer, and the waveforms recorded. During a typical swing of slightly over one second duration, the shaft bends around 3 inches in all directions through 1.25 cycles of its flex frequency, in both the Swing and Toe Plane, both axes having the same flex frequency. The Torque Plane features an oscillation that is independent of the other two flex frequencies and is three to four times higher, 3.75 to 5 cycles, depending on the shaft model, with amplitude of a few degrees of angle. All three axes can have different phase angles at ball contact, varying from swing to swing for the same player, and varying more from player to player. The Toe Plane phase angle predominantly determines where on the club head the ball is struck, and the Swing Plane and Torque Plane phase angles determine the aiming direction of the club head at contact.
[0011] For example, if the club head is slightly open at ball contact due to player-induced Swing Plane error and Torque oscillation combined, which would cause the ball to go to the right of the target, then striking the ball off-center near the toe of the club face is best, since that will bring the ball back toward the target line. This is known as the gear effect due to right-to-left spin imparted from such contact, the latter of which being well known in the art. The net result of all these errors, without identifying the extent of any of them, is that some errors will cancel each other and cannot be predicted in their net effect, which is required to build optimized clubs with fixed parameters. The best compromise of each player's swing idiosyncrasies and club design parameters can only be found by adjusting the flex after club manufacture in order to adjust shaft deflection incrementally in the Toe Plane. This has the effect of determining where the ball strikes the club head, which the inventor believes allows fine tuning of directional control for most players. This concept runs counter to almost all that is written and most likely believed by experts who teach golf and design golf equipment, but is the crux of this invention. Most preferably, the adjustment of the flex of a club is performed after the club has been assembled as this technique provides an opportunity to compensate for all the variables in a practical manner
PRIOR ART
[0012] Heretofore, there have been competing attempts to modify the flexural characteristics of golf shafts after club assembly by adding either fixed or adjustable materials to either the outer or the inner surface of the shaft. Almost all of these attempts which add material to the outer surface of the shaft are accompanied by adverse cosmetic results. Those which attempt to change the shaft frequency from inside the shaft have been too heavy, too expensive, or are fixed in place after insertion and allow for no further adjustments during practice or play. Thus there remains a need for a system which will allow for continual flex adjustments over a large range in small steps.
[0013] A number of patents have alleged to adjust golf dub shaft flex or place objects inside the shaft to accomplish other missions and the most important ones are listed below.
[0014] U.S. Pat. No. 6,113,508 of M. Locarno et al (Sep. 5, 2000) employs an internal eccentric stiffening rod having a different stiffness depending on the angles of attachment. Because the patent deliberately causes the shaft flex to be radially unequal in shape as well as in flex, clubs produced by this method violate the USGA rules.
[0015] Another method for modifying flex entails adding a stiffening rod to the inside of a shaft, e.g. U.S. Pat. No. 3,833,233 of R. Shullin (Sep. 3, 1974). Varying lengths of shaft elements are inserted into dubs used specifically for fitting flex to a player. The inserted shaft elements are not to be adjusted in their position once in place, but only exchanged and are not intended to be present in a set of clubs during play. Rather, the elements are only to be used for fitting.
[0016] In U.S. Pat. Appln, No. US 2001/0005696 of M. Hendrick (Jun. 28, 2001), a short, generally 1-3 inch long, hollow shaft insert is used to change the swing weight of a club. It can be readjusted at any time, but does not, of itself, have any impact on the swing characteristics of the club other than swing weight. The patent specifically excludes changing the shaft flex using this design and inserts less than 11 inches long have little or no effect on flex as shown in FIG. 6 .
[0017] U.S. Pat. No. 5,478,075 of C.R. Saia et al (Dec. 26, 1995) describes a method of changing shaft flex using an insert with radially expandable rubber discs that can be expanded by turning a threaded energizing rod. The rubber discs are stationary as they expand and do not move in or out of the outer shaft.
[0018] U.S. Pat. No. 6,361,451 of B. Masters et al (Mar. 26, 2002), U.S. Pat. No. 6,241,623 to C. Liabangyang (Jun. 5, 2001), and U.S. Pat. No. 6,394,909 to C. Laibangyang (May 28, 2002) utilize a wire strung down the center of a golf shaft the tension of which is adjustable to exert varying compressive forces on the shaft thereby seeking to change its flex. The three inventions allow players to adjust flex in order to deliver more energy stored in the flex at ball impact, a near impossibility in practice, as mentioned earlier.
[0019] Another attempt to change the overall flex and also dampen the shock effect of a ball strike from the club head to the hands is referred to in U.S. Pat. No. 5,083,780 of T. C. Walton et al (Jan. 28, 1992). In this patent, the grip end is reinforced by a cylinder placed between the grip and the shaft under the grip thereby lowering the flex point, increasing the flex and dampening vibrations from the club head to the hands. Once set, it is not adjustable in practice or play.
[0020] U.S. Pat. No. 6,045,457 of T. Soong (Apr. 4, 2000) discloses a method of inserting a second shaft inside a bulged outer shaft to increase the flex of the resultant shaft combination. The patent claims that the resultant fixed amount of increase in flex and lowering of the flex point increases dub head speed. The bulged outer shaft serves to ensure that the second shaft only contact the main shaft at the two ends of the second shaft, i.e. the middle section of the second shaft does not contact the main shaft The force exerted by the second shaft is due only to rigidity of the insert because the insert is anchored at its butt end at the grip and only touches the outer shaft at the opposite end. Our tests show that an inner shaft must contact present invention provides such contact.
[0021] U.S. Pat. No. 5,054,781 of T. Soong (Oct. 8, 1991) discloses a method of building a shaft with a fold back shaft that is inserted and contacts the inner wall of the outer shaft only after some degree of shaft bending. The claim of increased energy storage and release at ball contact is dubious, and while it employs an insert to change the flex of the shaft, once set, it is not adjustable as the present invention provides.
[0022] U.S. Pat. No. 6,056,646 of T. Soong (May 2, 2000) employs a fixed insert to stiffen the flex of the outer golf shaft but is non-adjustable once installed. It is intended to stiffen the flex only when the shaft is flexed beyond a certain point The flex is increased when the tip of the insert is in contact with the outer shaft which occurs only when the shaft is extremely bent unlike the present invention which exerts pressure throughout the range of bending of the shaft.
[0023] U.S. Pat. No. 5,004,236 of Makoto Kameshima (Apr. 2, 1991) employs tubular elements inserted at various points to stiffen a golf club shaft, but all must be permanently fixed in place at the kick points once the optimum flex is determined and cannot be adjusted thereafter. The length of the elements is not defined but the one shown under the grip does not extend beyond the length of the grip. Since the standard grip length is 10.5 inches, the insert is below the minimum of 11 inches needed to affect the flex of the shaft as shown in FIG. 6 .
[0024] U.S. Pat. No. 5,632,691 of Richard Hannon (May 27, 1997) teaches adding a weight of 100 to 570 grams to a putter shaft to change the balance point. Not only does he specifically warn away from using these weights in shafts of other clubs in the set that are swung dynamically, but anyone skilled in the art would never add weights of this magnitude knowing full well that swing speed would be reduced considerably as shown in FIG. 8 . Adding more than 50 grams to a club other than a putter would defeat the good work of the shaft manufacturers over the last 30 years wherein they have reduced the weight of shafts by employing graphite and other space age materials from over 100 grams to around 50 grams. This shaft weight reduction allowed 20 grams to be added to the heads for the same club swing weight Adding back 100 grams to the club at any position, under the grip, down the shaft or to the head is obviously impractical. Also, Hannon advocates employing material suitable for changing weight distribution only. These materials lack rigidity and would not stiffen the shaft of a putter or any other club as the present invention advocates. U.S. Pat. No. 5,716,289 of Joseph Okoneski (Feb. 10, 1998) teaches the permanent attachment with an adhesive of an assembly of a receptacle and a weight under the grip eliminating further movement of the assembly. It adds weight but does not affect the flex of the golf dub shaft since none of the elements are longer that the grip which is less than 11 inches, the shortest insert found to have an appreciable effect on flex as shown in FIG. 7 .
[0025] Many other patents feature shaft inserts that are primarily concerned with damping high frequency vibrations transmitted from the club head to the hands.
[0026] None of the prior art has succeeded in creating a practical golf club which allows a player to repeatedly adjust the flex and play with that club after it has been determined that the club performance is maximized nor to allow future adjustment of the flex as playing conditions change. It should be noted for those unfamiliar with recent USGA rules changes, that it is now permissible to play with an adjustable flex club shaft as long as no adjustments are made during a competitive round of golf wherein scores are reported.
[0027] Several patents by Richard M. Weiss, U.S. Pat. No. 6,183,375 (Feb. 6, 2001), 6,494,109 (Dec. 17, 2002), and 7,024,953 (Apr. 11, 2006) teach how to find the spine of a golf club shaft and to align it so that the pattern traced by the dub head, when clamped by its grip and oscillated in the swing plane which is the accepted spine alignment test, remains oscillating in the swing plane, as shown in FIG. 10 , and does not gallop in the toe plane, as shown in FIG. 9 . This invention makes no claim on orienting the spine before or after the shaft is installed, but teaches that adding an insert should not disrupt the test for proper spine alignment in the finished club. The pattern shown in FIG. 9 indicates a spine misalignment while the pattern shown in FIG. 10 signifies proper alignment. By rotating the insert circumferentially using the, the oscillations can be forced to conform in most cases, to the pattern of FIG. 10 and should be left in that orientation for all flex adjustments.
[0028] Accordingly, it is the object of this invention to provide a means which will enable a player to adjust the shaft flex of a golf club during practice and play in order to discover the best shaft flex for that player with minimal disruption of the weight distribution.
[0029] It is the further object of this invention to align the insert circumferentially with the shaft spine to avoid unwanted galloping when the club is oscillated by its grip in the accepted spine alignment test.
[0030] Still further objects and advantages will become apparent from a consideration of the ensuing description and accompanying drawings
DRAWINGS—BRIEF DESCRIPTION OF THE DRAWINGS
[0031] FIG. 1 is a plan view of the rigid tubular insert assembly 19
[0032] FIG. 2 is a plan view of a golf club with a shaft insert assembly in place
[0033] FIG. 3 is an expanded view of section cc in FIG. 2 with threaded extractor 17
[0034] FIG. 4 is and end view of section dd in FIG. 3
[0035] FIG. 5 is an expanded view of an alternative construction of the insert assembly
[0036] FIG. 6 is a graph of flex increase versus insert penetrations for various insert lengths
[0037] FIG. 7 is a graph of club head speed versus added weight for various weight positions
[0038] FIG. 8 is a plan view of a 45 inch driver showing positions of weights in FIG. 8
[0039] FIG. 9 is a dub head oscillating pattern of a golf club with misaligned shaft spine using the accepted static spine alignment test
[0040] FIG. 10 is a club head oscillating pattern of a golf club with properly adjusted spine the accepted static spine alignment test
DRAWINGS—REFERENCE NUMERALS
[0041]
[0000]
10
golf club shaft
12
grip
19
shaft insert assembly
14
club head
16
shaft insert
17
insert adjuster
18
compressible
friction agent
SUMMARY OF THE INVENTION
[0042] The object of the invention is to provide a means to adjust the flex of a dynamically swung golf club at any time after the club is assembled. This is achieved by placing a moveable rigid tubular shaft insert assembly in the hollow portion of the grip end of the golf club shaft whose penetration can be altered. The insert assembly comprises a shaft insert, which is a piece of rigid tubular material about 12 to 24 inches, preferably about 13 to 18 inches, coated with a compressible friction agent. To prepare the insert assembly, the insert is coated with a compressible agent that is self adhering to the insert and is allowed to cure before insertion of the assembly into the golf shaft. In this way, the agent adheres permanently to the insert and is held in place inside the shaft only by the friction caused by compression of its cured surface providing purchase to the inner surface of the golf shaft. The assembly has a smaller diameter than the golf club shaft into which it is inserted. The insert and can be tapered or cylindrical. By changing the depth of penetration of the shaft insert assembly between about 1 to 10 inches, the flex of a golf club can be adjusted to a particular player's swing dynamics to achieve better performance. The insert assembly is fixed in place by friction within the shaft and there is little to no likelihood of it working loose during a round of golf. However, it can be readjusted and thus the fitting of the club to the player can be revisited at any time. This invention can be used on any clubs with hollow shafts but has maximum benefit for the longer clubs, such as drivers and fairway woods and no effect on putters whose shafts bend very little, if at all.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0043] As shown in FIG. 1 , the preferred embodiment of this invention is a tapered rigid tubular shaft assembly 19 comprising an insert 16 , of 12 to 24 inches in length, coated with a compressible friction agent 18 , such as silicone. Alternatively, the rigid tubular shaft may have internal female threads at one end allowing for extraction with an insert adjuster 17 , as shown in FIG. 3 . The insert assembly 19 , comprised of insert 16 and friction agent 18 , are inserted into a golf club shaft 10 , as shown in FIG. 2 , for the purpose of adjusting the stiffness of the golf club shaft.
[0044] As shown in FIG. 2 , a conventional golf dub comprises a golf club shaft 10 , usually about 34 to 47 inches in length, having a grip 12 at the butt end and a club head 14 at the tip end of said golf club shaft. A club head may be a “wood” head or an “iron” club head, both or which can be manufactured from a variety of materials including metals, wood, composites, graphite and poly-carbonate or combinations of materials. Shafts are constructed from a variety of materials, mostly steel, aluminum, graphite, or titanium. They are usually tapered but must be of homogeneous circular cross section and have equal stiffness in all orthogonal directions in order to conform to the current rules governing competition enforced by the U.S. Golf Association.
[0045] Shaft materials have a high strength to weight ratio to minimize the overall weight of the club while providing the necessary rigidity for desired performance. The development of graphite and other composites in shaft construction over the last 30 years has reduced driver shaft weight from over 100 grams for steel to around 50 grams for graphite, allowing a redistribution of weight favoring increased head weight for the same swing weight for the finished club. This evolution permits increased swing speeds or heavier heads or some combination of both for added distance. Adding back weight to the shaft must be approached carefully or the gain in shaft weight reduction will be nullified. As FIG. 7 shows, adding weight under the grip has the least effect on swing speed and can even increase it due to the optimizing effect of adjusting shaft flex, which is one of the objects of this invention. The best compromise of added weight versus flex adjustment for the shaft material used in this embodiment is a preferred length of assembly of 13 to 16 inches: lengths smaller than 12 inches have little range of flex adjustment (see FIG. 6 ) and longer lengths become too heavy and the benefit of added flex is contravened by the decreased speed contribution of excess weight (see FIG. 7 ). If lighter materials are used to manufacture the shaft insert, the range of insert lengths could be increased from 16 to perhaps 24 inches.
[0046] Common shaft manufacturing techniques for both steel and graphite require a thin wall construction with a circular cavity in the center of the golf club shaft 10 . The existence of this cavity creates the opportunity for this invention, namely, the placement of a rigid shaft insert assembly within the cavity as shown in FIG. 2 and in detail in subsequent figures.
[0047] Refer now to the preferred embodiment of the invention shown in FIG. 3 . The hollow rigid tubular shaft insert assembly coated with the cured compressible friction agent 18 is positioned inside the hollow cavity of the golf club shaft 10 . A silicone adhesive, such as GE Silicone™, is a suitable material for the compressible friction agent To insure that the silicone adheres to the insert and not to the golf shaft itself, the silicone should cure while not in contact with the golf club shaft. It has the desirable properties of bonding to the shaft insert 16 after curing, and after insertion, holding the assembly in place by providing friction to the golf dub shaft 10 , a large degree of compressibility enabling a wide range of insertion positions, and long life expectancy.
[0048] By adjusting the insertion depth P, of a shaft insert assembly that is 12 to 24 inches long, from about 1 to 10 inches will change the overall flex of the shaft of the golf club without altering its accepted cosmetic look. The assembly can be positioned most easily if the inside surface of the assembly is threaded so that an insert adjuster 17 , which has the complimenting thread, can be joined to the assembly to easily decrease its penetration depth P. Once positioned, the shaft insert assembly is held by friction at the desired penetration depth P such that there is no reasonable likelihood of it working loose during a round of golf. The range of insertion possible, before the compressible friction agent will compress no more, is best accomplished if the shaft insert is tapered with a pitch roughly equal to the shaft into which it is to be placed. However, a cylindrical or non-tapered insert can be used for this purpose by using a thicker coating of compressible friction agent such that the overall shape of the shaft insert assembly is somewhat tapered.
[0049] A few shafts sold today are cylindrical under the grip having the taper begin some distance toward the shaft end attached to the head These shafts are more suitable to use with this invention, but the more common fully tapered shafts are found to have a suitable range of adjustment.
[0050] While a tubular shaft insert configuration is preferred due to its strength-to-weight ratio advantage, solid cross-section configurations can be employed and may enjoy a cost advantage.
[0051] The shaft insert assembly can be inserted before or after a grip has been installed on a shaft or club. The grip must have an opening at the butt end about 0.55 inches which is the approximate inner diameter of the shaft A special grip with an opening of this size can be installed or a standard grip modified to have a hole at the butt end of this size. This size hole will allow insertion of the shaft insert assembly as well as an insert adjuster 17 , to make penetration adjustments or to completely remove the shaft insert assembly.
[0052] In general the extent of penetration P of the shaft insert assembly into the shaft will range from about 1 to about 10 inches. Adjustment of the extent of penetration P of the shaft insert assembly determines the overall flex of the shaft in the Toe and Swing Planes of the golf club and therefore the club's dynamic swing parameters. For instance, as the penetration of a 14-inch tubular graphite shaft insert assembly is varied over a seven inch range, the overall shaft flex, as measured in industry standard terms of frequency, changes approximately 7 cycles per minute (see FIG. 6 ). If a greater range is desired, an 18 inch assembly can be substituted providing a combined range of 12 cycles per minute, almost a complete flex as measured by industry standards. Alternatively, a stiffer shaft can be used as the starting point and the 14 inch assembly used with it to increase its flex by another 7 CPM. In this manner, a range of 30 CPM can be covered by three or four starting shafts and one 14 inch insert assembly. This CPM range covers 90 percent of the hundreds of golfers tested by the inventor using the traditional trial and error fitting methods to find the best flex for each player.
[0053] Other higher strength-to-weight ratio materials can be used to form the shaft inserts, e.g. graphite, aluminum, or titanium. These materials will increase the range of a single insert length and are within the scope of this invention. It should be obvious but for the sake of complete disclosure, an insert can only increase the overall stiffness of a golf shaft and cannot decrease the stiffness below the stiffness of the original golf shaft into which it is placed.
[0054] As the amount of penetration P of the shaft insert assembly is increased, the overall flex of the golf club shaft increases due to increased stiffness caused by the presence of the insert as it moves from a position under the grip farther into the middle portion of the golf club shaft 10 where bending of the shaft increases during a swing. When the golf club shaft 10 is not bent there is little effect from the presence of the shaft insert But during the swing of a club, the shaft typically bends a total of about three inches over its entire length, which affords the insert an opportunity to change the overall stiffness of the shaft
Alternative Compressible Friction Agent Configuration
[0055] An alternative embodiment of the invention, shown in FIG. 5 , employs small pockets of said compressible friction agent 18 spaced over the length of the shaft insert 16 instead of covering the entire length of the insert as shown in FIG. 1 . The holding power of each setting may be somewhat diminished compared to the previous alternative, but performance is comparable, and it is less costly to manufacture. In practice, as few as three pockets have been tested and found to be satisfactory.
[0056] Although the description above contains much specificity, these should not be construed as limiting the scope of the invention but as merely providing illustrations of some of the presently envisioned embodiments of this invention. Various other embodiments and ramifications that would occur to a workman in the field are possible within its scope. The scope of this invention is determined by the appended claims and their legal equivalents, rather than by the description and example given. | A moveable shaft insert assembly about 13 to 18 inches long weighing less than 50 grams is inserted into a hollow golf dub shaft wherein the depth of insertion of the shaft insert assembly may vary from about 1 to 10 inches. Changing the location of the shaft insert assembly allows a player to change the flex of the shaft and thereby optimize the performance of the club dynamics for that player for that day. The shaft insert is held in place by friction between the shaft and the shaft insert assembly. So shaft flex fitting can be administered by a player with or without coaching, and can be revisited at any time by a simple adjustment The shaft inserts are useful on all hollow shaft clubs, and can be retrofitted to existing clubs without removing the grip. | 0 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] The present application claims priority under 35 U.S.C. §119 to German Patent Application No. DE 10 2012 010 768.4 (filed on (May 31, 2012), which is hereby incorporated by reference in its entirety.
TECHNICAL FIELD
[0002] A structural component for a motor vehicle, such as a mounting bracket configured to be mounted at the front or rear region of the vehicle. The structural component is composed of a material such as plastic and is manufactured as a moulded part. The structural component includes in at least partial regions two or more fabric layers which are overmoulded with a thermoplastic polymer.
BACKGROUND
[0003] In modern motor vehicles, the radiator grille and the auxiliary components located spatially behind it, such as, for instance, the heat exchanger of the engine cooling system, are not directly mounted on the vehicle structure but on a supporting structure mounted thereon, which is typically referred to as a mounting bracket. This offers the advantage known per se that different engine variants with different auxiliary components can be implemented without any change to the vehicle structure. Moreover, the mounting bracket simplifies the pre-assembly of the radiator module and may in a suitable embodiment also save weight in comparison with direct mounting.
[0004] Known mounting brackets are disclosed in the official publications DE 10 2008 026 977 A1 and DE 10 2010 012 123 A1. DE 10 2008 026 977 A1, in particular, describes how the mounting bracket is connected to the vehicle structure in a customary manner, and discloses a mounting bracket made of plastic, which besides a saving in weight also offers advantages in manufacture.
[0005] The aforementioned documents further disclose that the customary mounting brackets are, from a point of view of cost consideration, advantageously made from fibre-reinforced polymer material in an injection moulding process. In addition, they and the further document DE 20 2006 019 341 U1 describe that sheet metal structures or blanks made from so-called organometallic sheet may be embedded as reinforcements in highly stressed areas of the injection moulded polymer material of the conventional mounting brackets. The term organometallic sheet here refers to a textile surface structure soaked in a thermoplastic synthetic resin. The surface structure may, in particular, be a fabric or non-woven made from natural, carbon, glass or mineral fibres. The thermoplastic property of the synthetic resin allows that the thus formed matrix can be softened by means of heating and that the organometallic sheet, which is typically flat in its shipping state, can be remoulded into a contoured shape by means of compression moulding after having been heated to its softening temperature. As suggested by the name of the basic material, a similarity with the drawing or forming of sheet metal exists in the context of its processing and the shapes thus achievable.
[0006] DE 10332969 A1 discloses a module support made from a fibre composite plastic. This module support is formed by compression moulding and at least partially consists of fabric layers. The entire component is reinforced by means of a fabric layer of continuous filaments and, depending on requirements, receives additional reinforcements by way of fibre inserts.
[0007] DE 1020596581 discloses a construction element made from fibre reinforced plastic. The element comprises a multiple-layer construction with different types of fibres and different fibre orientations and a hollow core. The individual components here are always overmoulded with a simple plastic.
SUMMARY
[0008] Embodiments relate to a structural component of enhanced design as compared with the known embodiments.
[0009] In accordance with embodiments, a structural component for a motor vehicle includes a mounting bracket which is mountable in a front or rear region of the vehicle. The structural component is composed of a plastic material and is manufactured as a moulded part. In at least partial regions the structural component has two or more fabric layers which are overmoulded with a thermoplastic polymer, and in which a polymer surrounding the fabric layers comprises glass fibres.
[0010] In accordance with embodiments, a structural component for a motor vehicle includes at least two fabric layers which are overmoulded with a thermoplastic polymer to form a thus form a multilayer structure, in which a polymer surrounding the fabric layers comprises glass fibres.
[0011] In accordance with embodiments, a structural component for a motor vehicle includes: a mounting bracket composed of plastic and in which partial regions thereof. The multi-layered structure includes: an upper fiber layer composed of glass fibers; a lower fiber layer composed of glass fibers; an intermediate fiber layer composed of carbon fibers provided between the upper fiber layer and the lower fiber layer; an upper thermoplastic polymer layer over the upper fiber layer; a lower thermoplastic polymer layer under the lower fiber layer; a first intermediate thermoplastic polymer layer between the upper fiber layer and the intermediate fiber layer; and a second intermediate thermoplastic polymer layer between the lower fiber layer and the intermediate fiber layer.
[0012] The structural component comprises a plurality of fabric layers which are overmoulded with a thermoplastic polymer. In accordance with embodiments, PA 6 GF35 (polyamide 6 with 35% glass fibre) is used as the thermoplastic polymer. Alternatively, other materials may be used in the overmoulding, for instance PP, PA, in each case with or without a filler.
[0013] The fabric layers may be composed of the same material, for instance, glass fibre or carbon fibre. Depending on the intended strength, different layers may also be applied, alternating between GF and carbon. Ultimately, it is also possible for fabric layers of the same material but with different orientations of fibres and/or of fabrics to be applied. This means that a different orientation of warp/weft is selected for successive fabric layers.
[0014] The structural component in ccordance with embodiments comprises a different construction in its individual parts. In this way, the strength requirements can be specifically met, at the same time saving both material and weight in areas that are less stressed. The appropriate combination of GF/CRP is calculated on the basis of a stress simulation conducted earlier.
[0015] The differently selected and shaped GF/CRP insert parts make possible a lightweight construction which completely dispenses with metal components. As a result, an otherwise necessary anti-corrosion coating, in particular, becomes obsolete. Ultimately, a metal-free construction also offers an improvement in the electromagnetic behaviour, the absence of any reciprocal effect means that there is less interference with the sensors located in the front end of the vehicle and/or allows them to be operated using less power. Overall, an environment which is more favourable to the vehicle sensor system is created.
DRAWINGS
[0016] Embodiments are described by way of example below with reference to the drawings.
[0017] FIG. 1 illustrates a perspective view of a mounting bracket provided at the front end of a motor vehicle.
[0018] FIG. 2 illustrates an exploded view of the individual insert parts for the mounting bracket of FIG. 1 .
[0019] FIG. 3 illustrates a cross-section of the multi-layered construction of an insert part.
[0020] FIG. 4 illustrates the relative orientation of the warp and weft threads to one another.
DESCRIPTION
[0021] The mounting bracket 1 , which is embodied in one piece, is composed of plastic with integrated reinforcement parts, and indeed, advantageously has no metallic insert parts at all. The mounting bracket 1 made in one piece includes a frame section 2 , an upper transverse section, which is attached to the top of the frame section 2 , and two struts which extend from approximately the centre of the frame section 2 in both directions. The mounting bracket 1 is illustrated in its entirety in FIG. 1 , that is to say with all the reinforcement and/or insert parts yet to be illustrated in greater detail.
[0022] As illustrated in FIG. 2 , the individual insert parts for the mounting bracket 1 includes the frame section 2 , the lower brace 3 , the centre section of the upper brace (upper transverse section) 4 , the left and right lateral sections 5 of the upper brace, the one-piece upper brace 6 , the upper section of the upper transverse section, and the vertical struts 7 located laterally on the left and right of the frame section, are reinforced and/or embodied as insert parts. The named parts, being insert parts, are inserted into a mould which corresponds to the shape of the finished mounting bracket 1 illustrated in FIG. 1 and overmoulded or inserted into a pre-fabricated plastic component and bonded to the pre-fabricated plastic component by way of overmoulding.
[0023] As illustrated in FIG. 3 , a cross-section of the multi-layered construction of an insert part 8 is provided. In the example illustrated, the insert part is formed by a plurality of (e.g., three) fabric layers which are overmoulded with a total of four layers KU of a thermoplastic polymer (for instance PA 6 GF35). The upper and the lower fabric layer is composed of a glass fibre GF, the centre layer is composed of carbon fibre CF. A layer each of the thermoplastic polymer KU is located between these layers and respectively as a top and bottom final layer.
[0024] As illustrated in FIG. 4 , the relative orientation of the warp and weft threads K,S to one another is provided. It is usual in this context for the angle a between warp and weft threads K,S to be 90°, with a fabric having an angle between the warp and weft threads K,S deviating from 90° also being usable. With reference to the layered construction illustrated in FIG. 3 , it is possible for the orientation of threads and/or the angle between the warp and weft threads K,S to be different in successive fabric layers. This is implemented with the objective of homogenizing the anisotropic material properties of the individual fabric layers in their entirety and/or of creating a preferred direction of stiffness, such as a specified bending point, at certain locations, for instance with a view to providing a predetermined direction of deformation in the event of a crash.
[0025] The insert parts illustrated in FIG. 2 may be embodied as described in the following according to the predefined requirements.
[0026] The three-piece upper brace (the upper transverse section) includes a left and a right lateral section 5 and a centre section 4 . The lateral sections 5 comprise only layers of glass fibre GF in their layered construction, the centre section 4 has a layered construction consisting of a combination of materials. The outer layers are glass fibre GF, the centre layer is carbon fibre CF.
[0027] The upper brace 4 , 5 , 6 is embodied as a single section or multiple sections. All sections and the vertical struts 7 include a material combination of glass fibre GF and carbon fibre CF, which is indeed variable with reference to layer thickness and layer sequence.
[0028] The insert parts of the mounting bracket 1 may, in terms of their layered construction, completely consist of carbon fibre CF or of glass fibre GF. Ultimately, the different insert parts may also be embodied in different ways, as described above.
[0029] Although embodiments have been described herein, it should be understood that numerous other modifications and embodiments can be devised by those skilled in the art that will fall within the spirit and scope of the principles of this disclosure. More particularly, various variations and modifications are possible in the component parts and/or arrangements of the subject combination arrangement within the scope of the disclosure, the drawings and the appended claims. In addition to variations and modifications in the component parts and/or arrangements, alternative uses will also be apparent to those skilled in the art.
LIST OF REFERENCE SIGNS
[0000]
1 Mounting bracket
2 Frame section
3 Lower brace
4 Centre section of upper brace
5 Lateral sections of upper brace
6 One-piece upper brace, upper part of upper transverse section
7 Vertical strut
8 Insert part
GF Glass fibre
CF Carbon fibre
KU Polymer overmoulding, thermoplastic polymer
S Weft thread, direction of weft
K Warp thread, direction of warp | A structural component for a motor vehicle which is mountable in the front or rear region of the vehicle. The structural component is composed of plastic and is manufactured as a moulded part, and which includes in at least partial regions thereof two or more fabric layers which are overmoulded with a thermoplastic polymer. | 1 |
BACKGROUND OF THE INVENTION
This invention generally relates to a construction and method for shipping products in a manner permitting efficient and safe and ready display in the store using the shipping materials. In particular, this invention enables the manufacturer to ship its product in a sturdy and durable manner on a pallet while permitting the retailer to display the product for sale on the floor of a grocery or other retail store without the need for disturbing or removing the product from its basic shipping materials.
It is known in the art how to ship a product in a sturdy and rigid fashion. It also known in the art how to create a store display by stacking cartons and even to permit cutting of shipping cartons to create point-of-sale individual displays. The advantage of that arrangement is convenience to the retailer and positioning of products in preferred positions in aisles or at the end of aisles rather than on shelves.
However, a construction permitting individual shipping and display on a pallet basis of a plurality of cartons with a minimum of manipulation, and particularly adapted for liquid products provided in rigid containers such as glass containers, has not been heretofore provided and is deemed of outstanding commercial advantage.
SUMMARY OF THE INVENTION
Generally speaking, in accordance with the invention, there is provided a construction and method for shipping and displaying rigid containers by using a plurality of base cartons of a height less than the height of the containers. Each base carton is formed with a plurality of holding regions each shaped to receive and retain a lower portion of a container, positioning the containers in spaced relation and a flat bottom surface suitable for support by the tops of a group of containers themselves contained in a base carton. At least one top carton overlies an upper region of at least a portion of the containers in the uppermost of a stack of filled base containers. The top carton is of a height less than the height of the container and is adapted to engage the upper portions of the containers.
The base cartons are each preferably formed of a blank having fold lines and cuts. The blank is manipulated along the fold lines and cuts to form an essentially rectangular base carton of a height selected to permit viewing of at least a portion of the containers supported thereby, and even a portion of the product identification information on the containers. A plurality of the base cartons, once formed and loaded, are placed on a pallet in a specified configuration. In the preferred embodiment the formation is 3 × 4, three base cartons lengthwise, four base cartons widthwise.
Once the first layer of base cartons and containers is formed, a corrugated board sheet may be placed on top of the layer and a second layer of loaded base cartons are applied in a like or different array. The process is repeated until the desired height is reached. In a preferred embodiment, five layers of loaded base cartons is the desired height. A number of top cartons sufficient to cover the entire top layer is then position on the top layer. The top cartons are each formed by a lid portion containing a bottom and four downwardly facing sides receiving an insert portion containing four upwardly facing sides and a bottom containing holes positioned to receive the top region of the bottles. Each top carton is preferably dimensioned to cover and engage the cartons on more than one base carton. In a preferred embodiment two top cartons are provided, each covering the containers in six base cartons.
To further support and steady the product for shipping, corner pieces preferably made of corrugated board are added to the tops and sides to lock the cases in place. Straps are then wrapped around the entire display and pallet to form a shippable unit. A pallet base decorative strip suitable for covering the periphery of the pallet and containing advertising material may be retained by the straps or a wrapping material for shipping and eventual removal and application when the product is displayed in the retail store. Finally, plastic stretch wrap is used to wrap the assembled shipper display to protect the product containers from contamination and pilfering and to aid in holding the assembly together during shipping and transportation. In an alternative embodiment, corner pieces and straps may be dispensed with and replaced by a plastic container dimensioned to capture the assembled top cartons, base cartons, containers and pallet when shrunk into engagement therewith.
The containers are formed preferably with indented regions above the bottoms, the holding regions of the base cartons including deflectable tabs positioned to be displaced by the lower region of the container during insert and to engage in the indented regions of the container to retain the container. The holding regions are each preferably formed with a symmetrical array of displaceable tabs greater in number than the number of indented regions on the container. While the indented regions are not symmetrically positioned, the tabs permit the container to be retained without regard to the orientation of the container in the holding region.
Accordingly, it is an object of this invention to provide a construction for the steady and sturdy shipping of a product.
Another object of the invention is to provide a method and construction for shipping rigid product containers in several layers on a pallet and transforming the shipping materials into a display unit without the need to remove the product from the pallet or to cut open cartons, and with minimum manipulation.
A further object of the invention is to provide a shipping construction and method using minimum materials which exposes the product labels during shipping and display and permits display and shipping on a pallet without removal therefrom.
Still other objects and advantages of the invention will, in part, be obvious and will, in part be apparent from the specification.
The invention accordingly comprises an article of manufacture possessing the features, properties, and the relation of elements which will be exemplified in the article hereinafter described, and the scope of the invention will be indicated in the
BRIEF DESCRIPTION OF THE DRAWINGS
For a fuller understanding of the invention, reference is had to the following description taken in connection with the accompanying drawings, in which:
FIG. 1 is a perspective view of the shipper display in accordance with the invention;
FIG. 2 is a perspective view of the shipper display in accordance with the invention in the display configuration;
FIG. 3 is a top plan view of a base carton blank in accordance with the invention having identified slots, fold lines, cuts and tabs;
FIG. 4 is a fragmentary plan view of a holding region a base carton in accordance with the invention;
FIG. 5 and 6 are fragmentary views of the carton taken along the lines 5-5 and 6-6, respectively of FIG. 4;
FIG. 7 is a top plan view of the sectional blank for the insert portion of the top carton;
FIGS. 8 and 9 are fragmentary views taken along lines 8-8 and 9-9 of FIG. 1; and
FIG. 10 is a partially sectional view of an alternative embodiment of the shipper display in accordance with the invention with shrink bag in position over a loaded pallet above a suction mechanism; and
FIG. 11 is a side elevational view of the shrink bag embodiment of the shipper display in the shipping configuration, inclined at an angle to show the structural integrity of the construction.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to the drawings in detail, it will seen that there is illustrated in FIG. 1 through 8 a shipper display which is formed in accordance with the invention, the shipper display being generally referred to in FIG. 1 by the reference numeral 12. As more particularly seen in FIGS. 1 and 2, the base of the shipper display is a pallet 16 of conventional construction, preferably formed of wood. A plurality of base cartons 14, each carrying six rigid bottle containers 82, are stacked on the pallet in a solid three base carton by four base carton array. Five layers of said three by four base carton arrays are stacked one upon another with flat sheets of corrugated board 86 between each layer (FIGS. 2 and 9). Two top cartons 18 are laid on top of the top layer of containers 82, each top carton mating with the tops 112 of containers 82.
Four top corner protectors 104 are positioned along each of the horizontally extending top corner edges defined by the two side-by-side top boxes. The top corner protectors 104 and the entire assembly of pallet 16, base cartons 14, containers 82, top cartons 18 and corrugated boards 86 are held together by strapping material 108 preferably formed of a plastic material. Side corner protectors 106 are mounted on each of the four vertically extending edges defined by the stacks of base cartons 14 and are held in place by protective plastic stretch wrap material 110 extending at least about the four vertical sides of the assembled shipper display as more particularly shown in FIGS. 1, 8 and 9. Also captured and retained by the plastic stretch wrap material 110 can be a point-of-sale poster 114 and a folded pallet base decorative strip 116 (FIG. 1).
The assembled shipper display 12 can be stored and shipped as a unit, each unit including 360 containers in the example depicted. The shipper display 12 can be positioned in a retail establishment at a preferred position at the end of an aisle or in an aisle and readily agreed by the retailer to present the product bearing containers for display and sale.
Specifically, the stretch wrap material 110 and straps 108 are readily cut away and the top corner protectors 104, side corner protectors 106 and top cartons 18 are removed and discarded to expose the top layer of containers for removal by customers.
As more particularly shown in FIG. 2, the pallet base decorating strip is unfolded and secured to the periphery of the wooden pallet, as by staples. The result is both more decorative and provides a surface suitable for promotional material such as repetitions of the trademark and product description. The outer periphery of each base carton 14 can be similarly decorated. Further, as more particularly shown in FIG. 2, a large portion of each layer of the containers 82 and the labels 120 thereof are visible between the spaced base cartons, providing an effective and eye-pleasing display
When the top layer of containers are removed, or as each base carton 14 is emptied, the base carton of the top layer can be removed and discarded. When an entire layer is removed, the protective corrugated board 86 above the next layer is removed and discarded. When the pallet is entirely empty, it can be removed and discarded or recycled. In any event, the location is available for the next shipper display -2.
Referring now particularly to FIG. 3, illustrated is a blank, generally identified by the reference numeral 20, from which a base carton 14 is formed. The carton blank 20 is preferably formed of corrugated sheet material provided with a suitable decorative external coating to display information or trademarks for the product, preferably on side wall panels 54, 58, 62A and 62B. The corrugated sheet material is preferred because of its ability to support the weight of the containers 82.
The blank 20 is defined by an outer essentially rectangular portion 22 and an inner essentially rectangular portion 24. The blank 20 contains a plurality of fold lines 26, 28A, 28B, 30A, 30B, 34, 36A, 36B, 38, 40A, 40B, 42 and 44 (indicated by dashed lines). These fold lines, formed during the cutting of the blank by die portions which do not penetrate the material but compress same, are used to bend and fold the blank in order to create each bottom carton. The blank further contains cuts to define desired tabs and apertures and to enable elements of the blank to fold and be displaced relative to other portions to add support to the structure. These cuts are represented by numerals 43, 45, 46A and 46B, 48A and 48B, 50A and 50B and 52.
A base carton 14 is formed by pivoting the side panel 54 by 90° on the axis of fold line 34 towards the outer bottom panel 55 of the rectangular portion 22 whereby it rests perpendicular to the bottom panel. Flaps 56A and 56B which are attached to the side panel 54 are then pivoted 90° about the fold lines 36A and 36B, respectively. The flaps are thus extended perpendicularly to side panel 54 parallel to fold lines 30A and 30B. The side panel 58 is then pivoted 90° towards the outer bottom panel 55 along the axis of fold line 26 to become perpendicular to the bottom panel 55 and parallel to side panel 54. The flaps 60A and 60B which are attached to side panel 58 are then pivoted 90° towards the center about the axis of fold lines 25A and 25B, respectively, such that they are perpendicular to both the outer bottom panel 55 and side panel 58 and extend parallel to fold lines 30A and 30B.
Side panel portions 62A and 62B are then pivoted 90° about the axis of the fold lines 30a and 30b, respectively, toward the outer bottom panel 55 so as to each extend perpendicular to bottom panel 55 and parallel to tabs 56A, 56B, 60A and 60B. Side panel portions 62C and 62D of the outer bottom panel 59 are then pivoted 180° towards dual fold lines 28A and 28B so that they also extend parallel to side panel portions 62A and 62B and tabs 56A, 56B, 60A and 60B. When so positioned, tabs 64A are received in slots 68A and tabs 64B are received in slots 68B to hold the side panel portions in position. When so engaged, tabs 56A and 60A are captured between side panel portions 62A and 62C and tabs 56B and 60B are captured between side panel portions 62B and 62D, to form a strong outer portion of the bottom cartons. In lieu of engaging or capturing tabs 56A, 56B, 60A, 60B, 64A and 64B, the tabs may be glued or stapled to their respective side panels 62A, 62B, 62C and 62D to form a rigid assembly free from slippage during shipping.
The side panels 72A and 72B of the top rectangular portion 24 are then pivoted 90° towards the rectangular container receiving panel 52 about the axis of the fold lines 40A and 40B, respectively. The side panel 74 is then pivoted 90, toward the container receiving panel 52 90° about the axis of fold line 44. The entire rectangular portion 24 is then rotated 90° relative to side panel 54 towards the outer bottom panel 55 whereby the side panels 72a and 72b and are positioned on the inside of and parallel to side panel portions members 62C and 62D and side panel 74 is positioned inside of and parallel to side panel 58, thereby creating a rectangular box with apertures 76A, 76B, 78A, 78B, 80A and 80B on the top thereof, defined by irregular rectangular cut lines.
Each container 82 is a rigid glass or plastic bottle having a neck region 83 supporting a cap 112 and a wider lower region 85 (FIGS. 2, 8 and 9). The lower region 85 of each container 82 is formed with a pair of spaced vertically extending indented regions 87 defining a gripping portion or handle for the manipulation of the container during use (FIGS. 4 and 9). Each indented region 87 is formed with an undulating surface (FIG. 9) to define finger receiving recesses 89 in the indented regions. The lowermost region 95 of the container 84, below the indented region 87, is essentially a rounded rectangle in cross-section. A liquid 91 for example a juice product is contained within container 82. A suitable label 93 is provided on the side surface of the lower region of each container.
Referring to FIGS. 4-6 and 9, each of the apertures in container receiving panel 52 are provided for receiving a container 82. In the preferred embodiment, each aperture receives a bottle container 82 which is subsequently releasably retained in the aperture. Each aperture is formed with four pairs of tabs 84A, 84B, 84C, 84D, 84E, 84F, 84G and 84H, symmetrically positioned in each corner of the aperture and defined by cut lines 43 and fold lines 42, 40A and 40B. When a container 82 is inserted into an aperture (e.g. 76A), the enlarged lowermost region 95 of the container is of a large enough cross-sectional area that it must deflect downwardly tabs 84 while being inserted so as to rest on outer bottom panel 55. However, when so positioned, the tabs in registration with indented regions 87 of container 82, (tabs 84H and 84C in FIGS. 4 and 9) return to the horizontal position and serve to hold the container in the aperture. Although the indented regions are asymmetrical, the tabs 84 are symmetrical and can cooperate with a container irrespective of the rotational portion of the container in the aperture.
As shown in FIGS. 6 and 9, tabs bearing on the enlarged region 85 of container 82, out of registration with indented regions 87 are bent and bear against the side of the container to further retain it in position.
As noted above, a bottle container 82 is placed in each of the apertures 76a through 80b. In this configuration, there are six apertures, hence the base cartons 14 each carry six bottles per carton. To create the shipper display, twelve base cartons are placed on the pallet forming the first level so as to form the above described 3 × 4 array. Atop this first level is placed a corrugated board 86 as depicted in FIG. 2 and FIG. 9. The purpose of the corrugated sheet 86 is to create a smooth surface such that a new layer of base cartons can be placed upon it to create stacks of cartons, and to provide further cushioning for the tops of the containers which support the next layer. This enables the cartons to be stacked in an upward direction of four, five or six layers of bottom cartons from the pallet. Other arrays of base cartons can be used depending on the dimensions of the base carton and pallet. Also depending on the dimensions of the base carton, different arrays can be used for each layer, so that each base carton rests on the containers of more than one of the base cartons below it.
In the preferred embodiment, the base cartons are stacked to the height of five cartons as depicted in FIG. 2. The containers 82 remain separated by the construction of the shipper display during shipping. The height of the base cartons is selected to provide structural strength, to insure that some of tabs 84 are received in indented regions 87 and to insure that a substantiated portion of containers 82 and labels 93 are visible from the exterior of the shipper display. This permits packaging of several varieties (e.g. flavors) of the product in each shipper display since the contents are readily visible from all ends.
The top layer of the shipper display 12 is a two piece top carton 18 as depicted in FIGS. 1, 7 and 8, used to cover the top level of bottles. The blank 92 for the insert section of the top carton 18 is depicted in FIG. 7. This section is constructed by four side panels 122A, 122B, 95A and 95B which are folded 90° along fold lines 124A, 124B, 126A and 126B, respectively so as to be perpendicular to the horizontally extending rectangular neck supporting region 96 of insert section 92. The neck supporting region 96 contains a plurality of apertures 94 used to receive the neck 83 of container 82.
The insert portion 92 of the top carton 18 is inserted in a lid portion 98 formed from a blank similar to blank 92 but without apertures 94 and with a slightly larger horizontally extending central panel 136 so that the insert portion is received snugly in the lid portion with panels 122A, 122B, 95A, 95B facing upwardly.
Blank 92 is formed with cut lines 128A, 128B, 128C and 128D defining tabs 130A, 130B, 130C and 130D extending from both sides of panels 122A and 122B and rotated 90° relative thereto along the axis defined by extensions of fold lines 126A and 126B. Tabs 130A and 130C are secured to panels 122A and 122B, respectively, by adhesive or staples, as are tabs 130B and 130D, to define the insert portion.
The relation between the lid and insert portions of top carton 18 is shown in FIG. 8. The insert portion is depicted with its side walls pointing in an upward direction. The lid portion receives the insert portion as shown. When mounted on the top layer of containers, the central panel 136 of the lid portion of the top carton 18 rests atop caps 112 of containers 82. This position hinders the upward movement of the bottles during shipping. The apertures 94 of the insert portion engage the necks of the containers, providing further stability to the shipper display.
Referring now to FIGS. 10 and 11, an alternative embodiment is shown for the shipper display in accordance with the invention. Shrink bag 150 is manufactured from a tube of plastic film heat sealed at point 152 to form a bag configuration. Then, shrink bag 150 is applied over the pallet as shown in FIG. 10 either manually or by automation. Pallet 16 is supported over suction or vacuum means 154 such that when the machine is operating it forces the ends of shrink bag 150 to slide under pallet 16, allowing the lower ends of shrink bag 150 to fold under the lower edges of pallet 16. Next, a heat shrinking unit such as a MSK-290 Safety Shrink, manufactured by MSK Covertech Inc. and designed to essentially surround a portion of the height of the bag, is applied from the bottom up. This causes the shrink bag 150 to shrink to fit tightly about the shipper display including containers 82, bottom cartons 14, top cartons 18 and corrugated sheets 86 as shown in FIG. 11. Further, the lower end of shrink bag 150 extends under and captures pallet 16, leaving the underneath center region of pallet 16 uncovered by shrink bag 150. Shrink bag 150 holds the entire configuration in a vertical compression so that internal shifting of the pallet does not occur even when shipper display is tilted up to a 30° angle. This construction does not require top and side corner protectors 104, 106 or strapping material 108.
It will thus be seen that the objects set forth above, and those made apparent from the preceding description, are efficiently attained and, since certain changes may be made in the above construction without departing from the spirit and scope of the invention, it is intended that all matters contained in the above description or shown in the accompanying drawings shall be interpreted as illustrative and not in a limiting sense.
It is also to be understood that the following claims ar intended to cover all of the generic and specific features of the invention herein described, and all statements of the scope of the invention which, as a matter of language, might be said to fall therebetween. | This disclosure relates to a shipper display providing for construction and system for shipping and displaying a rigid container. The shipper display includes a plurality of base cartons for receiving the containers while leaving a substantial portion of the length thereof exposed. Stacks of filled base cartons are supported on a pallet and covered by a top carton which couples to the top of the containers. The assembly is joined for shipping by strappings and stretch wrap, or by a shrink bag, which, together with the top carton, are removed for display. The container may be formed with spaced indented regions which cooperate with tabs in the base carton to help hold the containers in place. | 1 |
RELATED PATENT DOCUMENTS
This application is a continuation of U.S. patent application Ser. No. 12/962,553 filed on Dec. 7, 2010, now U.S. Pat. No. 8,048,545 which is a continuation of U.S. patent application Ser. No. 11/235,208 filed on Sep. 27, 2005, now U.S. Pat. No. 7,846,564, which are incorporated herein by reference in their entireties.
FIELD OF THE INVENTION
The present invention relates to improved perpendicular magnetic data/information storage and retrieval media. The invention has particular utility in the design and use of hard disk media comprising granular perpendicular-type magnetic recording layers.
BACKGROUND OF THE INVENTION
Magnetic media are widely used in various applications, particularly in the computer industry for data/information storage and retrieval applications and in consumer electronics, typically in disk form, and efforts are continually made with the aim of increasing the areal recording density, i.e., bit density of the magnetic media. Conventional thin-film type magnetic media, wherein a fine-grained polycrystalline magnetic alloy layer serves as the active recording layer, are generally classified as “longitudinal” or “perpendicular”, depending upon the orientation of the direction of the magnetic anisotropy of the grains of magnetic material.
Perpendicular recording media have been found to be superior to longitudinal media in achieving very high bit densities without experiencing the thermal stability limit associated with the latter. In perpendicular magnetic recording media, residual magnetization is formed in a direction perpendicular to the surface of the magnetic medium, typically a layer of a magnetic material on a suitable substrate. Very high to ultra-high linear recording densities are obtainable by utilizing a “single-pole” magnetic transducer or “head” with such perpendicular magnetic media.
Efficient, high bit density recording utilizing a perpendicular magnetic medium requires interposition of a relatively thick (as compared with the magnetic recording layer), magnetically “soft” underlayer (“SUL”), i.e., a magnetic layer having a relatively lower anisotropy of about 1-1,000 Oe, such as of a NiFe alloy (Permalloy), between a non-magnetic substrate, e.g., of glass, aluminum (Al) or an Al-based alloy, and a magnetically “hard” recording layer having relatively high anisotropy, typically about 3-50 kOe, e.g., of a cobalt-based alloy (e.g., a Co—Cr alloy such as CoCrPtB, CoCrPtTaB, etc.) having perpendicular anisotropy. The magnetically soft underlayer serves to guide magnetic flux emanating from the head through the magnetically hard perpendicular recording layer.
A typical conventional perpendicular recording system 20 utilizing a vertically oriented magnetic medium 21 with a relatively thick soft magnetic underlayer, a relatively thin hard magnetic recording layer, and a magnetic transducer head 16 , is illustrated in FIG. 1 , wherein reference numerals 10 , 11 , 4 , 5 , and 6 , respectively, indicate a non-magnetic substrate, an optional adhesion layer, a soft magnetic underlayer, at least one non-magnetic seed layer (sometimes referred to as an “intermediate” layer or as an “interlayer”), and at least one magnetically hard perpendicular recording layer with its magnetic easy axis substantially perpendicular to the film plane.
Still referring to FIG. 1 , reference numerals 7 and 8 , respectively, indicate the main (writing) and auxiliary poles of the magnetic transducer head 16 . The relatively thin interlayer 5 , comprised of one or more layers of nonmagnetic materials, serves to (1) prevent magnetic interaction between the soft underlayer 4 and the at least one hard recording layer 6 ; and (2) promote desired microstructural and magnetic properties of the at least one magnetically hard recording layer.
As shown by the arrows in the figure indicating the path of the magnetic flux φ, flux φ is seen as emanating from the main writing pole 7 of magnetic transducer head 16 , entering and passing through the at least one vertically oriented, magnetically hard recording layer 5 in the region below main pole 7 , entering and traveling within soft magnetic underlayer (SUL) 3 for a distance, and then exiting therefrom and passing through the at least one perpendicular hard magnetic recording layer 6 in the region below auxiliary pole 8 of transducer head 16 . The direction of movement of perpendicular magnetic medium 21 past transducer head 16 is indicated in the figure by the arrow above medium 21 .
With continued reference to FIG. 1 , vertical lines 9 indicate grain boundaries of polycrystalline layers 5 and 6 of the layer stack constituting medium 21 . Magnetically hard main recording layer 6 is formed on interlayer 5 , and while the grains of each polycrystalline layer may be of differing widths (as measured in a horizontal direction) represented by a grain size distribution, they are generally in vertical registry (i.e., vertically “correlated” or aligned).
Completing the layer stack is a protective overcoat layer 14 , such as of a diamond-like carbon (DLC), formed over hard magnetic layer 6 , and a lubricant topcoat layer 15 , such as of a perfluoropolyether (PFPE) material, formed over the protective overcoat layer.
Substrate 10 is typically disk-shaped and comprised of a nonmagnetic metal or alloy, e.g., Al or an Al-based alloy, such as Al—Mg having a Ni—P plating layer on the deposition surface thereof, or alternatively substrate 10 is comprised of a suitable glass, ceramic, glass-ceramic, polymeric material, or a composite or laminate of these materials. Optional adhesion layer 11 , if present, may comprise an up to about 200 Å thick layer of a material such as Ti, a Ti-based alloy, Cr, or a Cr-based alloy. Soft magnetic underlayer 4 is typically comprised of an about 100 to about 4,000 Å thick layer of a soft magnetic material, which, for example, may be selected from the group consisting of Ni, NiFe (permalloy), Co, CoZr, CoZrCr, CoZrNb, CoFeZrNb, CoFe, Fe, FePt, FeBNi, FeN, FeSiAl, FeSiAlN, FeCoB, FeCoC, etc. Interlayer 5 typically comprises an up to about 300 Å thick layer or layers of non-magnetic material(s), such as Ru, TiCr, RU/CoCr 37 PT 6 , RuCR/CoCrPt, etc.; and the at least one magnetically hard perpendicular recording layer 6 is typically comprised of about 50 to about 250 Å thick layer(s) of, for example, Co-based alloy(s) or FePt intermetallic compounds with L1 0 structure and including one or more elements selected from the group consisting of Cr, Fe, Ta, Ni, Mo, Pt, V, Nb, Ge, B, N, C, and Pd.
A currently employed way of classifying magnetic recording media is on the basis by which the magnetic grains of the recording layer are mutually separated, i.e., segregated, in order to physically and magnetically decouple the grains and provide improved media performance characteristics. According to this classification scheme, magnetic media with Co-based alloy magnetic recording layers (e.g., CoCr alloys) are classified into two distinct types: (1) a first type, wherein segregation of the grains occurs by diffusion of Cr atoms of the magnetic layer to the grain boundaries of the layer to form Cr-rich grain boundaries, which diffusion process requires heating of the media substrate during formation (deposition) of the magnetic layer; and (2) a second type, wherein segregation of the grains occurs by formation of oxides, nitrides, and/or carbides at the boundaries between adjacent magnetic grains to form so-called “granular” media, which oxides, nitrides, and/or carbides may be formed by introducing a minor amount of at least one reactive gas containing oxygen, nitrogen, and/or carbon atoms (e.g. O 2 , N 2 , C0 2 , etc.) to the inert gas (e.g., Ar) atmosphere during sputter deposition of the Co alloy-based magnetic layer. The latter process does not require heating of the substrate to an elevated temperature.
Magnetic recording media with granular magnetic recording layers possess great potential for achieving very high and ultra-high areal recording densities. An advantage afforded by granular recording layers is significant suppression of media noise due to great reduction in the exchange coupling between adjacent magnetic grains, resulting from the presence of non-magnetic material, typically an oxide material, at the grain boundaries. As indicated above, current methodology for manufacturing granular-type magnetic recording media involves reactive sputtering of a target comprised of the ferromagnetic material for the magnetic recording layer (typically a Co-based alloy) in a reactive gas-containing atmosphere, e.g., an atmosphere comprising oxygen or a compound of oxygen, in order to incorporate oxides in the deposited film or layer and achieve smaller and more isolated magnetic grains. Granular magnetic layers formed in this manner have a reduced saturation magnetization (M s ) due to the oxide formation and consumption of a certain amount of the Co component of the ferromagnetic alloy. Alternatively, a target comprised of the ferromagnetic material (typically a Co-based alloy) and the oxide material may be directly sputtered in an inert atmosphere or an atmosphere comprising oxygen or a compound of oxygen. However, the oxide material sputtered from the target is subject to decomposition in the environment of the sputtering gas plasma, and, as a consequence, a certain amount of the Co component of the ferromagnetic alloy is again consumed.
In order to continually increase the bit density of recording over the next decade, it will be necessary to achieve a corresponding continual decrease of the dimensions of the magnetic grains in order to maintain a good signal-to-noise ration (SNR) of the magnetic media. Therefore, in practice, it will be necessary to decrease the grain volume as the desired linear recording density increases in order to maintain a usable SNR. Such reduction in magnetic grain size, however, will result in grain sizes which approach the so-called superparamagnetic limit of magnetic particles and thereby limit the ability of the media to retain stored information without significant thermal decay. A significant factor with thermal decay associated with grain sizes approaching the superparamagnetic limit is the steepness of onset of the thermal decay. In this regard, it has been estimated that at a certain point a 15% decrease of grain diameter can result in a reduction of storage lifetime of the media from about 20 years to as little as 1 day.
One proposal for overcoming the superparamagnetic limit is to raise the energy barrier to thermal reversal of grain magnetization by development of media with higher anisotropy. However, such approach is problematic in designing high data recording rate media because media with very high coercivities greater than about 10,000 Oe cannot be accurately written to by means of the head fields provided by currently available read/write transducers. This is especially true in high frequency recording applications because of a drastic increase in dynamic anisotropy, resulting in inability of the write field to function at high frequency, leading to incomplete magnetization reversal and causing significant increases in noise level and error rate.
Since the early 1990's, advanced magnetic media have been designed and fabricated for achieving better SNR's. For example, dual layer longitudinal CoNiCr/CoCrTa and dual layer CoCrPt/CoCrPtSi gradient media were fabricated in order to enhance the SNR. Such dual layer media actually are gradient systems wherein the top (upper) layer provides the media with high anisotropy and the lower layer is optimized for reducing media noise.
The ever-increasing need for disk drive media and systems with higher storage capacities, faster data read/write rates, and lower costs form a triad of conflicting and competing requirements for designing, developing, and fabricating the next generation of disk drives. As a consequence, the magnetic recording media design practice faces a number of challenges extending magnetic recording technology to its limits.
Inasmuch as perpendicular magnetic recording media are expected to remain the predominant type of magnetic media for use in disk drives for at least the foreseeable future (e.g., 5-6 years), unique design and engineering schemes are considered necessary for fabrication of improved perpendicular media capable of meeting future challenges and requirements for high recording density, high data recording rate disk drive applications.
In view of the foregoing, there exists a clear need for a new avenue or approach for the engineering and development of advanced perpendicular magnetic recording media which achieves the goals of high linear recording density and high data recording rate without significant loss of thermal stability.
The present invention addresses and solves the need for engineering and development of improved, high performance advanced perpendicular magnetic recording media suitable for use in disk drives, comprising a novel combination of gradient magnetic properties and local vertical exchange coupling, while maintaining full compatibility with all requirements of cost-effective automated fabrication processing.
DISCLOSURE OF THE INVENTION
An advantage of the present invention is improved perpendicular magnetic recording medium adapted for high recording density and high data recording rate.
Another advantage of the present invention is an improved method for performing magnetic data/information storage and retrieval at a high recording density and high data recording rate.
Still another advantage of the present invention is an improved method for fabricating magnetic data/information storage and retrieval media having a high recording density and high data recording rate.
Additional advantages and other features of the present invention will be set forth in the description which follows and in part will become apparent to those having ordinary skill in the art upon examination of the following or may be learned from the practice of the present invention. The advantages of the present invention may be realized and obtained as particularly pointed out in the appended claims.
According to an aspect of the present invention, the foregoing and other advantages are obtained in part by an improved perpendicular magnetic recording medium adapted for high recording density and data recording rate, comprising:
(a) a non-magnetic substrate having at least one surface; and
(b) a layer stack formed on the surface of the substrate, the layer stack
including a perpendicular recording layer containing a plurality of columnar-shaped magnetic grains extending perpendicularly to the substrate surface for a length, with a first end distal the substrate surface and a second end proximal the substrate surface, wherein each of the magnetic grains:
(1) has a gradient of perpendicular magnetic anisotropy field H k extending along its length between the first and second ends; and
(2) has predetermined local exchange coupling strengths along its length.
In accordance with embodiments of the present invention, application of an external magnetic field to the recording layer induces a progressive reversal process of an initial magnetization direction of each of the plurality of columnar-shaped magnetic grains which originates at one of the ends, progresses toward the other end, and results in reversal of the initial magnetization direction to yield a final magnetization direction.
According to preferred embodiments of the invention, the perpendicular magnetic anisotropy decreases from the first end to the second end of each of the grains.
Preferably, each of the magnetic grains comprises a plurality of overlying sub-layers of magnetic material, each of the sub-layers of magnetic material having a different perpendicular magnetic anisotropy which progressively decreases from a sub-layer at the first end to a sub-layer at the second end of each of the magnetic grains.
In accordance with embodiments of the present invention, tailoring of the local exchange coupling strength between adjacent sub-layers to achieve a desired coupling strength is accomplished by utilizing one or more of the following means: (1) a non-magnetic, paramagnetic, or superparamagnetic spacer layer of selected thickness positioned at the interface between the adjacent sub-layers; (2) adjacent sub-layers positioned in direct contact; and (3) a magnetic layer of selected thickness positioned between adjacent magnetically hard sub-layers.
According to embodiments of the invention, each of the magnetic grains comprises two overlying sub-layers with different magnetic material composition, a first sub-layer at the first end of each of the magnetic grains is comprised of CoCrX 1 first magnetic material, where X 1 is at least one element selected from the group consisting of Ta, Pt, B, V, C, Nd, Cu, Zr, Fe, P, O, Si, and Ni, with a magnetic moment M r from about 200 to about 800 emu/cc, a relatively high perpendicular anisotropy field H k from about 8,000 to about 20,000 Oe, a thickness δ 1 from about 6 to about 25 nm, and a grain size from about 4 to about 10 nm; a second sub-layer at the second end of each of the magnetic grains is comprised of CoX 2 second magnetic material, where X 2 is at least one element selected from the group consisting of C, B, Cr, Pt, O, Fe, Ta, Cu, Nd, Ni, and Ti, with a magnetic moment M r from about 400 to about 900 emu/cc, a relatively low perpendicular anisotropy field H k from about 1,000 to about 9,000 Oe, a thickness δ 2 from about 3 to about 15 nm, and a crystal structure and grain size matching those of the first sub-layer; and the total thickness δ 1 +δ 2 of the first and second sub-layers is less than the exchange coupling distances of the magnetic materials, whereby domain walls are not present in the magnetic grains. According to this embodiment, a non-magnetic spacer layer is present at an interface between the first and second sub-layers for providing an interfacial coupling strength between the first and second sub-layers from about 10 −2 to about 10 −9 erg/cm, the spacer layer having a thickness up to about 5 nm and comprised of at least one non-magnetic element selected from the group consisting of Cr, Pt, Cu, Zr, V, C, Ru, Ta, and Si.
Further embodiments of the present invention include those wherein each of the magnetic grains comprises three overlying sub-layers with different magnetic material composition, wherein the relatively high perpendicular magnetic anisotropy field H k1 of a first sub-layer at the first end is about 12,000 Oe, the relatively low perpendicular magnetic anisotropy field H k3 of a third sub-layer at the second end is about 3,000 Oe, the perpendicular magnetic anisotropy field H k2 of a second sub-layer intermediate the first and third sub-layers is about 9,000 Oe, and the thickness of each of the three sub-layers is about 6-8 nm.
Still other embodiments of the present invention include those wherein each of the magnetic grains comprises four overlying sub-layers with different magnetic material compositions, the relatively high perpendicular magnetic anisotropy field H k1 of a first sub-layer at the first end being about 12,000 Oe, the relatively low perpendicular magnetic anisotropy field H k4 of a fourth sub-layer at the second end being about 3,000 Oe, the perpendicular magnetic anisotropy field H k1 of a second sub-layer adjacent the first sub-layer being about 9,000 Oe, the perpendicular magnetic anisotropy field H k3 of a third sub-layer adjacent the second sub-layer being about 6,000 Oe and the thickness of each of the four sub-layers is about 5 nm.
In accordance with preferred embodiments of the present invention, the perpendicular recording layer is a granular type layer, and the layer stack comprises a magnetically soft underlayer (SUL) intermediate the recording layer and the substrate surface.
Another aspect of the present invention is an improved method for performing magnetic data/information storage and retrieval at a high recording density and high data recording rate, comprising steps of:
(a) providing a magnetic recording medium comprising: and
(i) a non-magnetic substrate having at least one surface; and (ii) a layer stack formed on the surface of the substrate, the layer stack including a perpendicular recording layer containing a plurality of columnar-shaped magnetic grains extending perpendicularly to the substrate surface for a length, with a first end distal the substrate surface and a second end proximal the substrate surface, wherein each of the columnar-shaped magnetic grains has a gradient of perpendicular magnetic anisotropy field H k extending along its length between the first and second ends, and predetermined local exchange coupling strengths along its length;
(b) applying an external magnetic field to the recording layer to reverse an initial magnetization direction of each of the plurality of columnar-shaped magnetic grains to yield a final magnetization direction.
According to embodiments of the invention, step (b) comprises inducing a magnetization reversal process of the initial magnetization direction of each of the plurality of magnetic grains which originates at one of the ends and progresses toward the other of the ends to result in reversal of the initial magnetization direction to yield a final magnetization direction.
According to embodiments of the present invention, step (a) preferably comprises providing a magnetic recording medium wherein the perpendicular magnetic anisotropy decreases from the first end to the second end of each of the grains.
Preferably, step (a) comprises providing a magnetic recording medium wherein each of the magnetic grains comprises a plurality of overlying sub-layers of magnetic material, each of the sub-layers of magnetic material having a different perpendicular magnetic anisotropy which progressively decreases from a sub-layer at the first end to a sub-layer at the second end of each of the magnetic grains.
In accordance with embodiments of the present invention, step (a) comprises providing a magnetic recording medium wherein tailoring of the local exchange coupling strength between adjacent sub-layers to achieve a desired coupling strength is accomplished by utilizing one or more of the following approaches: (1) positioning a non-magnetic, paramagnetic, or superparamagnetic interfacial spacer layer of selected thickness at the interface between the adjacent sub-layers; (2) forming the adjacent sub-layers in direct contact; and (3) positioning a magnetic layer of selected thickness between adjacent magnetically hard sub-layers.
Still another aspect of the present invention is a method of fabricating a magnetic data/information storage and retrieval medium having high recording density and high data recording rate, comprising steps of: (a) providing a non-magnetic substrate having at least one surface; and (b) forming a layer stack on the at least one surface, the layer stack including a soft magnetic underlayer (SUL) and an overlying perpendicular recording layer containing a plurality of columnar-shaped magnetic grains extending for a length perpendicularly to the substrate surface, with a first end distal the substrate surface and a second end proximal the substrate surface, wherein each of the columnar-shaped magnetic grains has a gradient of perpendicular magnetic anisotropy field H k extending along its length between the first and second ends, and predetermined local exchange coupling strengths along its length.
According to embodiments of the present invention, step (a) comprises forming a perpendicular recording layer wherein the perpendicular magnetic anisotropy decreases from the first end to the second end of each of the grains.
Embodiments of the present invention include those wherein step (a) comprises forming a perpendicular recording layer wherein each of the magnetic grains comprises a plurality of overlying sub-layers of magnetic material, each of the sub-layers of magnetic material having a different perpendicular magnetic anisotropy which progressively decreases from a sub-layer at the first end to a sub-layer at the second end of each of the magnetic grains.
In accordance with certain embodiments of the present invention, step (a) comprises forming a perpendicular recording layer wherein tailoring of the local exchange coupling strength between adjacent sub-layers to achieve a desired coupling strength is accomplished by utilizing one or more of the following approaches: (1) positioning a non-magnetic, paramagnetic, or superparamagnetic interfacial spacer layer of selected thickness at the interface between the adjacent sub-layers; (2) forming the adjacent sub-layers in direct contact; and (3) positioning a magnetic layer of selected thickness between adjacent magnetically hard sub-layers.
Additional advantages and aspects of the present invention will become readily apparent to those skilled in the art from the following detailed description, wherein embodiments of the present invention are shown and described, simply by way of illustration of the best mode contemplated for practicing the present invention. As will be described, the present invention is capable of other and different embodiments, and its several details are susceptible of modification in various obvious respects, all without departing from the spirit of the present invention. Accordingly, the drawings and description are to be regarded as illustrative in nature, and not as limitative.
BRIEF DESCRIPTION OF THE DRAWINGS
The following detailed description of the embodiments of the present invention can best be understood when read in conjunction with the following drawings, in which the various features are not necessarily drawn to scale but rather are drawn as to best illustrate the pertinent features and the same reference numerals are employed throughout for designating similar features, wherein:
FIG. 1 schematically illustrates, in simplified cross-sectional view, a portion of a magnetic recording, storage, and retrieval system according to the conventional art, comprised of a perpendicular magnetic recording medium and a single pole transducer head;
FIG. 2 schematically illustrates the magnetism reversal mechanism of the magnetically hard perpendicular magnetic recording layer of the conventional perpendicular medium of FIG. 1 ;
FIG. 3 schematically shows the quasi-incoherent (“buckling”) magnetization reversal process of a magnetically hard perpendicular recording layer of a perpendicular medium according to the invention, comprised of a stack of 4 sub-layers;
FIG. 4 schematically illustrates a perpendicular recording layer according to embodiments of the invention wherein a non-magnetic spacer layer positioned at the interface between adjacent sub-layers is utilized for tailoring the local exchange coupling strength between the sub-layers;
FIG. 5 schematically illustrates a perpendicular recording layer according to embodiments of the invention wherein layers of soft magnetic material are positioned between adjacent sub-layers of magnetically hard material for tailoring the local exchange coupling strength between the sub-layers; and
FIGS. 6(A)-6(B) , respectively, graphically show the magnetization distributions at the written transitions in the case of large and small deviation angles of the easy axis of magnetic media.
DETAILED DESCRIPTION OF THE INVENTION
The present invention is based upon recognition by the inventors that perpendicular magnetic recording media fabricated with a main recording layer comprised of columnar-shaped magnetic grains with specifically designed gradients of magnetic anisotropy field (H k ), and with local exchange coupling strengths which provide good writability and signal-to-noise ratio (SNR) at ultra-high recording densities (i.e., >˜250 Gbits/in 2 ) and high data recording rates (i.e., >˜2,000 Mbits/sec.) without significant sacrifice in thermal stability of the media. Further, it has been determined that all significant performance parameters of the media can be controllably optimized via appropriate selection of the H k gradient and local exchange coupling strength(s).
Briefly stated, perpendicular media and systems fabricated according to the principles of the invention are structurally similar to media 21 and system 20 shown in FIG. 1 , except that the magnetically hard perpendicular magnetic recording layer 6 is replaced with recording layer 6 ′, which, as indicated above, comprises a plurality of columnar-shaped magnetic grains with specifically designed gradients of magnetic anisotropy, i.e., gradients of perpendicular magnetic anisotropy field (H k ), and with preselected local exchange coupling strengths.
The principles of the present invention will now be described with reference to FIGS. 2 and 3 , wherein FIG. 2 illustrates the magnetism reversal mechanisms of the magnetically hard perpendicular magnetic recording layer 6 of a conventional perpendicular medium (such as media 21 ) including a uniform magnetic grain of thickness δ and FIG. 3 shows the progressive, quasi-incoherent magnetization reversal process (such as a “buckling” process) of a magnetically hard perpendicular recording layer 6 ′ of a perpendicular medium according to the invention. (In each of these figures, the direction of magnetization within a grain or sub-layer is indicated by the arrow, and optional interlayer 5 of FIG. 1 is omitted for clarity).
More specifically, FIG. 2 shows the coherent magnetization reversal (“rotation”) process within a conventional (i.e., uniform) columnar-shaped magnetic grain which is effected by means of an externally applied magnetic field from a write head spaced at a distance d from the upper end of the magnetic grain (in the following the head field gradient is assumed to be Karlqvist type), where the initial magnetization direction prior to application of the external magnetic field is indicated at T=t 0 and the final magnetization direction after application of the external magnetic field is indicated at T=t 1 ; whereas FIG. 3 shows the quasi-incoherent magnetization reversal process (such as a “buckling” process) of a magnetic grain according to the invention, comprised of 4 moderately exchange coupled, vertically stacked sub-layers layers M 1 , M 2 , M 3 , and M 4 with respective thicknesses δ 1 , δ 2 , δ 3 , and δ 4 , and where the perpendicular magnetic anisotropy field H k progressively decreases from sub-layer M 1 to sub-layer M 4 (SUL 5 is omitted from the figure for clarity). As shown, the magnetization direction of each of the sub-layers M 1 to M 4 is the same at T=t 0 (i.e., the initial magnetization direction before application of an external magnetic field from the write head), and magnetization reversal (“rotation”) occurs quasi-incoherently in progressive stages illustrated at T=t 1 , T=t 2 , and T=t 3 . Complete reversal of the initial magnetization direction is indicated at T=t 4 .
In the above, H k1 >H k2 >H k3 >H k4 , the topmost sub-layer M 1 has the highest switching field, and it is assumed that the permeability of the underlying SUL is infinite. Assuming that no interlayer (e.g., such as layer 5 of FIG. 1 ) is present, according to the incoherent magnetization reversal process of the invention, the magnetization direction of sub-layers M 1 , M 2 , M 3 , and M 4 occurs sequentially, as illustrated. The magnetization reversal process is initiated at the bottom-most sub-layer M 4 of lowest perpendicular magnetic anisotropy field H k4 , and proceeds upwardly in sequence from sub-layer M 4 to the overlying sub-layers M 3 and M 2 of progressively lower perpendicular magnetic anisotropy fields H k3 and H k2 , and is ultimately controlled by the topmost sub-layer M 1 of greatest perpendicular magnetic anisotropy field H k1 . More particularly, re-orientation or reversal of the magnetization direction of the entire grain occurs when the magnetization direction of the topmost sub-layer M 1 is completely reversed (as at T=t 4 in the illustrated case).
Stated differently, when the magnetic grains are comprised of sub-layers with a anisotropy gradient, application of the external writing field from the head causes the sub-layer with the smallest perpendicular magnetic anisotropy field H k , i.e., the lowermost sub-layer of the stack, to switch or reverse its magnetization direction. This substantially simultaneously induces a quasi-incoherent rotation process in the overlying sub-layers of higher magnetic anisotropy. The magnetization reversal process in each grain is essentially an incoherent rotation process, i.e., a type of induced “quasi-buckling” or “curling” process, which is generated in the lowermost sub-layer with high magnetic moment and relatively lower intrinsic anisotropy, via tailored exchange interactions. By contrast, coherent magnetization reversal in conventional magnetic grains requires a larger switching field and poor media writability, resulting in difficulty in obtaining high density recording with good writability and thermal stability.
It is also noted that, with the materials conventionally utilized for fabricating high performance magnetic recording media, the intrinsic exchange coupling within the media is usually too strong to allow for any incoherent magnetization reversal as required by the invention. Therefore, according to the inventive methodology, multi-step incoherent magnetization reversal within the grains is facilitated by suitably tailoring the perpendicular magnetic anisotropy of the various sub-layers to obtain a desired gradient of H k and the local exchange coupling strengths between adjacent sub-layers. In this regard, it is noted that the strength of the exchange coupling between adjacent sub-layers and the thickness of each sub-layer play important roles in dictating the overall magnetization reversal/re-orientation process. For example, if the exchange coupling strength is too small, the overall magnetization reversal/re-orientation process can become a quasi-fanning process which does not afford good thermal stability. On the other hand, if the thickness of the lower-most sub-layer is too little, triggering of the magnetization reversal process would not be strong enough to induce incoherent magnetization reversal in the overlying layers if the exchange coupling strength is too high. Tailoring of the local exchange coupling strength between adjacent sub-layers is therefore necessary in order to achieve maximum local magnetization reversal torque, and for significantly reducing the overall switching field of each grain.
According to the invention, tailoring of the local exchange coupling strength between adjacent sub-layers to achieve a desired coupling strength is accomplished by utilizing one or more of the following approaches: (1) positioning a non-magnetic, paramagnetic, or superparamagnetic spacer layer SL of selected thickness at the interface between adjacent sub-layers, as schematically shown in FIG. 4 ; (2) forming the adjacent sub-layers in direct contact; and (3) positioning a magnetic layer of selected thickness between adjacent magnetically hard sub-layers, as schematically shown in FIG. 5 for a grain structure comprised of n stacked sub-layers of magnetically hard material with intervening magnetic layers.
It should be noted that despite apparent differences of approaches (1)-(3), the underlying physics is equivalent, because the fundamental magnetic properties of the magnetic material are associated with the dimensionality of the material per se. For quasi one-dimensional and two-dimensional thin-film magnetic materials, the weak spin effects will lead to reductions in the anisotropy, magnetic moment, and local exchange coupling strength. Approach (3) has an advantage in that continuity of the microstructure of the magnetic grains is more easily maintained. Finally, manipulation of the sub-layer thicknesses allows obtaining of desirable local magnetic properties for achieving optimal recording performance.
Tailoring of the magnetic anisotropies, i.e., the perpendicular magnetic anisotropy fields H k , of each of the sub-layers is accomplished, in known fashion, as by appropriate selection of the magnetic alloys and their processing conditions; and each of the sub-layers and spacer layers are sequentially epitaxially deposited (by conventional methodologies, including sputtering techniques) so as to replicate the crystal structure and cross-sectional dimensions of the underlying grains (i.e., grain sizes) and form a magnetically hard perpendicular recording layer comprised of columnar-shaped magnetic grains extending perpendicularly to a substrate for a desired length. Granular perpendicular magnetic recording layers embodying the principles of the present invention may be formed by means of reactive sputtering techniques, as known in the art and described above.
Advantageously, when the magnetization reversal process is incoherent according to the invention, the read/write head spacing is reduced, as compared with the head-media spacing (HMS) with conventional coherent magnetization reversal. More specifically, in the incoherent case ( FIG. 3 ), the HMS is given by (d+δ 1 /2), which is much smaller than the d spacing in the coherent case ( FIG. 2 ), which is given by (d+δ 2 ). For instance, if d=6 nm and δ=20 nm in the conventional, coherent reversal case, and δ 1 =5 nm in the incoherent reversal case, the effective HMS would be 8.5 nm in the incoherent case and 16 nm in the coherent case. As a consequence, the SNR's of the inventive anisotropy gradient grains and conventional, uniform grains will be dramatically different. For example, it is conservatively estimated that use of a 3 sub-layer perpendicular magnetic recording layer with anisotropy gradient according to the invention would provide at least a 1-3 db increase in SNR (facilitating a corresponding increase in recording density) by virtue of the dramatic decrease in HMS afforded by the invention.
It should be noted that the head field magnetic gradient should be less than the gradient of magnetic anisotropy of the various sub-layers constituting the magnetic grains, which requirement places several constraints on media design practice, resulting in significant reduction of the effective head-media spacing (HMS), and thus providing a very substantial improvement in recording performance. In addition, it should be recognized that anisotropy gradient perpendicular media fabricated according to the invention can also advantageously exhibit substantially reduced easy axis distributions by virtue of the presence of several sub-layers within a single columnar-shaped magnetic grain, leading to a reduction of the media switching distribution and an increase in the media nucleation field. In this regard, the number of sub-layers within a grain is not limited to the illustrative embodiments described below which comprise 2, 3, or 4 sub-layers. Rather, the greater the number of sub-layers within a grain, the smaller the deviation angle of the easy axis. As a consequence, the resultant magnetization becomes sharper and/or more symmetric at the written transition locations. For example, FIGS. 6 (A)- 6 (B), respectively, graphically show the magnetization distributions at the written transitions in the case of large and small deviation angles of the easy axis, wherein it is evident that the resultant magnetization becomes sharper and/or more symmetric at the written transition locations when the deviation angles of the easy axis are smaller.
Additional advantages of the inventive media include reduced grain size distributions and the ability to fabricate granular media with ultra-small grain sizes via reactive oxidation/sputtering processing.
According to an illustrative, but non-limitative, embodiment of the invention, each of the columnar-shaped magnetic grains comprises two overlying sub-layers with different magnetic material composition. A first sub-layer at the first (upper) end of each of the magnetic grains is comprised of CoCrX 1 first magnetic material, where X 1 is at least one element selected from the group consisting of Ta, Pt, B, V, C, Nd, Cu, Zr, Fe, P, O, Si, and Ni, with a magnetic moment M r from about 200 to about 800 emu/cc, a relatively high perpendicular anisotropy field H k from about 8,000 to about 20,000 Oe, a thickness δ 1 from about 6 to about 25 nm, and a grain size from about 4 to about 10 nm. A second sub-layer at the second (lower) end of each of the magnetic grains is comprised of CoX 2 second magnetic material, where X 2 is at least one element selected from the group consisting of C, B, Cr, Pt, O, Fe, Ta, Cu, Nd, Ni, and Ti, with a magnetic moment M r from about 400 to about 900 emu/cc, a relatively low perpendicular anisotropy field H k from about 1,000 to about 9,000 Oe, a thickness δ 2 from about 3 to about 15 nm, and a crystal structure and grain size matching those of the first sub-layer. The total thickness δ 1 +δ 2 of the first and second sub-layers is less than the exchange coupling distances of the magnetic materials, whereby domain walls are not present in the magnetic grains. According to this embodiment, a non-magnetic spacer layer is present at an interface between the first and second sub-layers for providing an interfacial coupling strength between the first and second sub-layers from about 10 −2 to about 10 −9 erg/cm, the spacer layer having a thickness up to about 5 nm and comprised of at least one non-magnetic element selected from the group consisting of Cr, Pt, Cu, Zr, V, C, Ru, Ta, and Si.
In accordance with another illustrative, non-limitative embodiment according to the present invention, each of the magnetic grains comprises three overlying sub-layers with different magnetic material composition, wherein the relatively high perpendicular magnetic anisotropy field H k1 of a first sublayer at the first (upper) end is about 12,000 Oe, the relatively low perpendicular magnetic anisotropy field H k3 of a third sub-layer at the second (lower) end is about 3,000 Oe, and the perpendicular magnetic anisotropy field H k2 of a second sub-layer intermediate the first and third sub-layers is about 9,000 Oe. The thickness of each of the three sub-layers is about 6-8 nm.
According to yet another illustrative, non-limitative embodiment of the present invention, each of the magnetic grains comprises four overlying sub-layers with different magnetic material compositions. The relatively high perpendicular magnetic anisotropy field Hu of a first sub-layer at the first (upper) end of the columnar-shaped magnetic grains is about 12,000 Oe, and the relatively low perpendicular magnetic anisotropy field H k4 of a fourth sub-layer at the second (lower) end is about 3,000 Oe. The perpendicular magnetic anisotropy field H k2 of a second sub-layer adjacent the first sub-layer is about 9,000 Oe, and the perpendicular magnetic anisotropy field H k3 of a third sub-layer adjacent the second sub-layer is about 6,000 Oe. The thickness of each of the four sub-layers is about 5 nm.
It is noted that, while magnetic materials with anisotropy values less than about 500 Oe are typically (or normally) characterized as soft magnetic materials and magnetic materials with anisotropy values greater than about 2,000 Oe are typically characterized as hard magnetic materials, all magnetic materials utilized in the present invention have a large intrinsic anisotropy, i.e., >˜3,000 Oe, and thus would normally be characterized as hard magnetic materials. Notwithstanding this characterization, the difference or variation between the intrinsic coercivities and anisotropies of the component magnetic materials of media according to the present invention can be fairly large, depending upon the purpose or ultimate use of the media design and the recording head field gradient. The invention, therefore, is conceptually different from merely combining hard and soft magnetic materials to form a recording medium. Rather, according to the underlying principle of the present invention, tailoring of the gradient of intrinsic perpendicular magnetic anisotropy/anisotropy, as well as the local exchange coupling strengths of the perpendicular media are utilized in conjunction with the recording head field strength to provide the media with maximum gain in SNR, thermal stability, and writability. Optimized media designs facilitated by the present invention afford the smallest actual effective head-media spacing (HMS), highest actual magnetic volume KμV, and highest achievable writability at the effective volume KμV.
In summary, the present invention provides perpendicular magnetic recording media fabricated with a main recording layer comprised of columnar-shaped magnetic grains with specifically designed gradients of magnetic anisotropy, i.e., gradients of perpendicular magnetic anisotropy field (H k ), and with local exchange coupling strength(s) which provide good writability and signal-to-noise ratio (SNR) at ultra-high recording densities (i.e., >˜250 Gbits/in 2 ) and high data recording rates (i.e., >˜2,000 Mhits/sec.) without significant sacrifice in thermal stability of the media. In addition, when the magnetization reversal process is incoherent according to the invention, the read/write head spacing is reduced, as compared with the head-media spacing (HMS) with conventional coherent magnetization reversal, resulting in the improved SNR's, i.e., at least a 1-3 db increase in SNR facilitating a corresponding increase in recording density.
In the previous description, numerous specific details are set forth, such as specific materials, structures, processes, etc., in order to provide a better understanding of the present invention. However, the present invention can be practiced without resorting to the details specifically set forth. In other instances, well-known processing materials and techniques have not been described in detail in order not to unnecessarily obscure the present invention.
Only the preferred embodiments of the present invention and but a few examples of its versatility are shown and described in the present disclosure. It is to be understood that the present invention is capable of use in various other combinations and environments and is susceptible of changes and/or modifications within the scope of the inventive concept as expressed herein. | A perpendicular magnetic recording medium adapted for high recording density and high data recording rate comprises a non-magnetic substrate having at least one surface with a layer stack formed thereon, the layer stack including a perpendicular recording layer containing a plurality of columnar-shaped magnetic grains extending perpendicularly to the substrate surface for a length, with a first end distal the surface and a second end proximal the surface, wherein each of the magnetic grains has: (1) a gradient of perpendicular magnetic anisotropy field H k extending along its length between the first end and second ends; and (2) predetermined local exchange coupling strengths along the length. | 8 |
[0001] This application claims the Convention Priority benefit of U.S. Patent application No. 60/801,068 filed on May 18, 2006, which is incorporated in its entirety herein by reference.
FIELD OF THE INVENTION
[0002] The present invention relates to air ventilation, filtration, purification, and cleaning. It relates more particularly to an apparatus for attachment to or use with an air supply outlet, such as an airplane gasper (personal air outlet), and to the local delivery and circulation of clean air with reduced air stream thermal and humidity gradients relative to ambient air.
BACKGROUND OF THE INVENTION
[0003] Air contaminants such as chemicals and pathogenic organisms, and ventilation air supply thermal and humidity gradients, particularly in high occupancy enclosed spaces such as in transportation vehicles, can present health and comfort concerns due to the limitations of existing ventilation systems. Existing centralized ventilation systems depend on conventional diffusers to deliver supply air locally. They may filter, purify and/or clean the air delivered and thus provide a limited amount of local dilution of air contaminants and central removal and/or killing of airborne pathogens, removal of particles, and removal, dilution or conversion of airborne chemicals to less hazardous chemicals. Centralized filtration, air purification and air cleaning have limitations: pathogens and air contaminants, for example, can still be circulated locally by the natural airflow patterns that are generated by the air supply diffusers, occupant movement and other forces, and may travel several seat rows forward and aft and from side to side in the case of transportation vehicles before being drawn from the occupied space to a central air cleaner and conditioner system and recirculated.
[0004] In an aircraft, trains, buses and the like, as in buildings or other environments, ventilation air is typically provided by a central environmental control system (ECS) or heating, ventilation and air-conditioning (HVAC) system. The system typically delivers a supply of thermally conditioned and filtered, purified and/or cleaned air through ducting to room air diffusers and in the case of aircraft and other passenger vehicles, to gaspers or personal air outlets (PAOs).
[0005] PAOs in aircraft are typically located in a Passenger Service Unit (PSU) above the passenger seats, and above crew seats, crew quarters and in galleys. They provide high velocity air directly to the occupants primarily as a cooling rather than air quality control mechanism. Passengers typically are able to control the direction and quantity of airflow from their PAO, which increase local air velocity around the passengers and thereby provide some thermal comfort for the passengers and crew. PAOs are typically low volumetric flow devices that contribute little to the improvement of air quality in the cabin. The flow of air to supply the PAOs is provided by relatively small supply lines leading to the PAOs. The air exiting the PAOs may be adjusted to a relatively high velocity to provide the desired cooling effect. An unwanted side effect is that the narrow, high velocity stream of air forms a turbulent boundary layer, which tends to entrain air from the immediately surrounding region and directs the combined airflow towards the passenger. This effect can draw in contaminants from the surrounding region, for example airborne microbes from a neighboring passenger or other source in the immediate vicinity of the PAO. As a result, even if the PAO air supply is itself filtered, purified and/or cleaned (which may or may not be the case), the use of a PAO can increase the level of contaminants bathing a passenger if the local level of contamination is high, despite the perception of purified air surrounding a passenger using the device.
[0006] Existing systems may filter, purify and/or clean the air supplied to the PAO or supplied by the PAO to the occupant, but these systems do not provide adequate treatment of entrained cabin air delivered to the occupant along with the PAO air. The relatively high velocity stream of air exiting the PAO tends to entrain a large volume of air in the region adjacent to the PAO nozzle, as momentum is exchanged in a turbulent shear layer between the two. This region will thus tend to draw in air from the region surrounding the PAO, including any contaminants therein. Thus, even if the air exiting the PAO has been purified, contaminants from the surrounding region can be drawn into the PAO air stream.
[0007] Entrainment of ambient air in the flow of ventilation air can thus result in pathogens, dust and odors being drawn into the occupant's personal air supply, in particular by the turbulent boundary layer which forms near the PAO nozzle where the air velocity is highest. When occupants and crew adjust their PAOs to increase air velocity and personal comfort, they may in fact be increasing their exposure to airborne contaminants.
[0008] There is a need for a PAO-type ventilation system for an enclosed cabin that reduces occupant exposure to one or both of a) pathogens, irritants and odors generated in the cabin by people, materials and systems, and b) air contaminants from the outside air used to ventilate the cabin such as engine exhaust combustion contaminants while on the runway, or from the engine compressor bearing lubricating oil if there is leakage during flight or on the ground. There is also a need to improve ventilation effectiveness in the individual occupant breathing zones. There is also a need to improve thermal comfort, for example particularly during boarding and while awaiting take-off in warm humid weather.
[0009] Personal air filtration systems and external air filtration systems which attach to a PAO are known. U.S. Pat. No. 6,780,213 to Chang et al. discloses a personal air cleaning apparatus which draws in air from a contaminated zone, filters, purifies and/or cleans the air and discharges it. The device disclosed by Chang requires the use of a fan-driven sucking/discharging unit to draw in contaminated air. Both U.S. Pat. No. 5,567,230 to Sinclair and U.S. Pat. No. 6,610,116 to Avery provide a filter, purifier and/or cleaner module configured to attach to the PAO air supply nozzle to filter the PAO air as it passes through the module. However, these methods and systems do not address the entrainment and ECS limited air supply problems discussed above. Rather, these devices primarily treat only the air supplied by the ECS to the PAO and do not treat air contaminants in the entrained cabin air surrounding or passing between occupants, nor do they provide much relief to occupants and/or equipment from the thermal gradients generated by typical gaspers and other PAO's. These devices are not as highly effective as desirable, and may actually increase the spread of airborne disease to passengers and crew using them under certain conditions.
[0010] Filtration systems designed to fit in constricted spaces, such as the cabin of an aircraft are also known. For example, U.S. Pat. No. 6,585,792 to Schneider et al., provides an air filter assembly with a replaceable filter. However, the Schneider assembly is not incorporated into the cabin or PAO air supply and may not significantly improve the volume of filtered and ventilated airflow provided to occupants. U.S. Pat. No. 6,787,782 to Krosney et al. discloses a system using ultraviolet light to sterilize air in a confined space such as a vehicle or aircraft. The Krosney system acts on air within a conduit, such as within the PAO supply of an airplane, but may not address direct passenger-to-passenger, passenger-to-crew and crew-passenger air contaminant and pathogen spread. The Krosney system also may not significantly improve the ventilation flow provided to occupants.
[0011] It is an object of the present invention to provide an improved system which when used with an existing source of ventilation air, may provide a supply of filtered, purified and/or cleaned air to passengers and crew, and which may mitigate against air contaminants emanating from neighboring occupants and equipment, and/or which improves thermal conditioning of a space for improved occupant and/or equipment comfort and performance.
SUMMARY OF THE INVENTION
[0012] The invention relates to air treatment of ventilation air supplied to the interior of an enclosed space such as an aircraft or other cabin, although it is not limited to this particular application and includes also ventilation air supplied to other end users and uses. The invention relies upon the momentum of a relatively high velocity stream of air exiting an air supply outlet to serve as a primary flow to entrain a secondary flow comprising ambient air from a region of the space. By enclosing the outlet within an enclosed housing and directing the airflow into a mixing chamber, one may harness this effect so as to create a reduced pressure suction in a region of the housing interior, referred to as the entrainment section of the housing, and entrain ambient air from outside the housing, which enters the housing through one more inlets. The ambient air entrained in airflow can originate in the breathing zone of the occupants and therefore contain the various gases and particulates associated with human metabolism and activity as well as contaminants from other sources. According to other aspects, ambient air can be entrained which originates from locations remote from the air supply outlet, which may tend to be at more desirable temperatures or air quality, and combined with the supply air stream. The incoming ambient air may be treated prior to or subsequent to entering the mixing chamber. For this purpose, treatment may comprise filtering, cleaning and/or purifying of the ambient air. The entrainment of ambient air is achieved by generating a region of reduced air pressure within the housing which may be used to draw the ambient air through a filter, purifier, and/or cleaner. The combined entrained or secondary air and the primary air supply from the gasper or other air outlet are combined in a mixing chamber and discharged at a lower velocity than the primary air supply velocity, thus reducing any subsequent entrainment which may occur downstream from the device outlet. In various aspects the invention may increase air circulation to occupants enable treatment of air contaminants in the ambient air it entrains and in the primary air flow. In another aspect the mixing of the entrained ambient air with the primary air flow in the mixing chamber may reduce the thermal and humidity gradients that otherwise exist between the air exiting the air outlet and the ambient air.
[0013] The primary flow air may itself be treated and the combined effect of the two treating systems may improve air quality locally at air discharge outlets.
[0014] According to one aspect, the invention relates to an apparatus for use in combination with a source of pressurized air, said source comprising an outlet for discharge of a high velocity primary air stream. The source may comprise a conventional gasper or PAO of the type used in an aircraft (or a similar structure used elsewhere) or alternatively the source may comprise any other type of air outlet or diffuser which releases a stream of breathable air in a relatively high velocity directed stream or may be made to release such high velocity air stream. According to this aspect the apparatus comprises:
[0015] a housing having a primarily inlet to receive said air stream from said gasper or other air outlet, an outlet for discharge of air, and a secondary inlet for the intake of ambient air; and
[0016] an air mixing chamber at least partly within the interior of said housing having open first and second ends, said first end having at least one opening for receiving an air stream from said gasper and additional air from the interior of said chamber, said second end for discharging air outwardly from said apparatus, said mixing chamber being configured to entrain ambient air from the interior of said housing when said air stream is directed through said chamber so as to discharge from said second end a combined stream composed of said ambient air and air from said gasper.
[0017] The apparatus may include an air treatment system for treating the ambient air entering the secondary inlet by filtering, purifying and/or cleaning this air either before or after it enters the secondary inlet. Alternatively or in addition, in order to introduce relatively clean air into the apparatus, the secondary inlet receives its airflow from a location distant from the housing and operatively connected thereto by a conduit.
[0018] According to one aspect, the air treatment system is a filter, purifier and/or cleaner abutting a wall of the housing which is provided with one or more openings into the interior of the housing, wherein air drawn into the interior of said housing through the opening or openings passes through said treatment system. The ambient air drawn through the system is thus treated as it enters the housing interior.
[0019] The secondary inlet may take several forms, including one or more walls of the housing having perforations or other openings therein, which are covered by a filter, purifier and/or cleaner which comprises an air treatment system for the incoming ambient air. Alternatively, the secondary inlet may consist of an inlet tube which receives ambient air from a location at a distance from the housing. The air treatment system, if provided, may be located at any convenient location along the path of the incoming ambient air, such as at the intake end of the tube.
[0020] According to another aspect, the air treatment system may comprise a UV source or other sterilizing or contaminant gas removal system, such as a sorbent material such as charcoal.
[0021] According to another aspect, the housing includes at least one wall, and the secondary inlet consists of one or more perforations within the wall, with a treatment means such as a media filter, a purifier and/or a cleaner such as a sorbent, electronic capture or an oxidation device abutting or adjacent to the wall such that the incoming ambient air flows through the treatment means. The perforated wall may consist of the entire or substantially all of the sidewall of the housing and optionally an end wall of the housing. The treatment means can be either inside or outside of the housing.
[0022] According to another aspect, the mixing chamber is substantially tubular. The chamber may comprise a straight tube or curving or coiled structure, or include internal baffles to provide this effect internally. Alternatively, the chamber may comprise one or more walls which taper outwardly towards said second end to form a truncated pyramidal shape. Preferably, the mixing chamber exceeds one inch in length. More preferably it exceeds two inches in length and in another aspect it exceeds six inches in length.
[0023] According to another aspect there is provided a manifold within the interior of said housing positioned to receive said air stream from the outlet, having a plurality of openings for directing a plurality of air streams into the first end of said mixing chamber.
[0024] According to one aspect, the apparatus directly attaches to a gasper or similar structure. According to another aspect, the apparatus may indirectly attach to the gasper, for example by mounting onto a panel immediately surrounding a gasper without physically contacting the gasper itself. The apparatus may be a readily removable portable apparatus suitable for carrying onboard by a passenger for temporary personal use, or alternatively being more or less permanently installed.
[0025] According to another aspect, the apparatus may replace a conventional gasper system. According to this aspect, the housing is built into the aircraft or other cabin, for example within the PSU. A plenum for delivering pressurized air enters the housing and branches into a plurality of sources of pressurized air within the housing. Each such source of pressurized air is associated with a separate (optionally independently controlled) passenger air discharger. The apparatus includes a corresponding plurality of mixing chambers each associated with a corresponding source, said plurality of chambers being optionally separated by internal dividers within the housing. In this version, the chambers may each be sealed with a cap at the first end and said multiple air sources each comprise a jet orifice entering said chamber through an opening in said cap. The first end of said chamber includes additional openings within or adjacent to the cap to permit ambient air from the interior of said housing to enter into said chambers.
[0026] According to another aspect, the invention relates to an airflow supply apparatus for a vehicle, including without limitation an aircraft, land vehicle or watercraft, to remove contaminants and provide increased flowrate to an interior of the vehicle. The apparatus according to this aspect comprises:
[0027] a) a housing having at least one intake opening for receiving intake air from the interior of the vehicle into the housing and further having at least one exit for discharging air from the housing toward the interior;
[0028] b) a filter mounted on the housing for removing contaminants from said intake air; and
[0029] c) a nozzle in communication with a supply of pressurized air for releasing a flow of pressurized air into the housing.
[0030] According to this aspect, the nozzle is positioned generally adjacent to the opening of the housing such that the flow of pressurized air entrains said intake air from the interior of the vehicle to flow into the housing, through the filter, and through the exit for discharge from the housing together with air from the nozzle.
[0031] According to another aspect, the invention relates to a method for delivering a stream of at least partially purified cabin air to an occupant, by supplying an air mixing chamber to receive a stream of pressurized air, for example from an aircraft gasper, generating a plume of air within the chamber which has a turbulent boundary layer, entraining additional ambient air within the boundary layer and thereby drawing additional ambient air into the chamber, and discharging the combined air stream from an opposed end of the chamber. A filter, air cleaner and/or purifier is optionally also provided, and the ambient air is filtered for pathogens and particulates such as combustion and oil aerosols, purified of harmful pathogens, and/or cleaned of odorous, noxious and/or toxic gases before it enters the chamber so as to remove contaminants. Preferably, this method is used to deliver a stream of air to an occupant within a relatively crowded environment such an airplane cabin, in which there is a risk of contamination from airborne pathogens from neighboring passengers. Accordingly, the method also relates to a method to reduce the exposure to pathogens and other airborne contaminants in a crowded environment.
[0032] While the invention will be described in conjunction with illustrated embodiments, it will be understood that it is not intended to limit the invention to such embodiments. 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 present patent specification as a whole. Any directional references included herein such as “horizontal”, “vertical” and the like are unless otherwise specified or if required by the context, purely for convenience of description and are not intended to limit the scope of the invention. In a similar fashion, any dimensions, choices of materials and the like described in the detailed description herein are unless otherwise specified, presented purely as an illustrative example and are not intended to limit the scope of the invention.
[0033] As well, it will be seen that although the invention has been described primarily by reference to its application in aircraft, the invention may readily be used in many other applications, including without limitation trains and other vehicles, spacecraft, watercraft and stationary uses.
BRIEF DESCRIPTION OF THE DRAWINGS
[0034] These and other advantages of the invention will become apparent upon reading the following detailed description and upon referring to the drawings in which:
[0035] FIG. 1 is a plan view from below of a first embodiment of the portable ventilation and treatment apparatus;
[0036] FIG. 2 is a sectional view along line 2 - 2 of FIG. 1 ;
[0037] FIG. 2A is a sectional view showing a variant of the mixing chamber of the first embodiment;
[0038] FIG. 3 is a side sectional view of a second embodiment;
[0039] FIG. 4 is a plan view of a third embodiment;
[0040] FIG. 5 is a cross-sectional view of line 5 - 5 of FIG. 4 ;
[0041] FIG. 6 is a side sectional view of a fourth embodiment;
[0042] FIG. 7 is a cross-sectional view of an airplane cabin showing the installation of a typical conventional gasper system;
[0043] FIG. 8 is a side view, partly in section, of a fifth embodiment which may be retrofitted into a personal storage unit of an aircraft or the like;
[0044] FIG. 9 is a side view, partly in section, of a sixth embodiment;
[0045] FIG. 10 is a side view, partly in section, of a seventh embodiment;
[0046] FIG. 11 is a side view, partly in section, of an eighth embodiment;
[0047] FIG. 12 is a schematic view of a ninth embodiment;
[0048] FIG. 13 is a plan view of the ninth embodiment;
[0049] FIG. 14 is a schematic view of a tenth embodiment;
[0050] FIG. 15 is a sectional view of a portion of the air supply tube, showing a first variant thereof;
[0051] FIG. 15 a is a sectional view along line 15 - 15 of FIG. 15
[0052] FIG. 16 shows a second variant of the air supply tube;
[0053] FIG. 16 a is a plan view from the front of FIG. 16 ;
[0054] FIG. 17 shows a third variant of the air supply tube;
[0055] FIG. 17 a is a sectional view along line 17 - 17 of FIG. 17 ;
[0056] FIG. 18 shows a fourth variant of the air supply tube;
[0057] FIG. 18 a is a plan view from the front of FIG. 18 ;
[0058] FIG. 19 is a perspective view of a mixing chamber according to one aspect of the invention;
[0059] FIG. 20 is a schematic view of a pressurized air outlet for supplying a primary air stream to the apparatus;
[0060] FIG. 21 is a schematic perspective view of a portion of the apparatus according to an aspect of the invention;
[0061] FIG. 22 is a schematic perspective view of a mixing chamber according to one aspect, showing also computational fluid dynamic (CFD) values representative of the performance of the device;
[0062] FIG. 23 is a perspective view of a portion of the device, showing additional CFD values achievable during testing of the device;
[0063] FIG. 24 is a schematic illustration of airflow patterns generated by a conventional gasper and an apparatus according to the invention mounted to a gasper;
[0064] FIG. 25 is a perspective view of a portion of the apparatus according to the fifth embodiment of the invention.
[0065] The present invention will now be further described and explained by way of a non-limiting description of certain detailed embodiments.
DETAILED DESCRIPTION
[0066] In the following description, similar features in the drawings have been given identical reference numerals where appropriate. All dimensions described or suggested herein are intended solely to illustrate an embodiment. Except as specifically indicated, these dimensions are not intended to limit the scope of the invention which may depart from these dimensions.
[0067] FIGS. 1 and 2 show a first embodiment of a ventilation and filtration, purification and/or cleaning apparatus 10 according to the present invention, intended to be installed over an existing conventional gasper. In other embodiments, the system may be built into or otherwise more or less permanently incorporated with a conventional gasper structure as described later. It will also be apparent to those skilled in the art that with modifications the system may be used in connection with other types of ventilation air outlets, for example as may be found in an aircraft, an automobile or other vehicles, or in a stationary source.
[0068] The apparatus is configured to attach to a gasper or personal air outlet (PAO) 14 , commonly found on the underside of a personal storage unit (PSU) 12 in an aircraft (see also FIG. 7 ). It may be provided as a portable, self-contained unit for temporary installation by a passenger, or it may be substantially non-removable. The apparatus is generally contained within a housing 16 , which includes a pressurized primary air supply inlet port 18 . The port 18 is surrounded by a flange or rim 20 which can encircle the gasper outlet 14 for attachment thereto by any convenient attachment means, such as friction fit, sticky tape, glued attachment or the like. The outlet of the gasper 14 thus protrudes in the interior of the housing 16 . Air exiting the gasper outlet 14 thus directly enters into the interior of the housing 16 . Typical dimensions of the housing 16 are about 6 inches in diameter by 2 inches in height, although these dimensions can vary to accommodate internal components of various dimensions. Conveniently, the housing will be openable so as to permit replacement of the filter, described below. For example, the housing may include a removable bottom plate or cap, such as a friction-fit or screw-off bottom cap. As will be seen, the dimensions of the housing are selected so as to provide a suitable surface area for filtration, purification and/or cleaning of incoming air and sufficient space to house a mixing chamber which is described in more detail below. The housing 16 includes within its interior a mixing chamber 30 and an outlet port 32 . The housing is effectively sealed against air inflow except through the inlet port 18 and the secondary inlets described below.
[0069] The housing 16 comprises side walls 36 and a bottom cap or wall 38 , all or some of which include one or more secondary inlets 17 to allow ambient cabin air to pass into the interior of the housing 16 . The housing is sealed against air inflow apart from the primary and secondary inlets. The secondary inlets may comprise perforations in the housing walls. The housing 16 may comprise any convenient shape—in the example herein the housing is cylindrical. The housing 16 is fully or partly lined within its interior with a filter 40 which is located adjacent to the side walls 36 and bottom wall 38 of the housing 16 to filter ambient cabin air which enters the apparatus 10 through the housing walls. Alternatively, the filter 40 may cover the exterior of the housing walls so as to be readily replaceable or the housing and filter may be a single unit. The filter medium is preferably selected to remove contaminant gases, particulates and/or airborne pathogens from the ambient cabin air. A suitable filter comprises filter media paper.
[0070] In other embodiments, the filter described herein and in the embodiments which follow may be replaced or augmented with a purifier or cleaner such as an ultra violet light generator or a charcoal sorbent. Those skilled in the art will recognize that numerous air filters, cleaners and purifiers are known to the art, and may become known to the art during the pendency of this patent, and that such devices may be readily adapted for use with the present invention. These include sorbents such as charcoal, and electronic capture and oxidation devices.
[0071] Preferably, the filter 40 is highly permeable to minimize the required pressure drop across the filter, purifier and/or cleaner, for example by providing a relatively large, low-pressure drop media filter so as to maximize the efficiency of the filter while still retaining its ability to remove and/or disable contaminants such as pathogenic organisms. The filter 40 covers all or substantially all of the 3 inch diameter perforated side walls and the bottom wall of the housing 16 .
[0072] The interior of the housing 16 defines a space which lies between the filter 40 and the mixing chamber 30 which is mounted within the interior of the housing 16 . The region of the housing interior which is external to the mixing chamber is termed the entrainment section 11 ; during operation, this is a region of lower relative pressure than the ambient air pressure. In one embodiment, the chamber 30 is generally tubular and cylindrical although it will be seen that other configurations may be employed. The chamber 30 is oriented generally vertically to receive downwardly-directed airflow from a conventional gasper, and has open upper and lower ends 42 , 44 . The open upper end 42 is positioned to receive a primary air stream from the gasper outlet nozzle 9 , and spaced apart from the outlet of the gasper 14 or otherwise configured so as to leave a gap between the gasper 14 and the open end 42 . This gap permits a secondary flow of air from within the interior of the housing to enter into the chamber 30 along with air from the gasper. The nozzle outlet 9 may protrude into the open end 42 or remain wholly outside the mixing chamber 30 . As well, other arrangements may be provided to introduce the secondary air flow into the chamber 30 , as will be seen by those skilled in the art.
[0073] The mixing chamber 30 is positioned and configured to receive the airflow from the gasper and to capture the momentum of this relatively high velocity primary airflow to draw in or entrain a secondary flow of ambient air from the interior of the housing 16 entrainment section. It is believed that this occurs largely or entirely at the boundary layer of the turbulent plume or stream of high velocity air as it exits the gasper outlet. The chamber 30 has a larger, and preferably substantially larger, inside diameter than the throat diameter of the gasper outlet, such that the air plume generated by air exiting the gasper is permitted to expand within the chamber 30 so as to create a suction and entrain ambient air into the entrainment chamber 11 and thence into the mixing chamber 30 . Depending on the dimensions of the chamber 30 and the mass, area and velocity of the air stream entering the chamber 30 , additional ambient air in a volume of up to ten times or more relative to the gasper air discharge may be entrained. It is believed that the number of high pressure outlets (for example, multiple jets as discussed below), the shape and the dimensions, including both the inlet and outlet area and length, of the chamber 30 as well as its distance from the gasper outlet, and jet outlets may be varied for obtaining efficient entrainment and filtration, purification and/or cleaning of the ambient cabin air.
[0074] The dimensions of the chamber 30 are 1.625 inches inside diameter and 2 inches long. The inside diameter and length of the chamber 30 may vary depending on the system requirements, for example the inside diameter may range from about 0.5 inches to 4 inches and the length from 1 inch to 12 inches or more. Preferably the inside diameter is about 1.5 inches and the length is at least 2 inches or at least 6 inches.
[0075] Preferably, the internal dimensions of the mixing chamber conform to the following:
[0000]
L
D
>
4
L
tube
length
D
tube
diameter
[0076] FIG. 2A illustrates a variant of the mixing chamber 30 which includes an internal helical baffle 15 which effectively provides a spiraling airflow path within the chamber 30 without increasing its overall length.
[0077] A different embodiment of the chamber 30 is shown in FIG. 3 . This version is generally a truncated pyramid shape. This configuration increases the area of the open lower end 44 , which increases entrainment rate, and creates lower more comfortable air velocities emanating from the device.
[0078] In operation, the entrainment of air within the chamber 30 causes a reduction of air pressure within the entrainment section 11 of the housing, which draws cabin air from outside the apparatus into the interior of the entrainment section 11 , passing through the filter 40 . Thus, the air exiting the chamber 30 contains a mixture of air from the aircraft ventilation system via the gaspers, and which is optionally filtered, purified and/or cleaned by the aircraft ventilation system, and entrained filtered air from the cabin interior in the region immediately surrounding the apparatus. Further, the air exiting the apparatus 10 is discharged in a more diffuse fashion which is lower in velocity than the air which would otherwise exit the gasper. This diffuse air stream tends to entrain minimal additional cabin air as it exits the apparatus, thus resulting in a substantially filtered, purified and/or cleaned stream of air impacting upon the passenger.
[0079] FIGS. 4 and 5 show another embodiment wherein an optional manifold 50 is mounted over the nozzle 9 so as to receive the airflow therefrom. The manifold 50 includes a lower face 51 , perforated by multiple jet outlets 52 . These jets 52 comprise narrow diameter tubes or openings directing multiple fine air streams into the open upper end 42 of the mixing chamber 30 . The open lower end 44 of the chamber 30 exits through an opening within the housing 16 and forms an outlet for air to exit the apparatus into the interior of the aircraft cabin.
[0080] The total area of the plurality of openings 52 should equal the PAO flow divided by the PAO velocity:
[0000]
A
p
=
Q
q
V
g
V
g
=
2
P
g
ρ
[0081] A p Area of primary
[0082] Q p Normal PAO flow, i.e. 3 cfm
[0083] V g Available PAO velocity
[0084] P g PAO system gauge pressure
[0085] ρ density of air
[0086] In a further embodiment shown in FIG. 6 , the mixing chamber 30 also may be comprised of a permeable or perforated side wall 35 . Preferably, the perforations 13 or other openings within the wall of the chamber 30 are confined to an upper portion thereof to maintain a device entrainment capability.
[0087] FIGS. 7 through 11 illustrate further embodiments of the present invention, comprising an integrated filtration, purification and/or cleaning and ventilation apparatus 90 intended to be built into the gasper structure rather than being installed over an existing conventional gasper. FIG. 7 shows a cross-sectional view of a typical aircraft cabin 80 , including passenger seats 82 , a cabin floor 84 and a PSU 12 . Typically, one gasper unit per passenger is located in the PSU. The gaspers are fed by a main gasper air supply duct 86 which branches into multiple gasper air supply plenums 88 to feed gasper air to individual gasper units located above the passenger seats in the PSU 12 . In this embodiment of the invention, the filtration, purification and/or cleaning and ventilation apparatus 90 is incorporated into the existing PSU and gasper air supply environment.
[0088] FIG. 8 shows a detailed view of the apparatus 90 containing three air supply units 92 intended for the occupants of one row of seats. The units 92 may be individually controlled by the occupants of the three seats within the specific row. Obviously, depending on the number of seats a greater or lesser number of units may be provided. The apparatus comprises a housing 16 which is substantially sealed apart from the specific inlets and outlets described herein. The housing 16 may be installed within a suitable space within the PSU such that the lower wall of the housing forms the underside of the PSU and is flush or substantially flush with the remainder of the PSU. The lower wall of the housing 16 comprises a grill 94 with perforations 17 that allow ambient cabin air to be drawn through a filter 98 and into the interior of the housing. The motive force for drawing air through the grill 94 and filter 98 is reduced pressure within the housing interior, as will be described below.
[0089] The interior of the housing is divided into compartments, with each compartment retaining a separate air supply unit 92 . The compartments are separated from each other by walls 95 composed of a filtration medium 98 , such that air may pass between the compartments but is filtered when it does so. This prevents any possible cross-contamination between air supply units and possible short-circuiting if one of the units is shut off.
[0090] The air supply plenum 88 enters into the housing 16 and branches to supply air to a plurality of air supply units 92 which are connected to the plenum 88 by a threaded tubular fitting 202 . The fittings 202 are each fastened to a corresponding threaded orifice 200 within the pressurized air plenum 88 and include an internal bore 205 which forms a jet orifice for a high pressure airflow. The fitting 202 includes an disk-shaped valve seat 204 which when sealed abuts the upper rim of the orifice 200 . Rotation of the fitting 202 elevates or lowers the fitting 202 thereby opening or closing the opening into the orifice 200 to control the flow of air from the plenum 88 . The fitting 202 is fixedly mounted to the corresponding air supply unit 92 , such that rotation of the unit 92 by grasping the external grasping surface 203 thereof, permits the user to rotate the fitting 202 thereby adjusting the flow rate through the unit 92 .
[0091] The air supply units 92 further include a generally tubular mixing chamber 30 similar in structure and function to the mixing chamber of the embodiments described above. A cap 93 seals the upper end of the chamber 30 . The fitting 202 enters the chamber 30 through an opening 213 in the cap, such that a stream of incoming air from the supply ducts may enter the chamber 30 through the bore 205 . One or more air inlets 102 in the wall of the chamber 30 allow ambient air from the interior of the housing 16 to enter the chamber 30 . Preferably, the inlets 102 are located adjacent to the upper end of the chamber 30 so as to maximize the entrainment and mixing effect as air passes through the chamber 30 . Alternatively, the inlet or inlets 102 may extend through the cap 93 . The chamber 30 is substantially larger in diameter than the bore 205 , thereby providing an efficient means for entraining a substantial volume of air from the entrainment section 11 of the housing 16 , when air enters the chamber 30 with a relatively high velocity through the inlets 102 . The resulting air plume is thus permitted to expand within the chamber 30 in the same manner as in the first embodiment so as to entrain surrounding ambient air. Thus, as gasper air exits the jet orifice formed by bore 205 , the momentum of the gasper air entrains the ambient cabin air by causing a reduction of pressure within the housing entrainment section 11 . The pressure reduction draws ambient cabin air through the filter 98 such that the air within the housing, and which consequently is discharged to the passengers, is purified.
[0092] The unit 90 functions as a flow multiplier in that the volume of air directed to the passenger is increased, and as an air cleaner, diluting airborne ambient cabin air contaminants beyond what the ECS alone currently provides. The occupant is able to control the direction of the air supply through vanes 106 , and the flow rate by rotation of the unit 92 , according to his/her thermal comfort as well as health and odor protection needs.
[0093] The filter media 98 may comprise commercially available filter devices. The filter 98 may be augmented or replaced by a contaminant gas sorbent material, an electronic capture device, an electronic sterilization device such as a germicidal ultraviolet light, and/or an electronic oxidation device, with said device(s) shielded from passenger view and touch by the grill 94 .
[0094] Another aspect ( FIG. 9 ) provides mixing chambers 30 that admit the secondary air flow through a secondary opening in the cap 93 . Rotation of the chamber 30 in one direction thus simultaneous closes the secondary opening and opens the air passages at the valve seat 200 , thereby increasing the primary flow, while rotation in the reverse direction has the opposite effect. This allows for the removal of the filter dividers 95 and reduces the filter flow resistance. An air purifier 97 is optionally provided within the interior of the compartment entrainment section 11 for further purification of the entrainment air prior to entering the mixing tubes.
[0095] FIG. 10 shows an alternative embodiment of the apparatus 90 . The fitting 202 includes at its lower end a manifold 50 which is located below the bore 205 and within the chamber 30 . One or more holes 110 , preferably multiple holes, are located in the bottom of the manifold 50 to alter the flow of the gasper air. This arrangement is particularly effective for entraining air with mixing tubes of less than 6″ in length.
[0096] FIG. 11 illustrates an embodiment for use when the high velocity that is characteristic of PAOs is not desired. This aspect uses several units 92 as described above, and also several secondary mixing chambers 210 to deliver a low velocity, high quantity of air. Each mixing chamber 210 receives a primary airflow through a permanently open (non-valved) tube 230 which communicates with the plenum 88 . The secondary air flow enters the chamber 210 through an open upper end thereof. Airflow through these secondary chambers may be bypassed by the flow through high velocity entrainment mixing chambers 30 by rotating the grasping surface 203 . This embodiment provides entrainment and filtration for the occupant at all times via the secondary mixing chambers, except when he opens the unit 92 at which time he receives high velocity air for cooling and a smaller volume of entrained and filtered air. While the mix chambers 210 are shown as narrower than mix chambers 30 , in fact the reverse may be true in order to maximize entrainment and filtration of the device when it is not being used for cooling the passenger with a high velocity air stream. Further, one or more holes 110 , preferably multiple holes, may be located in the bottom of a manifold 50 to alter the flow of the gasper air into chambers 210 and increase entrainment filtration that way also.
[0097] FIGS. 12 through 14 schematically illustrate ninth and tenth embodiments, in which the intake for entrained air is located at a distance from the air supply/discharge region. In this version, the primary air supply tube, such as a gasper 14 , enters into the housing 16 through an opening 18 . The housing 16 encloses the discharge end of the supply tube 14 , and the receiving end of the tubular mixing chamber 30 , which is positioned to leave a gap 141 between itself and the air supply tube to permit ambient air to be drawn into the chamber 30 , in a similar fashion to the first embodiment described herein. The opening 140 of the air supply tube, seen in FIGS. 15 through 18 , is partly obstructed with a disk 142 that may comprise various embodiments for controlling air flow in different ways. These embodiments will be described in more detail below. The corresponding intake opening of the mixing/entrainment chamber 30 is fully open. The housing 16 effectively seals the region around the gap against air inflow, except as is provided by the entrainment air inlet. The entrainment air enters the housing 16 via an inlet, which in turn is joined to a tube 150 . The tube may be of any required length, although it must not be so long as to lose effectiveness. The tube communicates at its inlet end 152 with either a simple opening positioned within the cabin or outside the cabin at a location where the air drawn into the tube is reasonably clean; or alternatively, as seen in FIG. 14 , the tube 150 is in fluid communication with a filter compartment 154 , which has one or more walls that include openings 156 to permit the intake of air. One or more filters 158 line the walls either inside or outside of the compartment 154 , so as to filter air entering the compartment 154 . The filtered air is then drawn into the chamber 30 and discharged to the passenger. It will be seen that in this version, the filter compartment 154 may be located at a position close to the passenger, or alternatively at a position removed from any passengers so as to provide improved air quality.
[0098] FIGS. 15 through 18 show four variants of the air supply tube 14 , and in particular the portion of the air supply tube which is located within the interior of the housing 16 . These variants may be adapted for use with any of the embodiments of the invention described herein. In the first variant of FIG. 15 , the disk 142 includes a single central opening, with a tube 220 protruding outwardly therefrom so as to supply the primary air flow in a narrow, directed stream into or close to the entrance of the mix tube. The second variant shown in FIG. 16 , provides a single opening essentially disposed within the disk 142 , but without the tube of the first variant. In this case the primary air is directed to the mixing tube from a distance. FIG. 17 illustrates a third variant in which the disk 142 is provided with multiple openings, each of which is associated with a short, narrow tube 224 , so as to provide multiple, narrow primary air streams. The fourth variant shown in FIG. 18 provides a disk 142 that includes multiple openings 226 , as above, but without the tubes joined thereto.
Example 1
[0099] An experiment was performed in which a system similar to that illustrated in FIGS. 12 and 13 was set up to provide an assessment of device parameters on device performance, including:
Device air supply multiplier; Filter surface area; Filter particulate removal rate; Single and multiple air supply jets; 2″ long to 18″ long mixing chambers; Tubular and conical mixing chambers.
[0106] Air supply jets in front of the mixing chamber versus extending inside the mixing chamber.
[0107] Air was supplied at between 2 inch wc to 10 inch wc pressure into a 1.625″ i.d. tube via one or multiple jets. These jets were created both with 20 holes (total area=0.075 sq. inches) through a flat plate and via a 0.25 inch dia. tube. In the case of the flat plate jets, the plate was spaced away from the 1.625 inch i.d. secondary (mixing) tube at various distances from ¼ inch to a few inches.
[0108] Three mixing chambers were used. Two were tubes, one 2 inches long and the other 18 inches long, both with an i.d. of 1.625 inches. The third was a cone was a truncated cone (frustum) with a 1.625 inch i.d. intake and 3.5 inch i.d. outlet.
[0109] Air was entrained through a commercial 1 inch thick pleated filter typically used in residential furnace forced air circulation systems. Filter areas were 16″×20″ and 4″×5″.
[0110] Entrainment air was conducted to the entrainment capsule via a 1.625″ i.d. entrainment tube.
[0111] Pressure differences were quantified between the air supply tube and ambient, and the entrainment tube and ambient with a micromanometer to a 0.1 Pascal. 1 Velocities were measured with the micromanometer and a pitot tube. 1 Pressure difference: Air Neotronics™ MP20S micro manometer, resolution 0.1 Pa.
[0112] Respirable suspended particulate aerosol count concentrations were quantified by 0.3 micron and larger and one micron and larger mass median diameters using an electronic laser particle counter. 2 2 Air RSP: Met One model 227B™, laser particle counter, sample rate 0.1 CFM, coincidence error+/−5% at 2×10 6 particles/ft3; resolution 1 cpl; size fractions: >0.3 μm plus one of: >0.5, 1, 3 or 5 μm.
EXPERIMENTAL FINDINGS
[0113] Flow multipliers up to 6 times were created. Single jet air supplies created the lowest entrainment rates in the shorter 2″ long conical and tubular mixing tubes. The 20 jet supply performed the best in the short mixing tubes, (better with the conical mixing chamber than the cylindrical mixing chamber) creating entrainment rates there comparable to those measured with the 18″ long mixing chamber.
[0114] The filter pressure drop constant was measured in a furnace system as between 0.15 (new filter) and 0.18 lb.sec/ft̂3 (used filter) at filter face velocities of 700 to 780 fpm. A 20 square inch filter surface did not retard entrainment significantly. In the furnace situation, this filter removed between 22 and 24% of 0.3 micron diameter and larger airborne particles, and 72 and 73% of 1 micron diameter and larger airborne particles. In contrast the new 20 square inch entrainment filter removed 86% of the 0.3 micron diameter and larger airborne particles, and 99% of the 1 micron diameter and larger airborne particles. Improved performance appeared to be due to lower impingement velocity.
Mathematical Modeling
[0115] An incompressible ejector equation can be used to predict the entrainment airflow according to the above embodiments:
[0000] ( P j −P amb ) A j +( P 1 −P amb ) A 1 −( P 2 −P amb ) A 2 ={dot over (m)} 2 V 2 −( {dot over (m)} j V j +{dot over (m)} 1 V 1 ) {dot over (m)} j gasper mass flow slug/sec {dot over (m)} 1 entrained mass flow slug/sec {dot over (m)} 2 total mass flow slug/sec A j gasper flow area 0.000529 ft 2 A 1 mixtube entrance area 0.011743 ft 2 A 2 mixtube exit area 0.012272 ft 2 P j gasper exit static pressure lb/ft 2 P 1 mixtube entrance static pressure (=P j ) lb/ft 2 P 2 mixtube exit static pressure (=P amb ) lb/ft 2 P amb cabin pressure lb/ft 2 V 1 mixtube entrance velocity fps V 2 mixtube exit velocity fps V j gasper exit velocity fps
[0129] The filter pressure drop is based on □P=0.38 inches of water at 780 fpm face velocity:
[0000] P amb −P f =0.15 V j P f internal filter pressure lb/ft 2 V f filter face velocity fps
[0132] The mixing chamber entrance velocity is related to the filter face velocity by continuity:
[0000] A f V f =A 1 V 1
[0133] The mixing and diffusing chamber entrance pressure, P 1 (and the gasper exit pressure) is related to the internal filter, purifier and/or cleaner pressure, P f , by Bernoulli's equation:
[0000]
P
1
=
P
f
-
1
2
ρ
V
1
2
ρ
air
density
slug
/
ft
3
[0000] From continuity
[0000]
A
2
V
2
=A
1
V
1
+A
j
V
j
[0134] The equations were all solved together for the system dimensions and flows shown above for a gasper pressure of 2″wc to obtain a flow multiplier of 6.0 (total ventilation flow 6.0 times that of the original gasper injection flow of 3 CFM) when no filter is present. The flow multiplier at sea level air density is 5.4 for a filter area of 0.25 ft 2 and 4.3 for a filter area of 0.0625 ft 2 for a filter pressure drop coefficient of 0.15 lb.sec/ft 3 . Doubling the filter pressure drop coefficient from 0.15 to 0.3 lb.sec/ft 3 yields flow multipliers of 5.1 for a filter area of 0.25 ft 2 and 3.4 for a filter area of 0.0625 ft 2 . At 8000 ft cabin air pressure, the flow multipliers drop slightly, for example from 5.5 to 5.4 for a filter pressure drop coefficient of 0.15 lb.sec/ft 3 and a filter pressure drop coefficient of 0.15 lb.sec/ft 3 (gasper flow now 3.5 cfm vs. 3 cfm at sea level). Maintaining the 3 CFM flow by decreasing the gasper flow area, the flow multiplier is 6.5 at 8000 ft cabin pressure. Increasing the gasper pressure to 10″wc increases the flow multiplier to 8.7 times at sea level when no filter is present with A j adjusted to maintain a 3 CM gasper flow. Example 2: Computational Fluid Dynamics Modeling Several embodiments can be analyzed using Computational Fluid Dynamics (CFD). The CFD models incorporate several aspects of each embodiment.
[0135] Example 2 consists of a portable device that attaches to the gasper which includes either four small primary jets 270 ( FIG. 20 ) and a tapered mixing chamber 30 ( FIG. 19 ). A rectangular 1 inch thick filter 260 ( FIG. 21 ) surrounds a tapered mixing chamber. The filter outer dimensions are 6″×6″×6″ and the mixing chamber is 1.5″×1.5″ at the base and expands to 4″×4″ at the exit. There is a ½ inch gap between the plane of the orifices and the base of the mixing chamber 30 for entrained air to enter the diffuser. There are four jets 270 supplying 3 cfm at 94 fps at the base of the mixing chamber.
[0136] CFD results (in feet per second in FIG. 22 ) show that the air attaches well to the chamber and expands into the cabin (Filter not shown for clarity).
[0137] CFD results show a fairly uniform pressure gradient (lb/ft 2 ) across the filter 260 ( FIG. 23 ).
[0138] The amount of entrainment is 7.5 cfm for a total airflow of 10.5 cfm, and flow ratio of 10.5/3=3.5. The average exit velocity is reduced to 10.5 cfm/(4×4/144)=94.5 fpm or 1.58 fps.
[0139] The concentration of particles 15 inches away from the gasper is reduced from 0.95 of the local concentration (conventional gasper) to 0.63 (normalized scale) or a 34% reduction in particulate levels ( FIG. 24 ).
Example 3
[0140] The further example of a CFD model is the built-in version described in connection with FIGS. 7-11 ( FIG. 25 ). There is a single primary 94 feet per second jet orifice 202 with an area Of 0.07069 in 2 and a 1.5 inch diameter, 3 inch long mixing chamber. The lower surface and filter have been removed from the view to show the filter dividers 95 , fitting 200 and plenum 88 .
[0141] Although the present invention has been described by way of a detailed description wherein various embodiments and aspects of the invention have been described in detail, it will be seen by one skilled in the art that the full scope of this invention is not limited to the examples presented herein. The invention has a scope which is commensurate with the claims of this patent specification including any elements or aspects which would be seen to be equivalent to those set out in the accompanying claims. | The apparatus and method provide an airflow to a person or group of persons or a space such as within an airplane cabin or cockpit, operating in conjunction with an air supply which produces a high velocity air stream, such as an aircraft gasper ( 14 ). Existing systems may filter, purify and/or clean the air supplied to the occupant, and the air exiting the personal air outlet may be adjusted to a relatively high velocity. The narrow, high velocity stream of air forms a turbulent boundary layer, which tends to entrain potentially foul air from the surrounding region and directs it towards the passenger. The airflow from the apparatus and method may have reduced velocity and lower thermal and humidity gradient and may be treated to remove locally-originating contaminants. The apparatus includes a housing which receives a primary stream of air, such as from an aircraft gasper ( 14 ) or personal air outlet. A secondary inlet ( 17 ) into the housing admits ambient air into the housing interior A mixing chamber ( 30 ) within the housing receives the primary air stream and captures its momentum to entrain ambient air entering the housing through the secondary inlet. The combined streams are discharged, typically towards an occupant of the cabin. The ambient air may be treated before or after it is entrained so as to remove or disable pathogens or other air contaminants including gases and particles, or the ambient air may be drawn from a source distant from sources of air contamination and/or undesirable thermal conditions. | 5 |
RELATED APPLICATIONS
[0001] This application is a divisional application of U.S. patent application Ser. No. 10/980,645, filed Nov. 3, 2004, which application claims priority to United Kingdom Application Serial No.: 0415453.0, filed on Jul. 9, 2004, which application is incorporated herein by reference.
TECHNICAL FIELD
[0002] The application relates generally to drilling. In particular, the application relates to closed loop control of a steerable drilling tool during the drilling of a borehole.
BACKGROUND
[0003] Rotary steerable tools are one example of drilling tools used in the oil, gas and civil engineering industries to drill bore holes. Such tools are typically located between the drill bit and the drill pipe. While a rotary steerable tool may vary in principle, it will generally comprise of a bias or steering unit which exerts a force, either internally on a flexible central shaft or externally on the borehole wall to affect a change in the steering geometry to the desired direction. In one configuration, the drill pipe is connected to a drive unit located at the surface and transmits the rotary motion of the drive unit via the rotary steerable tool to the drill bit. The rotary steerable tool comprises a flexible central shaft which is connected at its top end via the necessary connections to the drill pipe. The bottom end of the flexible shaft is similarly connected to the drill bit. The flexible shaft is supported by two bearing systems, one at either end. The upper bearing is designed to prevent bending of the shaft above it and the lower bearing is typically of the angular contact type and thus allows movement of the shaft above and below it. Between the two bearings, around the centre of the length of the flexible shaft, is a bend unit that deflects the shaft. Various mechanisms may be implemented to cause the flexible shaft to be deflected to the designated amplitude so as to cause the correct angular deflection of the shaft in the required direction. It will be apparent that the portion of the flexible shaft located below the angular contact bearing will move in the contra-direction to the portion of the flexible shaft located immediately above the bearing in the bend unit. Other rotary steerable designs exist which generate deflection by alternative methods; for example, eccentric pressure pad application.
[0004] Rotary steerable tools typically incorporate a reference stabilized housing which is de-coupled, either actively or passively, from the drill string. For example, the outer housing may be restrained from rotating with respect the drill hole walls by a reference stabilizer located along the outer housing. The stabilizer typically has three or four sets of sprung rollers or contact pads which may accommodate over-gauge hole sections. The outer stabilized housing may in fact rotate in the same sense as the drill bit, but at a very slow rate as the system progresses down the hole. The reference stabilizer is designed and operated to ensure that the ratio of drill bit to outer housing turn rate does not exceed a fixed limit.
[0005] It can therefore be appreciated that as the drill bit and rotary steerable tool progress downwards along the drilled bore hole, the trajectory of the assembly, and hence that of the borehole, can be controlled. This control is typically performed and supervised by a drilling operator at the surface or start location of the bore hole.
[0006] Typically, a conventional Measurement While Drilling (MWD) survey tool is located above the rotary steerable tool in the Bottom Hole Assembly (BHA). BHA is the term used to refer to the units components and instruments positioned at the bottom of the drill string. The BHA does not necessarily include the drilling tool itself and in the present application the term BHA is used to refer to the units components and instruments placed between the drilling tool and the drill string.
[0007] Such a MWD survey tool comprises magnetometers and inclinometers which provide the drilling operators respectively with azimuthal deviation data (from a reference, e.g. magnetic north) and inclination measurements relating to the portion of bore hole in which the MWD survey tool and the BHA are currently located. When taken together these measurements provide information concerning the trajectory of the bore hole. Typically, the distance of the MWD survey tool from the surface, i.e. the well bore path length, is derived from the length of drill pipe which has been inserted into the well bore behind the MWD survey tool. Thus, the drilling operators are provided with the attitude (azimuth direction and inclination) of the bore hole at a given bore hole length. This information can be used by the drilling operators to guide the rotary steerable drilling tool.
[0008] However, there are various problems with the accuracy and latent reaction time of such a set-up. Firstly, given that the rotary steerable tool can be more than 18 feet long, the conventional MWD survey tool is located a considerable distance from the drill bit. Thus, if the drill bit veers off the desired trajectory (for example owing to rock mechanics) the drilling operator remains unaware of this condition until the MWD survey tool reaches the point at, or beyond which the unplanned deviation occurred. At this time the drill bit has progressed considerably along the deflected trajectory. Only at this point is the drilling operator aware that corrective action may be necessary.
[0009] Secondly, as MWD survey tools are typically located within the BHA at the lower end of the drill string. While drilling is in progress, the MWD survey tool is subjected to a high degree of vibration and rotary forces. This makes it difficult to obtain accurate survey data while drilling is in progress. Thus, in typical well bore drilling set-ups, drilling is stopped from time to time in order that accurate surveys may be undertaken; normally at pipe connections.
[0010] Thirdly, the drill string is typically made up of multiple segments of drill pipe with the BHA located at the lower end. The BHA also comprises tubular components of variable cross section, diameter and length. Both the drill string and BHA are limber in nature which enables the drill string to progress along the large radius curves of the drilled bore hole.
[0011] The BHA is normally composed of larger diameter, thicker walled, components, and is less limber than the drill string. In most, but not all, drilling applications, the BHA is stabilized and is nominally held concentric to the central axis of the bore hole. The standard MWD direction tool is in turn centralized within the BHA, thus providing sensor attitude data which can be said to represent the local bore hole axis, but not necessarily that of the newly drilled hole some distance below or ahead of the MWD tool.
[0012] The inherent flexibility of the BHA, and specifically, its connection to the rotary steerable system, is a necessary design attribute enabling the steering system to operate quasi-independently of the reaction forces of the BHA above. Hence, the rotary steerable system can be used to deflect the path of the bore hole in any desired attitude and direction.
[0013] The above problems could be addressed by positioning the survey sensors on the rotary steerable tool. If the survey sensors were fixed to the rotary steerable tool the measurements provided could be directly mapped to the actual direction of the rotary steerable tool hole section. As the spatial relationship between the drill bit and the rest of the rotary steerable tool will be known, the measurements taken by these sensors can also be mapped to the actual direction of the drill bit. Thus, the problems associated with the positioning of the MWD survey tool further up the drill string may be reduced and preferably eliminated.
[0014] However, in general rotary steerable tools are constructed using magnetically permeable materials. As conventional MWD survey tools contain magnetometers, they can not function accurately within the rotary steerable tool itself. Even if non-magnetic materials were used in the construction of the rotary steerable tool, the presence of large diameter steel rotating bodies can result in induced electromagnetic forces generating variable, unstable magnetic fields which preclude the use of magnetometers.
[0015] This problem is partially resolved by the use of At Bit Inclination (ABI) sensors (accelerometers) which are located within the outer housing of the rotary steerable tool itself. Such sensors are typically within a few feet of the drill bit and can thus detect relatively quickly any undesired changes in bore hole inclination at or immediately behind the drill bit trajectory and the bore hole axis. However, this sensor configuration does not provide actual azimuthal change. For example, if the drill bit veers from the desired azimuthal trajectory, but maintains the desired inclination, the operator would not be aware of this condition until the MWD survey tool data becomes available for the relevant section of hole. Additionally, the bore hole, at drill bit depth, would have strayed further from the intended trajectory.
[0016] Thus, it can be seen that present survey tool systems do not provide an accurate means for detecting the actual direction of the drill bit. This causes problems for the drilling operator when deciding to instruct a change of direction for either pre-planned or error correction reasons. In addition, knowledge of the actual position (i.e. coordinate based reference) of the drill bit, as opposed to just its direction in space, would bring additional real-time accuracy to bore hole drilling.
[0017] Another problem with existing systems is that they do not provide the drilling operator with reference quality continuous data from the survey sensors. Generally, the inhospitable environment in which the sensors may be required to operate during the drilling process precludes the availability and recording of accurate data. Thus, reference quality data is typically only obtained when drilling is interrupted and the sensors and BHA are stationary.
[0018] In view of the above problems, the provision of automated guidance of the drill bit using closed loop control is not practical in the systems outlined above. The lack of continuous, accurate information concerning the direction of the drill bit, or reference quality positional information, means that drilling operator intervention is required in order to maintain the drill bit trajectory along the pre-planned well path.
SUMMARY
[0019] Some embodiments of the invention may provide a steerable bore hole drilling tool comprising a main tool body having a first end connectable to a drill string and a second end connectable to a drill bit. The tool body is arranged to transmit rotary motion from said first end to said second end. The tool body comprises deflection means arranged to deflect said second end away from a longitudinal axis of the main tool body. The tool body also includes an inertial measurement unit and estimation means arranged to first estimate the direction of the main body on the basis of the output of said inertial measurement unit. The drilling tool further comprises control means first arranged to calculate the difference between the estimated direction and corresponding pre-stored direction information and second arranged to control said deflection means so as to deflect said second end on the basis of said difference.
[0020] The Inertial Measurement Unit (IMU) may not contain magnetometers, and is thus not susceptible to magnetic interference. This being the case, it can be located on the rotary steerable tool. By positioning the IMU on the rotary steerable tool, the relationship between the longitudinal axis of the IMU and the longitudinal axis of the rotary steerable will be known. Indeed in some embodiments, the axes may be the same. Thus the relationship between the measurements taken by the IMU and the direction and/or position of the rotary steerable tool may also be known enabling accurate determination of the direction and/or position of the rotary steerable drilling tool (and thus the drill bit). In addition, by placing the IMU on the rotary steerable tool, it is located closer to the drill bit than would be the case if it were placed in the BHA (as is the case for conventional MWD survey tools) above the rotary steerable system.
[0021] Thus, if the rotary steerable tool is caused to move away from the desired trajectory, by for example, rock mechanics, the IMU will be able to provide immediate indication of this. The vibratory forces experienced by the IMU when positioned on the rotary steerable tool are considerably lower than would be experienced by the IMU if placed in the BHA; above the rotary steerable tool. Thus, the IMU is able to provide accurate measurements when drilling is in progress.
[0022] In some embodiments, the main body of the rotary steerable drilling tool further comprises a flexible shaft, positioned within the main body, and a non-flexible shaft, positioned between the first end of the main body and the flexible shaft, wherein the IMU is positioned within the non-flexible shaft.
[0023] The main body of the rotary steerable tool may further comprise a rotationally stable platform positioned within the non-flexible shaft, wherein the IMU is positioned on the rotating platform. The stable platform may be arranged to rotate in the contra direction in which the drill string and shafts of the rotary steerable tool are rotating. Thus, the IMU may be kept substantially stationary with respect to the fixed Earth axis. A suitable rotary platform is described in PCT/GB00/02097, filed Jun. 1, 2000, and published in English on Apr. 26, 2001 as WO 01/29372 A1, which is hereby incorporated by reference.
[0024] In some embodiments the main tool body may further comprise an outer housing and the inertial measurement unit may be positioned within the outer housing. The outer housing of the rotary steerable tool may be stabilized and remain nominally static for much of the drilling process, turning only slowly as drilling progresses. For example, the rotary motion may be restrained by contact between a reference stabilizer, located along the outer body of the rotary steerable tool and the wall of the bore hole. In addition, this continuous contact with the wall results in much of the shock and vibration being attenuated significantly, in comparison to the levels of motion that may normally be experienced by down-hole equipment while drilling is taking place. Hence, the levels of shock and vibration experienced by the inertial sensors are much attenuated which enables meaningful measurements to be obtained continuously throughout the drilling process.
[0025] In some embodiments, the inertial measurement unit (IMU) may comprise gyroscopic sensors together with accelerometers which measure angular rate and linear acceleration respectively. The IMU may comprise orthogonal triads of linear accelerometers and gyroscopes.
[0026] In some embodiments, the rotary steerable tool may further comprise a signal processor, which together with the IMU constitutes an inertial measurement system. This system may be configured either as an attitude and heading reference system to provide directional survey data, or as a full inertial navigation system (INS) in order to provide both directional and positional survey data.
[0027] The provision of continuous, accurate information concerning the direction and/or position of the rotary steerable drilling tool and/or drill bit by the use of an inertial measurement system enables the implementation of an automated guidance system using closed loop control. The computational capability necessary to implement such a system may be located either at the surface or within the bottom hole assembly. Depth and/or bore-hole path length information may be transmitted from the surface and combined with the inertial measurements concerning inclination and azimuth. This data may then be compared with a pre-planned trajectory. The pre-planned trajectory may be expressed in angular form as a function of path length or as positional coordinates. The computational system may then provide the bend unit or steering system with instructions to maintain the drill bit within the path limits of the pre-planned trajectory.
BRIEF DESCRIPTION OF THE DRAWINGS
[0028] Embodiments of the invention may be best understood by referring to the following description and accompanying drawings which illustrate such embodiments. In the drawings:
[0029] FIGS. 1 a and 1 b are schematic representations of the well-bore guidance system, according to some embodiments of the invention.
[0030] FIG. 2 is a block diagram of an inertial navigation system, according to some embodiments of the invention.
[0031] FIG. 3 is a block diagram showing the use of depth information in conjunction with the inertial navigation system, according to some embodiments of the invention.
[0032] FIG. 4 shows how steering commands are generated in a down-hole closed loop control system, according to some embodiments of the invention.
[0033] FIG. 5 shows how steering commands are generated in a surface control system with possible manual intervention, according to some embodiments of the invention.
DETAILED DESCRIPTION
[0034] FIGS. 1 a and 1 b are schematic representations of the well-bore guidance system, according to some embodiments of the invention. In particular, FIGS. 1 a and 1 b show a rotary steerable tool 1 connected to a drill bit 3 , according to some embodiments of the invention. Like features are referenced with like numerals. The rotary steerable tool comprises an inertial measurement unit (IMU) 4 , a flexible shaft 5 and an outer housing 6 . The IMU may provide measurements of acceleration and angular rate about three orthogonal acceleration axes 7 and three orthogonal gyro axes 8 respectively.
[0035] A computer (not shown) may calculate on the basis of these measurements, the direction, i.e. inclination and azimuthal deviation, and/or the position of the IMU. The computer may also calculate the velocity of the IMU. Given that the spatial relationship between the IMU and the drill bit is known, the calculations of spatial position and velocity may be extrapolated to provide a measure of drill bit direction, position and velocity. The tool face deflection angle may also be calculated. The IMU and computer together form an inertial measurement system. This system may be configured either as an attitude and heading reference system to provide directional survey data, or as a full inertial navigation system (INS) in order to provide both directional and positional survey data. The direction and/or position of the drill bit may be calculated with respect to a pre-determined reference frame. In addition, the computer may be provided with depth/well bore hole path length information. In full inertial navigation mode, depth information may be used to obtain accurate co-ordinate position data. By combining the inertial system data with independent depth measurements, it is possible to bound the growth of inertial system error propagation.
[0036] In FIG. 1 b, the IMU is positioned in the rotating shaft 9 at the up-hole end of the rotary steerable drilling tool. In FIG. 1 a, the IMU is positioned in the outer housing of the rotary steerable drilling tool; the non- or slowly-rotating section.
[0037] FIG. 4 shows how steering commands are generated in a down-hole closed loop control system, according to some embodiments of the invention. In particular, FIG. 4 shows the down-hole closed loop control system 10 , according to some embodiments of the invention. Initial surface input data 11 , which comprise start co-ordinates and planned bore-hole trajectory, may be input into target position means 12 together with continuous measured bore path length updates 13 (surface to rotary steerable system). The target position means may generate target direction and/or position information as a function of bore hole path length. This information may then be input into a difference means 14 together with INS direction and/or position estimate information from the INS 15 . The difference between the planned direction and/or position and actual direction and/or position may then be input into well bore axes resolution means 16 . The well bore axes resolution means may then resolve the direction and/or position differences into well bore axes. This information may then be fed into steering command generation means 17 , which generates steering commands to pass to the rotary steerable tool bend unit 18 in the rotary steerable tool 19 . The rotary steerable tool may incorporate an Inertial Measurement Unit 20 and is connected to a drill bit 21 .
[0038] FIG. 5 shows how steering commands are generated in a surface control system with possible manual intervention, according to some embodiments of the invention. FIG. 5 shows a system in some embodiments of the invention in which the closed loop control system is located on the surface in a surface unit 22 . In FIG. 5 , features which correspond to those shown in FIG. 4 are referenced with like numerals. The additional features are a down hole unit 23 , a surface control unit 24 , a two-way communications link 25 , a drive unit 26 and operator interface 27 . The provision of the closed loop control system at the surface allows for possible operator intervention in circumstances where this is necessary. For example, if problems are encountered during the automated guidance process and a change of well-bore trajectory is required.
[0039] Thus by utilizing an Inertial Measurement System, which provides continuous and accurate information concerning the direction and/or position of the drill bit, and comparing this information with pre-planned well bore trajectory information, a closed loop control system for the automatic guidance of rotary steerable tools is achieved.
[0040] In some embodiments in which only direction calculations are used, the estimated inclination and azimuth readings at a given well depth/bore hole path length may be compared with a stored profile of these quantities corresponding to the required well profile. Steering commands may then be generated in proportion to the difference between these estimates. The differences between the desired and estimated inclination and azimuth may be resolved into steering tool axes, using the estimated tool face angle, to form the signals to be passed to the bend unit of the rotary steerable tool.
Δ x R ( d )= {circumflex over (x)} R ( d )− x R ( d )
[0041] In some embodiments in which position calculations are used, the position estimates, which may be generated in a local vertical geographic reference frame, may be compared with the desired trajectory profile specified in the same coordinate frame, as a function of well depth. In vector form:
[0000] where
[0000]
x R (d)=reference trajectory position at depth d, specified in reference axes
{circumflex over (x)} R (d)=estimated position at depth d, specified in reference axes
Δx R (d)=position error depth d, specified in reference axes
[0045] The differences between the estimated and desired positions may be transformed into well bore axes using the attitude estimates generated by the inertial measurement unit, to form:
Δ x W ( d ) = [ Δ x Δ y Δ z ] = C R W ( d ) Δ x R ( d )
where
C R W (d)=direction cosine matrix relating reference and well bore axes Δx W (d)=position error at depth d, specified in well bore axes Δx, Δy, Δz=components of position error
[0049] The z axis of the well bore coordinate frame (xyz) is coincident with the along-hole axis of the well, and the x and y axes are perpendicular to z and to each other. Steering commands (α and β) may then be derived as a function of the lateral positional errors specified (Δx and Δy) in well bore axis:
α=K α Δx
β=K β Δy
[0050] Other control strategies may be adopted, rather than the simple form shown here. For example, steering signals may be derived taking into account the rates of change of the position error components.
[0051] In some embodiments, the closed loop operation may include activation or reaction limits which could be specified or changed as required. This feature would inhibit the response of the control system to small measurement variations, thus suppressing mico-tortuosity in the drilled well path, the objective being to provide a smooth well path to the target location. The activation limit settings may be governed by prevailing drilling conditions and formation effects.
[0052] FIG. 2 is a block diagram of an inertial navigation system, according to some embodiments of the invention. The INS is shown here in configuration for drill bit position calculation. FIG. 2 shows the IMU 30 which comprises gyroscopes 31 and accelerometers 32 . The measurements taken by the gyroscopes concerning angular rate may be passed to an attitude computation means 33 . The attitude computation means may use the angular rate measurements and information concerning the Earth's rate 34 and may compute the attitude of the IMU. This may be output in the form of a direction cosine matrix 35 . An acceleration output resolution means 36 may take the acceleration measurement information output from the accelerometers and the direction cosine matrix and may pass this information onto a navigation computation means 37 . The navigation computation means may then produce inertial navigation system (INS) velocity estimates 38 .
[0053] The estimates 38 may be first fed into a Coriolis correction means 39 , the output of which is added by means 40 to the input of the navigation computation means forming a first feed back loop. The INS velocity estimates may be second fed into a velocity integration means 41 which produces INS position estimates 42 . The position estimates may be first fed into a gravity computation means 43 the output of which is added by means 44 to the input of the navigation computation means forming a second feed back loop. The INS position estimates may also be used to compute the components of Earth's rate which are fed into the attitude computation means. Finally the INS position estimates may be output from the INS to provide positional information.
[0054] In order to limit, or bound, the growth of errors in the INS arising as a result of instrument biases and other errors in the sensor measurements, independent measurements of bore hole path length may be used. These measurements may be compared with estimates of the same quantities derived from the INS outputs and used to correct the INS as indicated in FIG. 3 . Alternatively, zero velocity updates may be applied at pipe connections when the down hole system is known to be stationary, to achieve a similar effect.
[0055] FIG. 3 is a block diagram showing the use of depth information in conjunction with the inertial navigation system, according to some embodiments of the invention. In particular, FIG. 3 shows INS 50 path length estimates 51 being differenced with depth sensor 52 path length estimates 53 by difference means 54 . The INS path length estimates may be derived from the INS position estimates and may be received from the INS 50 . The depth sensor path length estimates may be derived from a depth sensor 52 and signal processor 55 . The difference between the two sets of estimates may then be passed to an error model filter 21 which may be a Kalman filter. The error model filter may first apply a gain to the difference data at gain means 56 . The output of the gain means may be fed into an INS error model means 57 , the output of which may be fed into a measurement model means 58 and a resent control means 59 . The output of the measurement model means may be taken away from the difference data which is initially input into the error mode filter and the resultant signal may be input into the gain means. The output of the resent control means may be input into the INS error model and the INS itself. Thus the INS is able to output a corrected estimate of borehole trajectory 60 .
[0056] As described above, the IMU provides measurements of acceleration and angular rate about three orthogonal axes. This is typically achieved using three single axis accelerometers and three single axis gyroscopes, the axes of which are mutually orthogonal. Alternatively, the three single axis gyroscopes may be replaced by two dual-axis gyroscopes. While it is often the case that the sensitive axes of the inertial sensors are configured to be perpendicular to one another, this is not essential, and a so-called skewed sensor configuration may be adopted. Provided the sensitive axis of one of accelerometers and one of the gyroscopes does not lie in the same plane as the sensitive axes of the other two accelerometers and gyroscopes respectively, it is possible to compute the required readings about three mutually orthogonal axes.
[0057] In addition to the survey data produced by the IMU system described above, other survey data generated by a conventional MWD survey tool located further up the tool string may be used in correlation with the IMU calculations. This data would provide additional survey checks and an increased confidence in the calculated well path position.
[0058] In the description, numerous specific details such as logic implementations, opcodes, means to specify operands, resource partitioning/sharing/duplication implementations, types and interrelationships of system components, and logic partitioning/integration choices are set forth in order to provide a more thorough understanding of the present invention. It will be appreciated, however, by one skilled in the art that embodiments of the invention may be practiced without such specific details. Those of ordinary skill in the art, with the included descriptions will be able to implement appropriate functionality without undue experimentation.
[0059] References in the specification to “one embodiment”, “an embodiment”, “an example embodiment”, etc., indicate that the embodiment described may include a particular feature, structure, or characteristic, but every embodiment may not necessarily include the particular feature, structure, or characteristic. Moreover, such phrases are not necessarily referring to the same embodiment. Further, when a particular feature, structure, or characteristic is described in connection with an embodiment, it is submitted that it is within the knowledge of one skilled in the art to affect such feature, structure, or characteristic in connection with other embodiments whether or not explicitly described.
[0060] In view of the wide variety of permutations to the embodiments described herein, this detailed description is intended to be illustrative only, and should not be taken as limiting the scope of the invention. What is claimed as the invention, therefore, is all such modifications as may come within the scope and spirit of the following claims and equivalents thereto. Therefore, the specification and drawings are to be regarded in an illustrative rather than a restrictive sense. | One embodiment includes an apparatus comprising a steerable well bore drilling tool having a main tool body. The steerable well bore drilling tool includes an inertial measurement unit to output a measurement used to determine an azimuthal deviation and inclination of the steerable well bore drilling tool during a drilling operation. | 4 |
CROSS REFERENCE TO RELATED APPLICATIONS
The present application is a continuation of U.S. patent application Ser. No. 13/287,040, filed Nov. 1, 2011, which is a continuation of U.S. patent application Ser. No. 13/047,718, filed Mar. 14, 2011, now U.S. Pat. No. 8,090,356, which is a continuation of U.S. patent application Ser. No. 09/591,381, filed Jun. 9, 2000, now U.S. Pat. No. 7,929,950, which is a continuation-in-part of U.S. patent application Ser. No. 09/281,739, filed Jun. 4, 1999, now U.S. Pat. No. 6,169,789, which is a continuation-in-part of now abandoned application Ser. No. 08/764,903, filed Dec. 16, 1996.
BACKGROUND OF THE INVENTION
Wireless devices are made to operate at a single set frequency to transmit and receive on a narrow frequency band. The ability to transmit/receive (T/R) and the protocols for executing the T/R function are primarily set in the hardware and are physically set for each mobile device (MD). Some mobile devices (MD) include the ability to reconfigure the MD for different environments and applications in cases where it is required that the phone be able to operate in these other environments and applications.
There is often a proliferation of mobile devices that must be carried by a user. For example, a user may need a device or remote for the public airwaves (cell phone), another for the local or office network and yet another for the home network such as wireless telephones, as well as controllers for TVs and other intelligent appliances. The present art offers limited Internet access and pager functions on some cell phones. Merely offering Internet access and pager functions is not a solution to the problem involved, such as relieving the proliferation of devices.
There is a need for a method to bypass the public wireless carrier, such as cell phones, for wireless telephones for local office or home networks where the public carrier services are not being utilized, without changing devices. This avoids the proliferation of devices mentioned before.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide a wireless communication and control system including a universal wireless device. There is a central server for storing communication protocols and control protocols. The central server communicates the communication protocols and selectively communicates the control protocols between the wireless device and the central server. The communication protocols configure the system for communication and the control protocols configure the system as one of an arbitrary number of intelligent appliance controllers. Alternately the control protocols configure the system as one of a selection of Internet terminals. The wireless device may be, for example, a hand-held computing device, wireless telephone, or cellular phone.
Other objects, features and advantages of the present invention will become apparent from the following detailed description when taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
The accompanying drawings, being incorporated in and forming a part of this specification, illustrate embodiments of the invention and, together with the description, serve to explain the principles of the present invention:
FIG. 1 is an embodiment illustrating different wireless devices.
FIG. 2 is an embodiment of a comprehensive wireless networking scheme.
FIG. 3 is an embodiment showing how a server is incorporated in the system.
FIG. 4 is an embodiment showing how modes and environments may be mapped.
FIG. 5 is an embodiment of a network control box.
FIG. 6 is an embodiment illustrating the various parts of a server.
FIG. 7 is an embodiment with tables illustrating the dynamic reconfiguration of frequency, power, and bandwidth.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Reference will now be made in detail to preferred embodiments of the invention, with examples illustrated in the accompanying drawings. The invention is described in conjunction with the preferred embodiments, however, it will be understood that the preferred embodiments are not intended to limit the invention. The invention is intended to cover alternatives, modifications and equivalents included, now or later, within the scope of the present invention as defined by the appended claims.
In the present invention, a cell phone acts as a radio, TV and pager to receive and transmit at different frequencies. In addition it is set to bypass the public wireless carrier for local office or home networks where the public carrier services are not required for communication.
The mobile device is dynamically software reconfigurable for the various environments. An example is such as the public networks in one or more countries, which may operate at different frequencies. Another example is found in the office, such as at one or more office locations operating at different frequencies, or in the home. It is desirable that the MD be dynamically tuned for transmit and receive functions suitable for each environment. For example, current wireless conditions may be determined by sensing the signal to noise ratio and the bit error rate. These parameters are a part of an error detection, error correction (EDEC) system in an embodiment of the system of the present The allowed power/channel bandwidth for a given environment or operating mode will be determined, for example, from a table in Server C. This would allow a phone in the USA to work on GSM, as an example. In the present invention a phone or other wireless device can be a remote TV controller, garage controller, or similar intelligent appliance. It can be a cordless phone.
The system of the present invention, including a wireless device forming a part of the system can work with, for example, GPS, or with public wireless location systems, to improve locating capabilities. For instance, since both the home and office network units/boxes are at known locations, tuning a CT/MD for operation as a GPS receiver, or other locating system, to the network units/boxes would give a precise location with respect to the home or office units/boxes. There are two possible locations for only two stations. Normally, therefore, three stations are required, but in many cases, for a CT/MD, one of the two locations is known to be invalid. For example, the location is known well enough to automatically rule out one location. In this case, the location will be precisely known from only the office and home network boxes, or from these units/boxes with respect to a public wireless station, or with respect to a satellite, or both. This software based configuration is available from the network, such as from a server C located on the Internet that enables dynamic reconfiguration anywhere in the world for a CT/MD.
The MD is able to sense which environment it is primarily operating in at a given moment while maintaining the ability to switch instantaneously to a different environment. It has the ability to be in a watchdog or sleep mode in different environments while very active in a given environment at a particular time. This allows the MD to be very useful in one or more environments as the use dictates.
The same MD can be a part of the wired network and one or more wireless networks obviating the need for multiple devices. The MD operates in the IP mode (Internet Protocol) in the wired or wireless domains. The invention also deals with either wired or wireless network control/management units such as a multichannel, multiplexing transmit/receive (T/R) device—referred to also as a network unit or box—when they exist in each environment.
The present invention deals with any wired or wireless network box as a dynamically configurable device utilizing the power of the Internet and a central server C working alone or in tandem with other servers where ever they are located, and local or Internet based network boxes. This is illustrated using a cellular telephone but is fully extendable to all mobile devices.
FIG. 1 illustrates embodiments of a cellular telephone (CT) and a mobile device (MD). In FIG. 1 , CT 102 is representative of the type of phone useful for the improved uses of the present invention. It will be clear to those of ordinary skill in the art that physical changes to the CT are not required. MD 104 is representative of the type of MD useful for the improved uses of the present invention, and as with the CT does not require physical changes. Wireless device (WD) 106 represents another embodiment of the CT and/or MD, and also will require no physical changes to implement the improvements of the present invention.
FIG. 2A is an illustration of an embodiment of a communication and control system 200 . In FIG. 2A :
Cellular telephone or mobile device (CT/MD) 202 working in a domain 200 is highlighted in FIG. 2 . In this embodiment the primary mode is through a public carrier 208 .
The cellular phone (CT) 202 can initiate wireless IP connection 204 to the Internet 206 via the public carrier 202 at a set frequency, Fp 208 , designated by the carrier and tuned for T/R for that particular carrier's FCC approved frequency band of operation. The carrier senses the T/R and makes either wired or wireless connections 210 to the Internet via an Internet backbone connection 212 to a desired Server C 214 or any web site 216 as defined by a URL request 224 of the CT/MD 202 .
When a CT/MD 202 wishes to use the services of Server C 214 , the Server C 214 delivers the content or performs functions as requested by the CT/MD 202 .
A CT/MD 202 can store profiles and other user specific information on the Server C 214 .
Server C 214 can be used to keep the various “functional instruction sets” (FIS) and software (S/W) 218 for use by the CT/MD 202 . The FIS and software 218 resident on Server C 214 will serve to provide the primary repository/exchange to deliver various mode reconfiguration requests to the CT/MD 202 . For example, the CT/MD 202 may send a request to the Server C 214 for configuration as a cell phone because it is not in the home environment. In this mode the CT/MD 202 may still receive inputs/outputs from to the local office loop network box or the home network box via the public carrier channel 208 .
The ability to sense and switch from one mode to the other may include linking 222 to a Global Positioning System (GPS) 220 that determines the exact location of the CT/MD 202 . Thus the CT/MD 202 may sense (or the appropriate network box at the office or home may sense) the location of the network box or the net to bring the CT/MD 202 into any local or carrier loop 208 .
The CT/MD 202 in conjunction with the Server C 218 can decide the preferred mode to be in. There may be a primary mode and several secondary modes or a hierarchy of modes. The primary mode may switch from local office FIG. 2B to a public carrier loop 208 , followed by a home loop FIG. 2C . This switching may be automatic or per specific functional instruction sets 218 and preferences stored on the Server C 214 or in the CT/MD 202 itself.
FIG. 2B is an illustration of an embodiment of a Local Office Loop 230 in accordance with the present invention. In FIG. 2B , a local wireless office IP network 232 , which could also be a local area network (LAN) or other connectivity means, communicates with local servers 234 . Servers 234 then connect on an as-needed basis with, for example, the world wide web (WWW).
The same CT/MD 202 can function in the local office loop 230 under the supervision of a local office wireless network switch or box 232 .
The local office 230 can operate at the same or a different frequency for T/R. It is preferable for the local network box 232 and loop 230 to be at different frequencies that are geared toward a smaller area of influence. In that way the local network box 232 and loop 230 do not interfere with, for example, a public carrier frequency domain. The local network box 232 and loop 230 will be under the control of the local office—such as an office building or office campus.
The local wireless network switch or box 232 may operate at one or more frequencies. In this way, one of more channels will be devoted to a public carrier frequency 210 for T/R and one or more channels 208 will be devoted for T/R optimized for localized use in the campus or office building.
The CT/MD 202 when in the local office loop 236 can switch itself for optimal performance in the local office loop 230 by downloading/uploading FSI 218 and/or protocols in tandem with Server C 214 .
Thus the CT/MD 202 can serve as a cordless phone in the local environment for interoffice phone calls or local area network 236 access working in tandem with a local network box 232 .
In a similar fashion as described above, the CT/MD 202 also serves as a remote controller 270 for controlling intelligent office appliances 238 such as copiers and faxes.
FIG. 2C illustrates a CT/MD 202 in the home loop 260 . In FIG. 2C , the CT/MD 202 communicates through an optional uplink/downlink such as a transmit/receive unit 262 to home server 264 . Home server 264 controls Home Intelligent Appliances (HIAP) 266 . In this way, the CT/MD 202 can be a TV remote 272 , remote access 274 for an oven or microwave for starting/stopping an operation at a desired time, or perform other household duties.
The same CT/MD 202 will function in the local home loop 260 under the supervisory control of a home network box 262 able to T/R in a specific home frequency band.
The home wireless network box 262 operates at same or different frequency of T/R as a public carrier 210 . However, it is desirable to have different frequency of T/R optimized for home area wireless networks.
The local home wireless network box 262 may operate at one or more public carrier frequencies 210 and one or more local home wireless network box frequencies 268 .
The CT/MD 202 when in the home wireless network mode may switch itself for this task for optimal performance by downloading/uploading FIS. 218 (function instruction software) and/or protocols in tandem with Server C 214 .
The CT/MD 202 may serve as a cordless phone (connected or hooked into a landed telephone line as an example, and operating as a telephone or as an IP phone) in the home wireless network loop 260 because it is now configured by the FIS. 218 . Also, the CT/MD 202 may be emulated by a cordless phone, such as by being configured with the FIS. 218 , allowing the functions of the CT/MD 202 to be performed without wasting air time. When the CT/MD 202 is being emulated by a cordless telephone, the cordless telephone base station may also be emulated by, for example, home server 264 , such as by inserting a memory card to reconfigure the home server 264 . One CT/MD 202 , even when being emulated by, for example, a cordless phone, serves many purposes as opposed to requiring many telephone hand sets (one for the home, one for the office, and one for the car, as an example). Paging from one phone to the other in the wireless home network may be done very easily. All you need to carry is your CT/MD 202 , real or emulated, which doubles as a regular telephone hand set.
In a similar fashion as described above, the CT/MD 202 may serve as a remote controller for various IP based intelligent wireless or wired home appliances 266 . The TV may be controlled using the cell phone if the TV set is capable of receiving wireless commands. Opening the garage door may be done with a macro command downloaded from the Central Server C 214 .
Any set of “macro commands” and or detailed FIS. 218 may be written for specific wireless intelligent appliances 266 or wireless intelligent equipment 238 to control/command all of these using the CT/MD 202 in conjunction with Server C 214 .
The commands/instructions are keypad, textual, sound or voice actuated and can be in one or more languages, such as Chinese, English or any other language supported.
FIG. 3 illustrates how a CT/MD 302 cooperates with a Server C 306 . In FIG. 3 , internal structure 304 of CT/MD 302 shows how CT/MD 302 is organized for operation with Server C 306 . Server C 306 also has instructions 308 as well as FIS. 218 for allowing operation with CT/MD 302 , and input/output paths 310 and 312 from Server C 306 for interfacing or transmitting and receiving from and to external devices such as intelligent appliances 266 or intelligent equipment 238 .
FIG. 4 illustrates how the communication and control system 200 of the present invention is mapped 402 , 404 to various modes. In FIG. 4 only primary, secondary and tertiary modes are shown in table 402 and in table 404 , but more modes can be easily accommodated by simple extensions of the entries shown. In connection with FIG. 4 :
The CT 202 wishes to be in the primary mode of the local wireless office loop 230 whereas it is currently in the public carrier wireless loop 200 .
A request, menu or macro command is chosen by the CT 202 and a request for reconfiguration is sent to the Server C 214 via the wireless Internet 204 using frequency Fp and utilizing a public carrier 208 .
The Server C 214 looks up the functional instruction set 218 and maps the instruction set for transmission to the CT 202 . The CT 202 processes the instruction set via the controller and processor electronics located within the CT 202 and loads the new FSI 218 into the memory block of the CT 202 , and tunes/sets the frequencies within the T/R blocks to primary frequency Fp and secondary frequency Fl. Now the CT 202 is converted to the primary local office mode 230 .
The CT 202 is now operating in the local office 230 loop and can control/communicate with various units, appliances and equipment 238 within the loop working in tandem with the local wireless network box 232 . Similar examples can be shown for home wireless network box 262 .
i) In the present invention Transmit and Receive frequencies may be tuned to one or more primary values and one or more subsidiary values. ii) The functional instruction sets 218 may be downloaded/uploaded from/to the central server C 214 for optimal performance in a given domain and may be downloaded/uploaded into the memory of the CT/MD 202 . iii) The secondary or subsidiary modes are active to instantly spring into action/service as needed without losing the full feature functionality. Thus the device 202 instantly becomes a cell phone in the public carrier network 210 upon receiving a signal even when it is operating in the local wireless network 208 loop. iv) Server C 214 may keep watchdog functions alive when the CT 202 is in a different mode or is inactive to instantly deliver all the content that might have been sent in the meantime as though the CT 202 was in the public carrier 210 domain. v) Controller electronics within the CT/MD 202 work in tandem with Server C 214 to deliver the functionality and maintain the ability to switch modes and keep track of modes. vi) The processor electronics within the CT/MD 202 along with the processing and software capability of Server C 214 is able to continually deliver all necessary processing horsepower and capability to device CT/MD 202 . vii) The memory electronics within the CT/MD 202 keeps/caches instructions and other data in conjunction with Server C 214 to quickly execute tasks and efficiently update changes in models. viii) The Transmitter and Receiver are independently tunable to one or more frequencies for operation in different environments based on the instructions of internal controller electronics and that of Server C 214 .
FIG. 5 is an embodiment of the wireless communication and control system of the present invention with more detail of the network control box 500 . Server C 214 is located at home 260 , office 230 or other location 200 and has one or more assigned channels of inputs and outputs 502 . Example: standard telephone line, cable, or standard public carrier cellular telephone frequency.
Other input and output channels 504 are each dynamically tunable, such as to specific power levels, channel bandwidths and frequencies of operation, for maintaining reliability and integrity and to receive/transmit wireless communications from/to one or more services.
Inputs and outputs 502 , 504 are multiplexed for optimal assignment by the controller, Server C 214 , based on requests and utilization/demand.
The network box 500 may have one or more static IP addresses and one or more dynamic IP addresses may be assigned by the network box 500 to a different MD/SD 202 in the wireless network 200 , 230 , 260 .
The functional instruction sets 218 for configuration to different modes is maintained on a Central Server C 214 located on the Internet 206 . The Server C 214 works in tandem with the controllers located within the CT/MD 202 or within the local or home wireless network switch/box 500 to dynamically configure the network switch 500 and the CT/MD 202 . Both the CT/MD 202 and the wireless network control box 500 are dynamically configurable working in tandem with Server C 214 located on the Internet 206 .
The present invention deals with the issues of functionality using a wired or wireless network box and the dynamically configurable device utilizing the power of the Internet. In accordance with the invention, a central server C 214 (one or more) works alone or in tandem with other local and Internet servers and local or other Internet based network boxes. This will be illustrated using a cellular telephone but is fully extendable to all mobile devices.
Cellular telephone or mobile device CT/MD 202 working in the domain 200 , 230 , 260 highlighted in FIG. 2A , FIG. 2B , and FIG. 2C . Primary mode is through public carrier 204 .
CT 202 initiates wireless IP connection to the Internet 206 via the public carrier 204 at a set frequency, Fp 208 , designated by the carrier and tuned for T/R for that particular carrier's FCC approved frequency band of operation. The carrier senses the T/R and makes either wired or wireless connections to the Internet 206 via the Internet backbone connection 212 to a desired Server C 214 or any web site 216 as defined by the CT/MD's URL request. CT/MD 202 completes the transaction as defined by this loop 200 , 230 , 260 .
When CT/MD 202 wishes to use the services of Server C 214 , the Server C 214 works to efficiently deliver the content or perform functions requested by CT/MD 202 .
CT/MD 202 utilizes the profiles and other user specific information 218 stored on the Server C 214 .
Server C 214 is used to keep the various “functional instruction set” and software 218 for use by CT/MD 202 . This FIS and software 218 resident on Server C 214 will serve as the primary repository/exchange to deliver various mode reconfiguration requests to the CT/MD 202 . For example, the CT/MD 202 may send a request to the Server C 214 to be configured as a cell phone because it is not in the home environment 260 . In this mode the CT/MD 202 may still receive inputs/outputs from to the local office loop network box 232 or the home network box 262 , but this is via the public carrier channel 208 .
The ability of a CT/MD 202 to sense and switch from one mode to the other may be linked to a Global Positioning System (GPS) 220 that determines the exact location of the CT/MD 202 . The CT/MD 202 may sense (or the appropriate network box 232 , 262 at the office or home may sense) the location of the network box 232 , 262 or the net to bring the CT/MD 202 into any local or carrier loop.
The CT/MD 202 in conjunction with the Server C 214 decides the preferred mode to be in. There may be a primary mode and several secondary modes or a hierarchy of modes. The primary mode may be local office 232 and then the public carrier 204 loop, followed by the home 262 loop. This switching may be automatic or per specific functional instruction set 218 and preferences stored on the Server C 214 or in the CT/MD 202 itself.
FIG. 2B is an embodiment of a Local Office 230 Loop. In FIG. 2C a local wireless office IP network 232 communicates with a CT/MD 202 and with Office Servers 234 . Office Servers 234 then connect to the Internet 206 and from there to Server C 214 . Server C 214 then connects to websites and servers on the Internet 206 as required.
The CT/MD 202 functions in the local office 230 loop under the supervision of a local office wireless network switch or box 232 .
The local office 230 , such as a local network box 232 , can operate at the same or different frequencies for T/R. It is preferable for the local network box 232 and loop 230 to be at different frequencies geared towards a smaller area of influence so as not to interfere with a public carrier frequency domain 210 . This also allows the local network box 232 to be under the control of the local office 230 —such as an office building or office campus.
The local wireless network switch or box 232 operates at one or more frequencies with one or more channels devoted to public carrier frequencies 210 for T/R and one or more channels for T/R optimized for localized use 236 in the campus or office building.
The CT/MD 202 , when in the local office 230 loop, switches itself for optimal performance in the local office 230 loop by downloading/uploading FIS. 218 instructions and/or protocols in tandem with Server C 214 .
In one embodiment the CT/MD 202 serves as a cordless phone in the local environment for interoffice phone calls or local area network 236 access working in tandem with local network box 232 .
In a similar fashion as described above, the CT/MD 202 also serves as a remote controller for controlling intelligent office appliances 238 such as copiers and faxes.
FIG. 6 is an embodiment of the communication and control system 600 of the present invention. In FIG. 6 , CT/MD 202 is being used in the home loop 260 and illustrates how a processor 602 and memory 604 form a controller 606 with a transmitter 608 and receiver 610 to provide the Server C 214 of the present invention.
The CT/MD 202 may function in the local home 260 loop under the supervisory control of a home network box 500 able to T/R at the specific home frequency band.
The home wireless network box 500 operates at the same or different frequencies of T/R as a public carrier. It is desirable to have different frequencies of T/R optimized for home area wireless networks.
The local home wireless network box operates at one or more public carrier frequencies and one or more local home wireless network box frequencies.
The CT/MD 202 , when in the home wireless network 260 mode, switches itself for this task for optimal performance by downloading/uploading FIS. 218 (function instruction software) and/or protocols in tandem with Server C 214 .
The CT/MD serves as a cordless phone (connected or hooked into a landed telephone line, as an example) in the home wireless network loop because it is now configured to be so by the FIS. Thus one CT/MD serves many purposes such as replacing many telephone hand sets (one for the home, one for the office, and one for the car). Paging from one phone to the other in the wireless home network may be done very easily. The CT/MD doubles as a regular telephone hand set.
In a similar fashion as described above, the CT/MD may also serve as a remote controller for various IP based intelligent wireless or wired home appliances. The TV may be controlled using the cell phone if the TV set is capable of receiving wireless commands/output. The electronic garage door opener may be a macro command downloaded from the Central Server C.
FIG. 7 is an embodiment of the communication and control system 700 of the present invention with tables demonstrating parameter setting for a CT/MD 202 or a Server C 214 , such as for different configurations and environments. In FIG. 7 , CT/MD 202 supports two frequencies in this embodiment, and both are dynamically changed in real time, including power output and channel bandwidth as well as frequency, in this embodiment. Table 702 represents the initial operating state, and table 704 represents the new operating state assumed by the CT/MD 202 or the Server C 214 .
Any set of “macro commands” and or detailed FIS. 218 may be written for specific wireless intelligent appliances 266 or equipment 238 to control or command all of these using the CT/MD 202 in conjunction with Server C 214 . The control of the intelligent appliances 266 or intelligent equipment 238 is done in real time with dynamic reallocation of the environment as shown in tables 702 and 704 .
The foregoing descriptions of specific embodiments of the present invention have been presented for purposes of illustration and description. They are not intended to be exhaustive or to limit the invention to the precise forms disclosed, and it should be understood that many modifications and variations are possible in light of the above teaching. The embodiments were chosen and described in order to best explain the principles of the present invention and its practical application, to thereby enable others skilled in the art to best utilize the present invention and various embodiments, with various modifications, as are suited to the particular use contemplated. It is intended that the scope of the invention be defined by the Claims appended hereto and their equivalents. | A wireless communication and control system including a wireless device. There is a central server for storing communication protocols and control protocols and communicating the communication protocols and selectively communicating the control protocols between the wireless device and the central server. A communication protocol configures the system for communication and control protocols configure the system as one of a selection of intelligent appliance controllers. Alternately the control protocols configure the system as one of a selection of Internet terminals. The wireless device is any hand-held communication device, such as a hand-held computing device, wireless telephone, or cellular phone. | 7 |
FIELD OF THE INVENTION
The invention relates to virtual environments in which user interaction with the environment modifies the behavior of the virtual actors. The interaction of the user can be through movement or sound.
BACKGROUND OF THE INVENTION
The creation of interactive games and environments requires complex computer programs and systems. The most important part of the developer's work is to create a model that will satisfy all requirements while making coding simpler by defining relationships between modules and components. From this model, the developer can identify key functions and items that will need to be persistent.
The animal kingdom has always captivated the human being's imagination. Researchers and scientists have long wanted to live with the animals in their habitat in order to study their behaviors. Marine animals are especially interesting in that studying them requires special equipment and skills. Through years of expensive study and research, scientists have identified behaviors that are specific to certain species. Through zoos, aquariums and museums, this information on the animal kingdom has been available to the public.
Combining the security of a controlled environment with the possibility to interact almost naturally with animal kind has always been a dream. Zoos and aquariums have been built to let the population see the animals and fish in their habitats. However, the conditions in which these animals live are often an outrage and they develop an indifference to human visitors which is non-characteristic of their wild counterparts. The habits of these species are modified in the enclosed environment and do not represent the real activities and behaviors of the species.
The creation of new animations, closer than ever to reality, has suggested a new way of observing nature. If humans are able to reproduce the behaviors of animals as they are in the wild, the population will be able to better understand the world around it. However, looking at animated scenes of wildlife is interesting in so much as there is an interest for the observer. For example, if a student is doing a research paper on the habits of gorillas in the African forests, looking at an animated scene showing the silver back gorilla attack a leopard to protect his herd will be highly useful. If, on the other hand, a scientist is trying to teach to a group of visiting children that belugas are curious by nature and that they will likely pursue the object of their concentration if it is new to them, merely looking at a scene where a beluga chases floating particles will not have great success.
The Virtual FishTank™ at the Computer Museum in Boston, Mass. is a good example of a virtual undersea simulation. Visitors create virtual cartoon-like fish, can give them particular features and characteristics and observe the effects of such features on the behavior of the fish. The schooling effect is also demonstrated. A special station, in front of a window to this virtual aquarium, allows the fish to detect the presence of a human with sensors and, via a digital video camera, to react to his movements. This exhibit, however, only explores the virtual aspects of fish and does not incorporate other biophysical models. Also, it allows the virtual fish to react to the presence of one human being, without taking into account the surrounding humans and their actions.
Virtual Reality development has produced promising results over the last years. However, while being able to navigate through virtual reality environments, the user cannot interact directly since he is bound to experiment with the pre-set scenarios of the apparatus. Giving a personality and a behavior model for a virtual reality module would require enormous processing time and could not be implemented efficiently. The gaming industry is therefore still reluctant to use the virtual reality modules as a replacement of adrenaline-driven games where a limited interaction with the actors is possible.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide a method for interacting with virtual actors in an interactive environment.
It is another object of the present invention to simulate “real-life” behaviors, of the virtual actors.
The present invention is directed to a method for generating a behavior vector for a virtual actor in an interactive theatre by interpreting stimuli from visitors, the method comprising: 1. providing a plurality of sensors detecting and sensing at least one physical characteristic at a plurality of positions within a theatre area within which a number of visitors are free to move about, the sensors generating sensor signals; 2. interpreting the sensor signals to provide at least one physical characteristic signal including position information, wherein said physical characteristic signal provides information on visitor activity and location within the theater area; 3. providing a behavior model for at least one virtual actor; and 4. analyzing the at least one physical characteristic signal and the behavior model for said at least one virtual actor to generate a behavior vector of the at least one virtual actor using the position information and the at least one physical characteristic signal, whereby a virtual actor reacts and interacts with visitors.
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 and accompanying drawings wherein:
FIG. 1 shows an interactive theatre in use;
FIG. 2 is a block diagram of the modules of the system;
FIG. 3 is a block diagram of the details of the behavioral module;
FIG. 4 is a flow chart of the general steps involved;
FIG. 5 is a flow chart of the detection of the stimuli;
FIG. 6 is a representation of the direction of the velocity vector for the actor;
FIG. 7 illustrates the swim wave used to calculate the displacement of the beluga;
FIG. 8 is an overall class diagram according to Example 1;
FIG. 9 is an illustration of the physical environment module according to Example 1;
FIG. 10 is a class diagram for the virtual environment module according to Example 1;
FIG. 11 is a class diagram for the behavioral module according to Example 1;
FIG. 12 is a class diagram for the attitudinal module according to Example 1; and
FIG. 13 is a class diagram for the rendering module according to Example 1.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
A preferred embodiment of the present invention is shown in FIG. 1 . An interactive theatre 15 is built in a shape that facilitates projection of large images on its walls. The images can also be projected on the floor and the ceiling. The images are composed of actors 16 which can be anything: objects, humans, animals, plants, etc. A preferred shape for the implementation of the system is a dome. Such a dome consists in a room in the shape of a half sphere. The interior is accessible through a door (not shown) that is camouflaged in the decoration of the interior of the sphere. The interior space is of a size suitable for welcoming groups of visitors 17 of different sizes. It is understood that the dome could be replaced by a closed room or even an open area and that the projection of large images could be replaced by holographic displays or any type of presentation.
The system created in the preferred embodiment of the present invention is divided into modules to help implement all aspects of the invention. FIG. 2 illustrates the correlation between these modules.
Signals from the physical sensors come from different sources: sonic 20 , positional 21 and haptic 22 . Other sensors could be used such as body language sensors, group sensors, etc. The sensors 20 , 21 and 22 in the theatre 15 each produce a stimulus. The Sonic Stimulus Generator 23 , the Positional Stimulus Generator 24 and the Haptic Stimulus Generator 25 analyze and filter the raw signals from their respective sensors 20 , 21 and 22 and produce a stimulus signal. Each of these stimulus signals is fed into the behavioral module 28 of every actor (in this case, actor # 1 ). The behavioral module 28 determines, according to the behavioral characteristics of the actor, an action to undertake. This planned reaction of the actor is fed into the biophysical model action generator 30 which calculates the physical reaction of the actor with respect to its bodily limitations and characteristics. The planned reaction can comprise the creation of a new actor. The new actor that can be created can be bubbles, baby belugas, waves or anything that can react to other actor's behavior or to the environment. In that case, the reaction signal is fed to the new actor creation module 29 which plans a reaction for the new actor and feeds it to its biophysical model action generator 32 .
The biophysical model action generator 30 of the actors sends a vector to the Rendering module 31 . The New Actor creation module 29 also sends a vector to the biophysical model action generator 32 which sends a vector to the rendering module 33 . An adder 42 combines all rendering vectors of all actors 34 and new actors. An overall rendering signal is sent to the Overall Rendering Generator 35 which calculates an overall rendering effect for all of the actors in the environment. A sound effect generator 36 , an haptic effect generator 37 and an image generator 38 analyze the calculated overall rendering effect and calculate a specific effect. The sound effect module 39 , the haptic module 40 and the projection module 41 generate what the visitor will hear, feel and see.
The biophysical model action generator 30 also sends a virtual environment update to the virtual environment database 26 . This database comprises all data concerning all actors at any point in time. The Virtual Environment Stimulus Generator 27 reads information from this database 26 in order to calculate the occurrence of random events such as the apparition of new actors, for example. Once the Virtual Environment Stimulus Generator 27 decides that a new actor should be created, a signal is sent to the new actor creation module 29 .
The biophysical model action generator 30 also reads information from the virtual environment database 26 in order to decide if an interaction with another actor is necessary. For example, a first actor could decide to go straight ahead for a distance of 2 meters but another actor is located straight ahead at 2 meters. Then, the biophysical model action generator 30 , when calculating what trajectory, motion and aspect the first actor would have when traveling the 2 meter distance, would read from the virtual environment database 26 that another actor is present. The trajectory would be adapted accordingly.
Different sensors will be located throughout the theatre, enabling technicians to record real activity signals from the theatre. For example, sound waves will be recorded at different points in the dome. Other types of sensors can include cameras, microphones, optical detection using lasers, handheld devices that the visitors carry, tactile plates, sensors affixed to the body of the visitors, body language interpreters, etc. It does not matter which type of detection is done, as long as the visitors and their actions are detected. These measurements will give an idea of the distribution of the ambient noise and activity in the dome. When a first derivative of this signal will be calculated, the general movement of this ambient noise will be determined. A second derivative of this signal will give an indication of sudden noises and their position in the theatre. Also, these signals could be fed into speech recognition or phoneme recognition systems. The sensors used to measure the sound level could be, for example, directional microphones.
The position of the visitor will also be determined. Sensors located at a plurality of positions will detect at least one physical characteristic such as position for the visitors. The plurality of positions should be at least four positions in order to get an accurate position using the triangulation method. However, only three positions could be used. More positions would yield more accurate results. Also, the information on the visitor activity and position could be represented on a contour map for ease of analysis and processing. This position indication will enable other modules of the system to trace guides for the movements of the virtual actor. For example, a curious actor will go towards the visitor and a frightened actor will retreat far from the visitor. The first derivative of the position of the visitor will indicate the displacement of the visitor. The second derivative of the position will detect sudden movements of the visitors. These signals could also be fed to gestural language recognition software or other gestural signs recognition systems. The sensors used to capture the position of the visitor will comprise, for example, tactile sensors, sonar systems, infra-red cameras, ultrasound detectors or other position determiners.
Other spatial data and their derivatives can also be used to determine stimuli on the actor. These signals, comprising logical sets of actions, could be decoded by the behavioral module and biophysical model action generator of the actor.
The behavioral module 28 will calculate, from the data collected at the user interface, the reaction of the actor. The actors will likely be virtual animals or virtual physical actors which have behaviors that are easier to simulate than those of humans. However, virtual plants, virtual humans and virtual extra-terrestrial beings could all be actors in such an interactive theatre. The calculation of the behavior of the actor will be done using their own factors. These factors will be, for example in the case of a marine animal: the age, hunger and thirst, tiredness, alertness, distance from stimulus, genetics and handicaps and other factors.
For example, the younger the animal, the sharper its reactions. It will be afraid more easily and will be curious more easily. An older animal will more likely be passive with respect to the stimuli of the visitors. An hungry animal will be more sensible to sudden noises and visual stimuli. An animal that is falling asleep will be more nervous with respect to sudden noises and movements but completely passive with respect to ambient noise and fixed position of the visitor. An alert animal, concentrated on the surveillance of a particular point in the environment will react promptly to all that concerns the point of interest and will react more slowly to other stimuli. The further the stimulus from the animal, the less impact it will have on its behavior. A blind animal will not react to visual stimuli. A deaf animal will not react to sound. An injured animal will be prompter in its reactions but less mobile.
An equation will be built that calculates the level of attractiveness (if the result is positive) or repulsion (if result is negative) of the animal towards the stimulus. This equation can be of the kind: (equation 1)
N =Σ( F i0 *S i ( t )+ F i1 *S i ( t )/δ t+F i2 *S i ( t )/δ t 2 ))/ d
Where:
N=extent of the speed vector (V)
F in =Psychological factor i acting on the nth derivative of the stimulus
S=Magnitude of stimulus (sonic, visual, etc.)
d=Distance between the actor and the stimulus.
The orientation of the velocity vector for the actor will always be located on a straight line passing through the point from which the stimulus 75 is coming and the position of the actor 76 . FIG. 6 shows this relation. The reaction can be attraction 77 or repulsion 78 . Then, equation 1 can be re-written in a matrix format to yield the following Velocity vector: (equation 2)
V ( x,y,z )=(Σ(| Ps−Pa||F|*|S |))/ d 2
where
Ps=Position of stimulus Ps(x,y,z)
Pa=Position of the animal or actor Pa(x,y,z)
F=matrix of the effects of a psychological factor on the environmental factor and its first two derivatives F(d 0 , d 1 , d 2 )
S=values of the stimulus and its first two derivatives s(d 0 , d 1 , d 2 )
d=distance between the stimulus and the animal
The behavior module 28 will also calculate, in addition to the direction taken by the actor, a reaction composed of sounds or other types of reactions from the animal or the object, according, again, to the actor's own factors. This module will also be responsible for calculating the behavior of the actor in a “normal” mode, that is when the actor is not responding to any stimulus but doing its own activities. For example, for a marine animal, this would include playing or catching a small fish.
The actor has decision layers that coordinate its reactions. For the example of the beluga, the primary decisional layer, directly connected to the muscles, models the primary actions of the marine animal: swimming, direction, glance, eating habits, sound emissions and echolocation. This active layer synchronizes in time and space all the different muscles and tissues of the animal in order to model these primary actions in a realistic manner.
The secondary decisional layer activates and synchronizes the reactions of the primary layer, modeling typical behaviors of the animal: curiosity, hunger, fear, laziness, sociability. Contrary to the primary layer, the secondary layer is specific to each individual of each species. The reactions to the events of the environment are mapped by the personality or the age and experience of each animal of the group.
The tertiary layer is the one that analyzes the information coming from the senses: the eye and the ear. After an analysis of the sensorial signals, it activates the secondary layers and the muscles. For example, a noisy boat passing rapidly by could activate fear (secondary) and a glance (primary) as well as stopping all muscle movement (muscular).
The events perceived are of two kinds: the real stimuli from the interactive theatre and the simulated events, generated more or less randomly from a scenario predetermined. The mixture of these stimuli will nourish the nervous system of the animal, its behavior, and its displacements within the simulated environment.
The generation of the stimuli being sent to the Behavioral module linked to every actor can be schematized as shown in FIG. 3 . FIG. 3 illustrates the processing done for each actor.
An event occurring in the dome or generated by the virtual environment module triggers different type of sensors 45 , 46 , 47 . Each of these generates a stimulus which is computed by the stimuli generator 48 , 49 , 50 . The actor can choose to react to it or not, using the reaction generator 53 , 54 , 55 , according to its own psychological properties. If it chooses to react to it, the behavioral module 58 computes the reaction of the actor to this stimulus. All the reactions are then combined together 57 in an overall reaction by the overall reaction generator 59 and will be fed to the Biophysical Model action generator module 61 .
A virtual environment database 51 keeps track, as explained earlier, of all activities in the dome. The virtual environment stimulus generator 52 computes random events and can create new actors. It can also generate a reaction using the reaction generator 56 , which will be added 57 to the overall reaction generator 59 . A new actor creator 60 uses the signal from the overall reaction generator 59 and the virtual environment stimulus generator 52 and decides on a reaction which is fed to the biophysical model action generator 62 of the new actor.
There are 2 main types of stimuli that can be treated in parallel by the system. They are: Sonic Stimuli and Visual Stimuli.
Once captured by the microphones present in the dome, the ambient noise and its first two derivatives will be transferred to the software module. The modules will take into account the following particularities in the calculation of the animal reaction:
Sound is omnidirectional. Therefore, a sonic stimulus will have an effect even if the animal attention is focused somewhere else.
A deaf actor will not be influenced by a sonic stimulus.
An actor that is sleeping can be woken up by a sudden sonic stimulus. As we have already seen, a sudden sonic stimulus is generated from the second derivative of the signal caught by a microphone or any other type of sonic sensor.
Once captured by the physical sensors for the position present in the dome, the position of the visitors and its first two derivatives will be transferred to the software module. This one will take into account the following particularities in the calculation of the animal reaction:
Visual stimuli are unidirectional. Therefore, if a visual stimulus is not in the field of vision of the actor, this one will not react to it.
A blind actor will not be influenced by a visual stimulus.
An animal that is sleeping will not be woken up by a sudden movement in the dome.
FIG. 4 is a general flow chart of the process. Sensors 65 are located in the dome. An interpreter 66 filters and analyzes the raw signals from these sensors a produces a physical characteristic signal which can be a bus or a single vector. The analyzer 67 reads from the behavioral module 68 and produces a rendering vector which will be used to display the environment.
FIG. 5 illustrates the following idea. Usually, an event that occurs 70 will produce, at the same time, a sonic and a visual stimulus 71 . If the animal is not actually looking towards the position from which the stimulus is coming, it will, most of the time, respond to the sonic stimulus by turning its eyes towards the position from where the stimulus is coming 73 in a manner that will let the visual stimulus enter its field of vision and then, and only then, will react to the visual stimulus 74 . If the animal is looking towards the event, he will react to the visual stimulus 74 .
An actor will react to a stimulus depending on a series of factors which are influenced by its own psychology. For example, a fearful animal that sees a predator far away will tend to stop and watch its behavior as long as the animal is far enough and will escape if the stranger is getting closer or coming too rapidly towards the actor.
We have already seen that the equation computing the extent of the actor reaction is
N =Σ( F i0 *S i ( t )+ F i1 *S i ( t )/δ t+F i2 *S i ( t )/δ t 2 ))/ d
where:
N=extent of the speed vector (V)
F in =Psychological factor i acting on the nth derivative of the stimulus
S=Magnitude of stimulus (sonic, visual, etc.)
d=Distance between the actor and the stimulus.
The psychological factors F in are not constant but can in fact be modeled by a non-linear equation.
For example, the degree of fear of an animal can be represented by a nonlinear equation of the type:
if d<T then F i2 =1 /d
else F i2 =0
where:
T=threshold value over which the animal does not react.
d=distance between the actor and the stimulus.
The Biophysical model action generator 32 controls the physical aspect of the actor according to its body limitations. For example, it is known that no animal nor physical object of non-zero weight can move at an infinite angular velocity or linear velocity. This explains why the following data are necessary to the proper operation of the system. These data are, for example, a model of the surface of the actor, a model of the skeleton or structure of the actor, and a model of the muscular network (if any) of the actor. The tri-dimensional model of the surface of the actor is essential to the calculation of its appearance. The model of the surface can be composed of, for example, polygons. At each vertex of these polygons or at each critical point of this model, a vector representing the Young module will have to be associated. It will introduce a factor of ductility to the surface of the actor. This factor will enable the calculation of a deformation of the surface according to the resistance of the fluid through which it circulates as shown in equation 3:
D ( x,y,z )= M ( x,y,z )* V r ( x,y,z )* R f
where
D(x,y,z)=distortion vector
M(x,y,z)=Young modules vector
V r (x,y,z)=relative velocity of the actor with respect to the (V fluid (x,y,z)−V actor (x,y,z))
R f =Mechanical resistance of fluid.
A model of the skeleton or structure of the actor will determine its inertia. At each point of the frame (representing the joints) will be associated two vectors representing the limits of the moments: limits of the torsion clockwise and limits of the torsion counterclockwise, one value of the resistance in compression and one value of the resistance in traction.
The muscular model will model the power of the actor. At each muscular junction point of the actor will be associated two vectors representing the power of the actor in traction and in compression. This power will serve to the calculations of its acceleration and the speed limit that this actor can attain (with respect to the mechanical resistance of the fluid R f as discussed).
If we consider the actor to be a marine animal, more particularly a beluga, it is necessary to reproduce the physical aspect of it. Using the coordinates that define the shape of the animal, a spine is constructed. When connecting the bones of the fins, the neck and the jaw, we obtain the skeleton of the beluga. We can then envelop this structure with muscles, fibrous tissue and skin.
The muscles are in fact algorithms of sinusoidal animation positioned on the boned structure. These muscles are force points that activate the bones. In reaction, the relaxation points are countering the force points and add a softer appearance to the fibrous tissues. These tissues are also sinusoidal algorithms, which are parameterized to counter the muscles. The force points are located on the spine, the neck, the wrists of the fins, at the basis of the melon and along the lips. The relaxation points are located at the extremities of the tail and the fins.
The animation on the skeleton is transmitted to all of the structure by projecting the displacement of each of the vertebras to corresponding points on the skin of the animal. This skin is composed of textured images. The muscles are connected to a nervous system. The nervous system stretches from the senses to the muscles through a series of decision layers that will determine the behavior of the actor.
Also, the calculation of the position of the actor will be given as input to the behavior module and will be used as a supplementary virtual stimulus. With all these parameters in hand, the biophysical model action generator module will be able to, according to the data calculated, give the object rendering module the necessary data to display the scene.
Once the position and the torsion applied to the surface of the actor are modeled by the other modules, the object rendering module is responsible to display the actor and its environment. The object rendering can be visual, composed of sounds, haptic, environmental or else. The object rendering can be displayed through cathode screens, holographic systems, lasers or other forms of visual display technologies. The sounds effects can be rendered through speakers located in the theatre or other sound effect technology. The haptic effect can be felt, for example, through release mechanisms that vibrate, electromagnetic systems or speakers that vibrate at low frequencies. These systems can be installed inside the theatre or directly on the visitor. The environmental effect can be rendered through automation systems, atmospheric simulation systems, pressurization systems, humidifiers, ventilators, lighting, robots, etc.
The environment in which the actors will live will first be created in a laboratory. It will, once ready, welcome the image of the belugas constructed in real time. A 2D animation module will combine these two techniques during display. This combination of multiple layers: sea bottom, belugas, and suspended particles, is combined with a projection and display surrounding the field of view of the visitors.
In order to model the behavior of the beluga, a target in the environment is given to the beluga by the environment module. An algorithm typical to homing devices used in the military can be implemented for the beluga. The animal will then tend to get closer to its target, taking into account the constraints of flexibility of the body, of speed, displacement and which are parameterized using the weight, the agility and the age of the individual. If the target is reached or if the target moves, a new event is generated, in a random fashion and this new event will dictate a new target. There is always an inertia factor associated with the displacement of the animal and upper and lower limits on the acceleration of the animal.
Knowing its target orientation and speed, the actor's structure can be displaced. The physical limitations of the actor's structure, that is, the angular and linear position, speed and acceleration, will dictate an overall iteration of its attitude through time. The center of gravity of the actor moving along a path determined by its overall inertia and its body moving in a way to maintain this center of gravity along this path. For the neck, a start point on the first vertebra of the neck is calculated and the flexibility factor of the neck is used instead of that of the spine. Since belugas usually roll on themselves, a roll factor is added to the calculation of the segment which will make the beluga pivot on its longitudinal axis.
Swimming is modeled using a swim wave 80 as shown in FIG. 7 . The wave has a sinusoidal shape that undergoes a displacement as a function of time, its amplitude being directly proportional to the velocity of the displacement of the animal and the position of the vertebra since the amplitude is less at the head than at the tail. Again, the amplitude of the wave will be proportional to the inertia of the body at this position along the spine, in a way to maintain a node in the wave at the center of gravity of the animal.
The generation of semi-random events is important to keep the virtual environment lively even when the visitors are less active. The passage of a school of fish, of a boat or of a killer whale as well as the marine currents are events that need to be simulated. The generator of random events will take into account the level of ambient noise, the cries, the displacement of a visitor nearby the screen and the quantity of people in the room. Using a pre-determined scenario, the generator will activate more or less randomly some events that render the environment lively. The events will influence the behavior of the animals and in the same manner, will activate the displacement and movements of the belugas. It will also activate the generation of sound waves and the activation of sea bottom animations.
In the case of belugas, generating sound waves is very important since these animals are really talkative. They emit different types of sounds: whistles, clicking and others. The modulation, the amplitude and the rhythm of each of these sounds enable him to communicate and express himself with his fellow belugas. In order to simulate in real time this language, a grammar can be constructed where the vocabulary of the beluga is inserted within grammar structures pre-defined. Some rules will manage the creation of sentences and phrases, simulating the monologues and dialogs of such species.
In order to simulate foggy water, a manipulation of the color and aspect (shade) of the actor is done. Equation 4
T
f
=T
l
*e
−ad
is used where:
T f =final shade
T i =initial shade
a=fog constant (as a increases, the opacity increases)
d=distance between the point and the visitor.
When trying to simulate the sun, a luminous source must be defined. The source that produces best results is an infinite source. The infinite luminous source simulates a global light for the whole environment (much like the sun, for example). This infinite source is then filtered with respect to the depth of the location of the actor, in such a way as to simulate the opacity of the ocean water, according to equation 5
E=e
−ap
where:
E=Luminous source
a=water opacity constant (when a increases, the opacity increases)
p=depth of the illuminated point.
The present invention will be more readily understood by referring to the following example which is given to illustrate the invention rather than to limit its scope.
EXAMPLE I
An example of the implementation of the present invention in a preferred embodiment will now be described. The modules discussed are: physical module, virtual environment, spatialization module, behavioral module, attitudinal module, rendering module. As mentioned earlier, this system can be understood as a “man-in-the-loop” type of simulation systems. Revisiting FIG. 2 will give an overview of the various modules of the system that are involved at each iteration. FIG. 8 presents a class diagram of the entire system's software components to be described with respect to the modules.
The Physical Environment
The physical environment is made of series of electronic sensors allowing it to provide the behavioral module with data relative to the real-world activity in the room. FIG. 9 illustrates the processing on the data provided by a single electronic sensor 81 .
Each of these sensors 81 , which can be sonic sensors, physical sensors or any other type of sensors, will have to be linked to an electronic module 84 (in this case, an A/D converter) computing a numerical value which represents one of the raw data from the sensor 81 , its first derivative 82 and its second derivative 83 . The data provided to the computer must include the sensor ID 85 (in our example, “81”) and three numerical values provided to the software components by the three states (raw, first derivative, second derivative) of the electronic component 81 . These data will be read by the computer by polling, allowing the electronic module to work asynchronously. Also note that in a way to spatialize the data in three dimensions, at least four sensors of each type will have to be positioned judiciously in the room, in a way to obtain a minimal error in the triangulation calculation methods.
This data 85 will then be added to the data provided by the module simulating the virtual environment and decoded by the spatialization module.
The Virtual Environment
This module creates a simulation using, preferably, software, of the data provided electronically by the sensors of the physical module. Essentially, it will generate sensorial data coming from a specific point in space. This data will then be decoded by the spatial module.
The Spatial Module
At each iteration, this module receives the data relative to each sensor from the physical module. This data comprises: an ID, the sensor level data, its first derivative and its second derivative.
This module accesses a calibration table allowing it to associate a position and a type to the sensor ID received. In a preferred embodiment of the present invention, data represented in Table 1 can be used to build the calibration table:
TABLE 1
EXAMPLE OF A CALIBRATION TABLE
Sensor
Type
X
Y
Z
A
Sonic
4.356
7.923
8.382
B
Sonic
2.748
1.038
2.661
C
Positional
8.233
8.018
0.000
Therefore, the spatial module will be able to provide the behavioral module with the stimuli presented to the virtual entities. FIG. 10 illustrates a class diagram of the interface that allows the module to compute the stimuli in a preferred embodiment of the present invention.
SensorData 87
Essentially, this class includes the data needed for the generation of a stimulus by the class StimuliGenerator 89 . Its pure virtual function getData( ) 88 will be re-definable in its derived classes, namely PhysicalSensorData 91 and VirtualSensorData 93 .
PhysicalSensorData 91
This class includes a re-definition of the virtual method getData( ) 88 . function can read the data provided by a specific type of electronic sensor.
VirtualSensorData 93
This class also includes a re-definition of the virtual method getData( ) 88 . This function can simulate the acquisition of data provided by any sensor.
StimuliGenerator 89
This class is the core of the spatial module. Known by the feedback controller of the system (the class VirtualWorld 115 ), it collects, at a pre-established frequency, through a call to its public method calcStimuli( ) 90 , the data relative to the sensors (via the classes defined above) and creates a linked list of stimuli, which will be returned to the calling function.
Stimulus 95
This container-class groups together the data relative to a particular stimuli.
The Behavioral Module
As mentioned, this software module computes, from the data provided by the user interface, the reaction of the virtual animal. This computation is made according to various entity-specific factors. The data relative to virtual entities will be defined in a file Entities.dat which will look as follows:
Entity 1
Stimulus
Value
Stimulus
Value
Stimulus
Value
Entity 2
Stimulus
Value
Stimulus
Value
Stimulus
Value
Entity 3
Stimulus
Value
Stimulus
Value
Stimulus
Value
FIG. 11 illustrates a class diagram that models the behavioral module
Animal 100
This class will simulate the animal behavior by computing its velocity vector (see FIG. 6) according to the stimuli calculated by the spacial module and accessible to the system through the class StimuliGenerator 89 . Animal's constructor method will receive the name of the associated configuration file as an argument and will call the method getAnimalData( ) 101 which will create a list of behavioral factors, kept in a linked list of instances of the class AnimalReaction 102 . The method CalcBehavior( ) 103 will compute a velocity vector by associating the data collected by the instance of StimuliGenerator 89 (through a call to the method GetStimuliData( ) 92 ) to this list of instances using equation 2.
AnimalReaction 102
As just mentioned, this class will essentially be a container for the data defining the animal reaction towards a specific stimulus.
The Attitudinal Module
As mentioned, no animal nor physical entity of non-zero weight can move at an infinite linear speed nor at an infinite angular speed. The attitudinal module is the one responsible to simulate the physical behavior of the animal according to its own physical constraints. FIG. 12 shows a class diagram that models the attitudinal module.
Animal 100
This class has already been defined in the behavioral module. Essentially, it is involved in the computation of the attitudinal module by calculating at each iteration the virtual entities' attitudes by using the velocity vector provided by the behavioral module through the method iterate( ) 105 .
AnimalStructure 104
This class embeds the structural data of the animal and allows the calculation of its skeleton's location in space (using the function getStructurePoints( ) 107 ) to finally iterate the position of all the polygons defining its surface (using the function calcAttitude( ) 109 ).
Torsion 106
This container-class will be used to embed any three-dimensional torsion-related data.
Moments 108
Derived from class Torsion 106 , this class will allow the system to associate a desired moment to a specific point on the animal structure. Note that this requested moment will be filtered by the optimal torsion data included in its base class (Torsion 106 ). This aims at iterating the real moment applied to the animal structure.
Skin 110
This class models the surface of the animal. Once the structure-related data is computed by the method Animal::getStructurePoints( ) 107 , its surface-related data, embedded herein, will be used to compute all the polygons forming the animal surface through the method Animal::calcAttitude( ) 109 .
The Rendering Module
The rendering module is responsible for the display of the virtual world, using a three-dimensional projection system or simply using a two-dimensional representation computed by means of a graphic library as OpenGL or OpenInventor, for instance. FIG. 13 is a class diagram that models the attitudinal module.
VirtualWorld 115
This class is the core class of the entire system. Its method iterate( ) 116 must be called at a predefined rate in a way to synchronize every module of the system. This method will first call the methods of the class Animal 100 which associates the stimuli and the behavioral data. It will then synchronize the rendering of physical entities and will add to the scenery the effects of the virtual environmental parameters computed by using instances of the Environment 117 .
Environment 117
This class is responsible for the computation of environmental effects over the virtual scenery. It embeds a linked list of environmental (defined in instances of the class EnvironmentalElement 119 ), from which it will call successively the method calcEffect( ) 118 .
EnvironmentalElement 119
This base class acts essentially as a container for a specific environmental effect. It contains only one pure virtual method, calcEffect( ) 118 , which will be redefined in its derived class. Each of those derived class embeds a specific environmental effect which will influence the final rendering. For example, we defined the classes Light 121 , embedding the effect of a generic light source, Fog 123 , simulating the effect of a fog, Humidity 125 and Temperature 127 , which, obviously, are encapsulating namely the effect of humidity and temperature.
The calculation of the actor's reaction is made by associating its phychological properties with the stimuli present in the simulation. Those stimuli can be provided by the virtual or the physical world and computed by Class StimuliGenerator. Here is an example of how this calculation is performed.
The following table represents an example of the reaction models of an animal according to its psychological factors:
TABLE 2
Example of Reaction Models for an Actor
Psychological
ID
factor
Stimuli
Type
Deriv.
Condition
Equation
1
Hunger
Fish passing
Visual
0
d < 10
−S/(d − 10)
2
Hunger
Fish passing
Visual
1
v < 20
S/(v − 20) 2
3
Hunger
Fish passing
Visual
2
a < 2
(0.5*S)/(a − 2) 2
4
Sleepiness
Fish passing
Visual
0
d < 50
−S/(d − 50)
5
Sleepiness
Fish passing
Visual
1
d < 50
−S/(d − 50)
6
Sleepiness
Fish passing
Visual
2
0
0
7
Nervousness
Noise
Sonic
0
none
0
8
Nervousness
Noise
Sonic
1
none
S/d
9
Nervousness
Noise
Sonic
2
none
S 2 /d
Where:
S=The magnitude of the stimulus (between 0 (none) and 1 (maximal value))
d=distance between the actor and the stimulus
v=speed projected on the direction vector of the actor (positive towards the actor)
a=acceleration projected on the direction vector of the actor (positive towards the actor)
The following algorithm explains the logic followed for the calculation of the actor's direction vector:
Initialize the actor's overall reaction to 0
For every stimuli present in the dome
If (the stimuli is visual and is located in the actor's field of view) or (the stimuli is a sonic one)
For every psychological factor associated by the actor Add the actor's reaction towards this stimuli to the overall reaction
Let us assume that the current stimuli present are:
A fish of interest magnitude of 0.4 passing at position ( 10 , 10 , 10 ), at a constant speed of ( 1 , 0 , 0 )
The ambient sound has a magnitude of 0.2 and its center of gravity is located at ( 0 , 0 , 0 )
The first derivative of this sound has a magnitude of 0.1
A sudden sound is triggered at position ( 1 , 1 , 1 ) with a magnitude of 0.7
The actor is located at position ( 5 , 5 , 5 ) looking in the direction ( 0 , 10 , 10 ) and has the psychological values:
Hunger: 0.2
Sleepiness: 0.5
Nervousness: 0.3
Reaction ID 1
Fish passing at a distance of 8,6 m (being less than 10 and the fish being in the field of vision of the actor, it will react):
Reaction=Hunger*Interest magnitude/(distance−10)=−0.2*0.41(−1.4)=0.057 in direction ( 10 , 10 , 10 )−( 5 , 5 , 5 )=(0.385, 0.385, 0.385)
Reaction ID 2
The magnitude of the speed ( 1 ) of the fish being less than 20, the actor will not react.
Reaction ID 3
The magnitude of the acceleration ( 0 ) of the fish being less than 2, the actor will not react.
Reaction ID 4
The distance being less than 50 m and the fish being in the field of vision of the actor, it will react
Reaction=−Sleepiness*Interest magnitude/(distance−50)=−0.5*0.4/(−41.4)=8.28 in direction ( 10 , 10 , 10 )−( 5 , 5 , 5 )=(2.02, 2.02, 2.02)
Reaction ID 5
The distance being less than 50 m and the fish being in the field of vision of the actor, it will react
Reaction=−Sleepiness*Interest magnitude/(distance−50)=−0.5*0.4/(−41.4)=8.28 in direction ( 10 , 10 , 10 )−( 5 , 5 , 5 )=(2.02, 2.02, 2.02)
Reaction ID 6
0, by definition
Reaction ID 7
By definition, the actor is not reacting to the background noise.
Reaction ID 8
The magnitude of the first derivative of the sound is 0.1. The distance between the actor and the center of gravity of the sound is sqrt(5 3 )=11.2
Thus:
Reaction=Nervousness*Magnitude of stimulus/distance=0.3*0.1/11.2=0.003 in direction ( 0 , 0 , 0 )−( 5 , 5 , 5 )=(−0.145, −0.145, −0.145)
Reaction ID 9
The magnitude of the second derivative (sudden sound) of the sonic stimulus is 0.7. The distance between the actor and the center of gravity of the sound is sqrt(4 3 )=8
Thus:
Reaction=Nervousness*(Magnitude of stimulus ) 2 /distance=−0.3*(0.7 2 )/8=−0,018 in direction ( 1 , 1 , 1 )−( 5 , 5 , 5 )=(−0.26, −0.26, −0.26)
Therefore, the attraction vector assigned to the actor will be the summation of all the reactions computed:
x
y
z
0.385
0.385
0.385
2.02
2.02
2.02
2.02
2.02
2.02
−0.145
−0.145
−0.145
−0.26
−0.26
−0.26
In this example, the overall reaction would be (4.02x+4.02y+4.02z) or 6.76 in direction ( 1 , 1 , 1 ).
While the invention has been described with particular reference to the illustrated embodiment in example 1, it will be understood that numerous modifications thereto will appear to those skilled in the art. Accordingly, the above description and accompanying drawings should be taken as illustrative of the invention and not in a limiting sense.
The preferred embodiment has been shown to pertain to belugas in a virtual sea bottom. However, other types of environments and actors can be used without changing major aspects of the invention. While the invention has been described in connection with specific embodiments thereof, it will be understood that it is capable of further modifications and this application is intended to cover any variations, uses, or adaptations of the invention following, in general, the principles of the invention and including such departures from the present disclosure as come within known or customary practice within the art to which the invention pertains and as may be applied to the essential features hereinbefore set forth, and as follows in the scope of the appended claims. | The described methods are directed to influencing movement of virtual actors in an interactive theater. This interactive theater can be in the shape of a dome. A method for generating a behavior vector for a virtual actor in an interactive theatre by interpreting stimuli from visitors is provided. The method comprises: providing a plurality of sensors detecting and sensing at least one physical characteristic at a plurality of positions within a theater area within which a number of visitors are free to move about, the sensors generating sensor signals; interpreting the sensor signals to provide at least one physical characteristic signal including position information, wherein the physical characteristic signal provides information on visitor activity and location within the theater area; providing a behavior model for at least one virtual actor; analyzing the at least one physical characteristic signal and the behavior model for the at least one virtual actor to generate a behavior vector of the at least one virtual actor using the position information and the at least one physical characteristic signal, whereby a virtual actor reacts and interacts with visitors. The methods also comprise using a generated virtual environment stimulus and generating new actors. | 6 |
BACKGROUND OF THE INVENTION
I. Field of the Invention
The present invention relates generally to motorized concrete finishing trowels. More particularly, the present invention relates to motor powered riding trowels of the type classified in United States Patent Class 404, Subclass 112.
II. Description of the Prior Art
It has long been recognized by those skilled in the art that freshly placed concrete must be appropriately finished. Motorized riding trowels can fine finish plastic concrete on very large floor jobs soon after pouring. Motorized riding trowels have proven themselves in the industry. Their effectiveness for quickly and efficiently finishing large surfaces of wet concrete with either revolving blades or pans is undeniable, and such trowels are rapidly becoming the industry standard.
A typical power riding trowel comprises two or more bladed rotors that project downwardly and frictionally contact the concrete surface for finishing. These rotors are driven by one or more self contained motors mounted on the frame. The motors are linked to rotor gearboxes to revolve the rotors. The riding trowel operator sits on top of the frame and controls trowel movement with a steering system that tilts the axis of rotation of the rotors. The weight of the trowel and the operator is transmitted frictionally to the concrete by the revolving blades. The unbalanced frictional forces caused by rotor tilting enable the trowel to be steered.
As freshly poured concrete "sets," it soon becomes hard enough to support the weight of the specialized finishing trowel. While concrete is still "green" (i.e., within one to several hours after pouring depending upon the concrete mixture involved), power trowel pan finishing is required. Soon after panning, trowelling with power blades may begin as the slab adequately hardens. Numerous concrete finishing machines are known in the art for these purposes. Proper and timely finishing insures that desired surface characteristics including smoothness and flatness are achieved.
Power riding trowels should be passed over the surface being treated several times as the concrete sets. It is recommended that finishing pans be used first, when the concrete is relatively green, to achieve "super-flat" and "super-smooth" floors. The advent of more stringent concrete surface finish specifications using "F" numbers to specify flatness (ff) and levelness (fl), dictates the use of pans on a widespread basis. Pan finishing is normally followed by high speed blade finishing, after the pans are removed from the rotor blades. The trowel blades are adjusted to a relatively high pitch angle, and they directly frictionally contact the concrete surface. Rotors operate at high speed, in excess of one hundred-fifty RPM or more, resulting in a smooth, slick surface. High power riding trowels that quickly and efficiently finish large surfaces of wet concrete with either revolving blades or pans are rapidly becoming the industry standard.
Holz, in U.S. Pat. No. 4,046,484 shows a twin rotor riding trowel. U.S. Pat. No. 3,936,212, also issued to Holz, shows a three rotor riding trowel powered by a single motor. Although the designs depicted in the latter two Holz patents were pioneers in the riding trowel arts, the devices were difficult to steer and control.
Prior U.S. Pat. No. 5,108,220 owned by Allen Engineering Corporation, the same assignee as in this case, relates to an improved, fast steering system for riding trowels. Its steering system enhances riding trowel maneuverability and control. The latter fast steering riding trowel is also the subject of U.S. Des. Pat. No. 323,510 owned by Allen Engineering Corporation.
Allen Engineering Corporation Pat. No. 5,613,801 issued Mar. 25, 1997 discloses a power riding trowel equipped with twin motors. The latter design employs a separate motor to power each rotor. Steering is accomplished with structure similar to that depicted in U.S. Pat. No. 5,108,220 previously discussed.
Allen U.S. Pat. No. 5,480,257 depicts a twin engine powered riding trowel whose guard structure is equipped with an obstruction clearance system. When troweling areas characterized by projecting hazards such as pipes or ducts, or when it is necessary to trowel hard-to-reach areas adjacent walls or the like, the guard clearance structure may be retracted to apply the blades closer to the target region.
Allen U.S. Pat. No. 5,685,667 depicts a twin engine riding trowel using "contra rotation." For enhanced stability and steering, the rotors rotate in a direction opposite from that normally expected in the art.
Although large, high power trowels are respected for their speed, horsepower, and efficiency, there are other considerations that deserve attention. For example, modem high power trowels require periodic maintenance and inspection. Easy access to critical parts is desirable. Downtime can be minimized by proper design that eases mechanical service requirements. Those parts that are most likely to require service from time to time should be easily accessed. At the same time, ease of access should not denigrate safety consideration. Very hot parts, for example, should be shrouded properly to prevent bums. (And adequate airflow must be established for proper cooling.) Besides service efficiency, operator comfort must be a paramount design goal.
With extremely large pours, troweling (i.e., panning) may begin soon after placement, continuing to late in the evening. Very large jobs may require two or more riding trowels, as critical finishing should ideally be completed before the concrete reaches a predetermined hardness. Thus the work hours may be long, and operator comfort must be insured. While operating a typical riding trowel the operator is obviously exposed to vibration, noises, and heat. The operator needs a comfortable, adjustable seat. Ideally, the seat is readily accessible to the controls. Further, the seat, and the platform mounting the seat, should be designed to dissipate the considerable heat generated by the high power trowel engines. In multiple engine designs airflow and cooling considerations are even more important. An ideal arrangement is obtained by combining the operator seat supporting structure with a ventilation pathway capable of readily dissipating engine exhaust heat. While the support structure preserves operator comfort and promotes safety, it may be relatively quickly released and deflected out-of-the way to expose critical trowel parts for service.
SUMMARY OF THE INVENTION
My new seating and shrouding system is ideal for multi-engine riding trowels, "stretch" trowels and other non-overlapping trowels. The preferred trowel comprises a pair of spaced apart engines secured near the frame ends. These engines drive conventional bladed rotors. Each motor is releasably covered by a protective hood that may be quickly deflected away to expose the motor for service.
A protective shroud is mounted in the middle of the frame between the hoods. When desired, portions of the shroud are simply unlatched and quickly displaced to expose various machine parts without machine disassembly. The preferred shroud thus functions cooperatively with the hoods. In the best mode of the invention known to me at this time, each hood end is hinged to the frame and the opposite end is selectively latched. In an alternative embodiment both hoods ends are releasably latched to the frame.
A basic object is to provide a comfortable, ergonomic seating and shroud system for use with multiple engine riding trowels.
Another important object is to provide a shroud system of the character described that is ideal for use with widened or "stretch" type power riding trowels.
A further object is to maximize operator comfort.
It is a fundamental object to keep the operator's hands away from critical moving parts.
A related object is to normally block operator access to any hot parts that may produce burns.
Another object is to provide an ergonomically optimized seating support in a power riding trowel.
Another object is to provide a quick access hood or shroud system for power riding trowels that may be easily displaced to an out-of-the way position for trowel service.
Another basic object is to maximize ease of service.
A further object is to combine a seating support of the character described with a properly ventilated shroud so that the considerable heat developed during power troweling can be comfortably dissipated.
A related object is to develop an air path that efficiently directs exhaust heat away from the operator seat.
An object of the present invention is to provide a serviceable riding trowel that is capable of quick adjustment.
A related object is to provide a comfortable trowel for panning or blading operations.
An object of the present invention is to provide a riding trowel that increases production and operator efficiency.
Another basic object is to provide a high speed, multiple rotor trowel that efficiently dissipates heat with maximum operator comfort.
It is also an object to provide a high power riding trowel that comfortably finishes concrete for long hours.
These and other objects and advantages of the present invention, along with features of novelty appurtenant thereto, will appear or become apparent in the course of the following descriptive sections.
BRIEF DESCRIPTION OF THE DRAWINGS
In the following drawings, which form a part of the specification and which are to be construed in conjunction therewith, and in which like reference numerals have been employed throughout wherever possible to indicate like parts in the various views:
FIG. 1 is a fragmentary, front isometric view of the best mode of a riding trowel equipped with my shroud system, with portions omitted for clarity;
FIG. 2 is a fragmentary, front isometric view showing the hoods displaced away from the motor compartments, with portions shown in section or omitted for clarity;
FIG. 3 is an enlarged fragmentary, partially exploded isometric view of the preferred shroud assembly, with portions thereof broken away or shown in section for clarity;
FIG. 3A is an enlarged, fragmentary isometric view of circled region 3A in FIG. 3;
FIG. 4 is a fragmentary, front elevational view of the preferred trowel, showing the end hoods displaced away, with portions omitted for clarity;
FIG. 5 is an enlarged, fragmentary transverse sectional view taken generally along line 5--5 of FIG. 1 with portions omitted for clarity;
FIG. 6 is a right side elevational view;
FIG. 7 is a fragmentary top plan view with portions omitted for clarity;
FIG. 8 is a fragmentary, front isometric view of an alternative riding trowel, with portions omitted for clarity;
FIG. 9 is a fragmentary, partially exploded front isometric view showing the end hoods displaced away, with portions shown in section or omitted for clarity; and,
FIG. 10 is a fragmentary, front elevational view of the alternative trowel and shroud system, showing the end hoods displaced away, with portions omitted for clarity.
DETAILED DESCRIPTION
The preferred powered riding trowel 9A is seen in FIGS. 1-7, and an alternative trowel 9B is depicted in FIGS. 8-10. Common structural details relating to riding trowel motors, rotors, steering, rotor tilting, steering linkages, rotor configuration, blade construction and the like are set forth in prior U.S. Pat. Nos. 5,108, 220, 5,613,801, 5,480,257, and 5,685,667, all owned by Allen Engineering Corporation. For disclosure purposes, the aforementioned Allen patents, and the previously described Holz patents, U.S. Pat. Nos. 4,046,484 and 3,936,212, are hereby incorporated by reference.
As explained in detail in one or more of the last mentioned patent references, each riding trowel comprises one or more engines for powering downwardly projecting, bladed rotors that frictionally contact the concrete. The steering system may include a plurality of both manual and hydraulic linkages and actuators. By tilting the rotors appropriately, directional steering forces are developed. In the embodiments described herein a protective cage 14 (i.e., FIGS. 3, 4) mounted to the frame guards the revolving rotor blades. The operator's seat 16 is mounted above the frame 10 upon a supportive shroud 20 to be described in detail hereinafter. A control panel 13 that houses one or more electrical indicators or controls is freely accessible from the seat. The steering actuators may comprise manually operated levers, as described in the above patents, that are accessible at the front of the trowel.
I. Best Mode
With initial attention now directed to the drawing FIGS. 1-7, trowel 9A comprises a frame 10 that supports lower cage 14 (FIGS. 4-6). Frame 10 comprises an upper subframe 10A that is generally in the form of a parallelepiped. A large, engine-surrounding volume 15 is enclosed by subframe 10A, shroud 20 and deflectable hoods 21, 22. Typical internal combustion engines 12, illustrated in FIG. 4, are shrouded by hoods 21, 22 within volume 15. Importantly, the engine mufflers are located externally of region 15. Shroud 20 encloses an optional water spray system and the trowel battery etc., not shown. It will be understood that engines 12 power the rotors (not shown) that directly contact the lower concrete surface to be finished. These engines require periodic servicing. Further, adequate high volume air flow is necessary for proper cooling.
Shroud 20 is disposed at the middle of the trowel between hoods 21 and 22. As best seen in FIGS. 2 and 5, shroud 20 preferably comprises a separate front plate 30, a spaced apart rear plate 32, and a planar, top plate 33 upon which seat 16 is mounted. Top 33 and front plate 30 are preferably formed from rigid, ten gauge metal. Rear plate 32 (FIG. 2) may be formed from rigid steel plate, but in the best mode steel mesh material of approximately ten or twelve gauge is preferred.
Shroud front plate 30 is generally rectangular. It comprises a plurality of louvers 34 for ventilation in combination with the shroud rear 32 and the hoods 21 and 22 to be described hereinafter. Plate 30 is releasably coupled to the trowel frame by a spring biased latch 36 (FIG. 2). Latch 36 extends from a latch mounting rail 35 secured to trowel frame 10. By lifting upwardly on the latch, prong portion 37 may be withdrawn from plate orifice 38 to free plate 30 for removal. As best seen in FIG. 3A, plate 30 has upper, rearwardly projecting tabs 40 adapted to be inserted into brackets 43. Alignment apertures 41 in tabs 40 register with bracket pins 42 when the plates are assembled.
Like front plate 30, shroud back plate 32 is generally rectangular. Is uppermost portion includes projecting, apertured mounting tabs 40A like tabs 40 previously described. These tabs secure the plate in place by mating with pills similar to pins 42. A central orifice 39A defined in plate 32 provides clearance for a water storage tank (not shown) which is part of the standard trowel spray system housed beneath shroud 20. Notches 39B defined in the bottom of late 32 provide clearance for exhaust pipes that run from the engines beneath the hoods 21, 22 to external mufflers 53. In some cases plate 32 may mount an electric fan 31 mounted to ring 31B (FIG. 3) for enhanced forced air ventilation. Alternatively, one or more suitable electric ventilation fans may be mounted to shroud front plate 30.
Plate 30 is preferably formed from rigid material equipped with suitable apertures or louvers for establishing airflow through the enclosed volume 15. Perforated steel plate or plate with adequate louvers may be used, but steel mesh material of approximately ten or twelve gauge is preferred. The preferred mesh construction establishes a positive airflow beneath shroud 20 within internal volume 15 to dissipate heat. Plate 32 is releasably coupled to the trowel by a spring biased latch 44 (FIG. 6) that is similar to latch 36 previously described. By lifting upwardly on the latch, prong portion 46 may be withdrawn from a suitable latching 3 orifice to free the plate for withdrawal.
The upper shroud plate 33 is preferably fixed to the subframe 10A (i.e., it is not field removable.) Arcuate terminal edges of plate 33 surmount the adjacent, transverse tube frame portions of subframe 10A (FIG. 2). Beneath plate 33 is an insulation layer 47 (FIG. 5) for thermally isolating the seat 16.
The hoods 21, 22 are disposed on opposite sides of the shroud 20. As these hoods are substantially similar, only one will be described in detail. Hood 22, for example, comprises a generally cubicle, metallic enclosure preferably formed from ten gauge steel. A front face 50 angularly is integral with a top portion 51 and a parallel, rear portion 52 (FIGS. 1, 2). A transverse shoulder portion 54 extends between plates 50 and 51, terminating adjacent a preferably mesh hood end 56. End 56 may comprise ten gauge steel mesh material. An upper ventilation slot 55 is preferably defined between top hood plate 51 and the upper edge of shoulder 54.
In trowel 9A the hoods are preferably hinged to the frame 10A. Suitable dogs 60 projecting from the hood front and back are hinged to the subframe at 61 (FIG. 1). A plurality of spaced apart ventilation louvers are preferably formed in front 50, rear 52, and shoulder 54. Latches 65 and 66 respectively secure the hood front 50 and rear 52. After the hood latches 65, 66 are manually released, the handle 57 may be manually grasped to deflect the hoods to the position illustrated in FIG. 2. Air cylinders 70 extend between the subframe 10A and a pivot point 71 near the bottom, inside of the front and back of the hood. The air cylinder elongates as the hood is folded outwardly, tending to brace and thus stabilize hood movement. With the hoods deflected outwardly (i.e., as viewed in FIG. 2) the motors (and other parts) are exposed for servicing. Additional access to critical parts is achieved by removing the shroud front and back previously described.
II. Alternative Embodiment
The alternative power riding trowel 9B of FIGS. 8-10 is similar to trowel 9A previously described. For ease of reading, the reference numerals used with this embodiment are the same as before for similar parts, except that the suffix "X" has been added to the previous reference numerals to indicate similar parts.
With attention now directed to FIGS. 8-10, trowel 9B comprises a frame 10X that supports an upper subframe 10AX similar to that previously described. The engine-surrounding volume 15X is enclosed by subframe 10AX, shroud 20X and deflectable hoods 21X, 22X. Shroud 20X at the middle of the trowel 9B is substantially the same as shroud 20 discussed in detail previously. The design of hoods 21X and 22X constitutes the primary difference between trowels 9A and 9B.
As before, hoods 21X, 22X are disposed on opposite sides of the shroud. Each hood 21X, 22X comprises a generally cubicle, metallic enclosure preferably formed from ten gauge steel. A front face 50X is integral with a top 51X and a parallel, rear portion 52X (FIG. 9). Transverse shoulder portion 54X terminates adjacent mesh hood end 56X. End 56X, which may comprise ten gauge steel mesh material, is preferably permanently attached to subframe 10X. An upper ventilation slot 55X is preferably defined between hood top 51X and the upper edge of hood shoulder 54X.
Hoods 21X, 22X are not hinged to the frame 10A. Instead latches 65X and 66X respectively secure the hood front 50X and rear 52X. After the hood latches 65X, 66X are manually released, the handle 57X may by grasped to lift the hoods away to the position illustrated in FIG. 9. At this time access to the engines is maximized.
From the foregoing, it will be seen that this invention is one well adapted to obtain all the ends and objects herein set forth, together with other advantages which are inherent to the structure.
It will be understood that certain features and subcombinations are of utility and may be employed without reference to other features and subcombinations. This is contemplated by and is within the scope of the claims.
As many possible embodiments may be made of the invention without departing from the scope thereof, it is to be understood that all matter herein set forth or shown in the accompanying drawings is to be interpreted as illustrative and not in a limiting sense. | A powered riding trowel comprises a pair of releasable, protective, quick access hoods that may be unlatched to quickly expose the power means for service without structural disassembly. In a preferred embodiment, the twin hoods are hinged to the frame. The trowel seat is mounted on an upper planar surface of a releasable shroud disposed between the hoods. The shroud front and rear are preferably removably latched to the frame. Major portions of the shroud and the hoods are formed from rigid, supportive material having airflow pathways for cooling and ventilating the normally protected trowel interior. In an alternative embodiment both hoods are releasably coupled to the frame by spring biased latches. | 4 |
This application is a Continuation of application Ser. No. 09/814,399 filed on Mar. 22, 2001 now U.S. Pat. No. 7,085,753, and which application is incorporated herein by reference.
FIELD OF THE INVENTION
The present invention relates to the field of search engines and Directories of Web sites. More particularly, the invention relates to a method and system for mapping and searching the Internet, and displaying the results a visual form.
BACKGROUND OF THE INVENTION
A “Search engine” is a system that searches for information that sustains some Search criteria. Regarding the Internet, a Search engine is a Web application that searches Web sites that sustain some Search criteria.
A search engine on the Internet usually comprises three parts:
A Spider-program (also called a “crawler” or a “bot”), which is a program that “visits” Web sites and reads their pages and other information in order to create entries for a search-index; An Index-program, a program that compiles a massive search-index from the pages read; and A Seeker-program, a program that receives search requests, compares each request to the entries in the search-index, and returns the results to the user.
A search-index is a database that contains information about a set of Web sites. Using the search-index, a sub-group of Web-site(s) can be obtained according to search-criteria.
There are various search Web-sites that maintain databases about the contents of other Web sites. Yahoo was the first search Web site to gain worldwide attention, and it differs from most other search sites in that its content is indexed by people who create a hierarchical directory by subjects. As a result, Yahoo and similar search Web sites are technically called “directories” rather than “search engines”. Most directories offer a search engine mechanism to query the database.
Most other search Web applications are highly automated, sending “Spider” programs out on the Web around the clock to collect the text of Web pages. Spiders follow all the links on a page and put all the text into a database. Sometimes a Web site offers both—a search engine and directory capabilities.
Major search engines such as AltaVista and Google index the content of the Web, while directories such as Yahoo and Looksmart try to categorize it manually. However, due to the huge size of the Web and other objective reasons (such as connectivity of sites), Google indexed only 30% of the Web, while Yahoo indexed only 2% (according to the assessments of the Web size)
There are dozens of search engines, each with its own anchor Web site. Some search Web applications, such as Yahoo, search not only using their search engine but also provide the results from simultaneous searches of other search indices.
Usually, the above-mentioned search engines do not provide focused answers, since the same keywords may be found in Web sites of different categories and subjects, while the user is not provided with means for distinguishing between the results. Search results can span for pages, and consequently overwhelm the user.
Yahoo displays not only Web sites that contain the specified keywords, but also a list of categories that contain the searched keyword(s), as may be seen in FIG. 1 . In the illustrated case, the word “chess” was searched. Hence, after obtaining the initial results, the user can focus his search by selecting the category best suited to the subject matter he is looking for. In that case, the search results are limited to the selected category as pre-grouped by the people of Yahoo. Such a search may be called a “context search”. However, the user is not provided with means for distinguishing the Web sites by importance or any other property. Moreover, since Yahoo does not scan the Internet by automated methods, each category contains a minor amount of Web sites.
Due to the fact that the categories of Yahoo were defined by a human factor and not by a machine, there are some ambiguities. For example, in FIG. 1 , the hierarchy of the categories “Computers and Internet>Hardware>Systems>Macintosh>Software>Games” is odd since regarding to computers, the category “Software” is not a sub-category of “hardware”.
One of the options of the Google search engine, introduces a different approach. The search starts from a selection of one or more predefined categories and the search refinement is carried out by the topical keywords. For example, a user wishes to search for a free computer chess game. The user starts the search from a Web page (within the Google Web site) called “Web directory”, where he selects the category “Games”. Google displays a list of sub-categories, and the user selects the “Computer games” sub-category. The next category is “Windows”, and in this category Google displays the following answers: 3D Graphics (18 Web sites), Cheats and Hints (46 Web sites), Downloads (21 Web sites), Fan Fiction (11 Web sites), and Shareware (146 Web sites). When selecting the final directory, the user submits the keyword “chess” to limit the results to only chess games.
In matter of fact, Google uses the directory of Open Directory Project (ODP), rather then its own directory. ODP is an organization of more than 30,000 volunteers that index the Internet.
Google results are ranked quite differently from those of other search engines. Ranking in Google is carried out according to the site's importance as determined by the number of links pointing to a Web site. After obtaining a list of Web sites that meet a text-oriented search criterion, Google ranks the obtained list according to the number of links pointing to each Web site, and the results are presented according to this order.
The main drawbacks in the existing search engines are the following:
The number of the results corresponding to a search criterion is often high, and consequently overwhelms the user. They do not provide easy means for distinguishing and noticing the results by their related content or subject. The presentation of results is text-oriented, while presenting such an enormous amount of information overwhelms the user. Although Google orders the search results by their importance (the number of links pointing to a Web site) this is not a precise criterion for the site's relevancy to the search goal, because the preliminary Web sites being ranked by Google was pulled out by text-oriented search criteria. The human-compiled tree of categories is subjective and not objective. Low cover rate at human-compiled directories (such as Yahoo and Looksmart).
All the methods described above have not yet provided satisfactory solutions to the problem of the searching of Internet Web sites.
It is therefore an object of the present invention to provide a method and system for carrying out a search of Web sites, which overcomes the drawbacks of the prior art.
It is another object of the present invention to provide a method and system for carrying out a search of Web sites, which provides presentation of the Web sites, such that the visualization reveals certain attributes of the presented Web sites.
It is a further object of the present invention to provide a method and system for carrying out a search of Web sites, which classifies the Web sites according to their attributes.
Other objects and advantages of the invention will become apparent as the description proceeds.
SUMMARY OF THE INVENTION
In one aspect, the present invention is directed to a method for carrying out a search of Web sites according to a search criteria, comprising: pre-indexing the sites of the Web, including grouping the Web sites according to predefined group-criteria; pre-classifying each Web site according to a predefined set of properties; pre-visual-formulating each Web site according to its identified properties; and upon searching of Web sites that sustain a search criterion, displaying the formed site results divided into the pre-indexed groups wherein each site within a group is displayed according to its visual-formulation.
Preferably, the grouping is carried out by a clustering process and the group-criteria is of a function among others the number of hyperlink(s) pointing from and to each the Web sites.
Preferably, the set of properties comprises parameters relating to the site's importance, the nature of the site's owner, the existence of an e-store within the site, the existence of a “chat room” within the site, the existence of a forum within the site, the existence of multimedia file(s) and/or their amount and/or size within the site, the frequent used keywords in the textual data of the site, whether the site in “official”, the essence of the site, and/or the amount of information in the site.
Preferably, the importance of a Web site is a function of the hyperlinks pointing to and from a Web site.
Preferably, the amount of information in a Web site is determined according to the number of characters, and/or the number of words, and/or the number of bytes included within the Web site.
Preferably, the visual-formulation is a distinguishable visual presentation of the properties in a visual presentation.
Preferably, each Web site is presented as a building, the height of the building is proportional to the importance of the Web site represented by it.
Preferably, wherein each Web site is presented as a building wherein the width of the building is proportional to the amount of information within the Web site.
Preferably, a commercial Web site is presented as an office-type building.
Preferably, a personal Web site is presented as a house.
Preferably, each Web site is presented as a building wherein a Web site owned by an academy and/or college and/or school is presented as a campus-type building.
Preferably, wherein the presence of an e-store in a Web site is presented as a display-window at the building.
In another aspect, the invention is directed to a method for visually presenting a set of properties of a Web site, comprising: associating to each of the properties distinguishable graphical representation within a Web site; and displaying the graphical representation within a Web site representation.
Preferably, the graphical representation is presented in 2 D or 3D.
Preferably, the Web site representation is a building.
Preferably, a group of Web sites is presented as a street and each Web site in the group is presented as a building.
In another aspect, the invention is directed to a method for finding sub-groups having a common basis in a set of Web sites, comprising: clustering the set of Web sites by determining groups having a common basis by their being related by hyperlink(s) pointing to and from each of the Web sites; and labeling the determined groups by analyzing their content.
Preferably, the analyzing is carried out by detecting keywords frequently used in a determined group.
In another aspect, the invention is directed to a system for searching of Web sites in the Internet, comprising: a Spider application, for scanning the Web sites of the Internet; a Database application, for storing the information collected by the Spider application; an Indexing application, for grouping, and/or for labeling and/or for classifying the found Web sites; and a Seeker application, for searching of Web sites that sustain a search criteria by querying the Database according to the search criteria.
Preferably, the system comprises a visual formulating application, for visually formulating each of the Web sites according to the classification and displaying the same to a user.
BRIEF DESCRIPTION OF THE DRAWINGS
In the drawings:
FIG. 1 schematically illustrates a hierarchically ordered list of categories that contain the keyword “chess”, according to the prior art.
FIG. 2 schematically illustrates a theoretical example of a collection of Web sites that are related to the movie “The Matrix”, according to the prior art.
FIG. 3 schematically illustrates a theoretical example of hyperlinks in three related groups of Web sites: Football, Basketball and Baseball, according to the prior art.
FIG. 4 schematically illustrates a theoretical example of a wider view of Web sites. There are three major groups: Sport, Health and Business, according to the prior art.
FIG. 5 schematically illustrates a theoretical example of clusters organized in a tree structure, according to an embodiment of the invention.
FIG. 6 is a high-level flow chart of a process for carrying out a search for Web sites, according to a preferred embodiment of the invention.
FIG. 7 schematically illustrates an example of a presentation of the first stage of a search, according to a preferred embodiment of the invention.
FIG. 8 schematically illustrates an example of a presentation of a stage of a search, according to a preferred embodiment of the invention.
FIG. 9 schematically illustrates an example of a presentation of a further stage of a search, according to a preferred embodiment of the invention.
FIG. 10 schematically illustrates an example of a “street” presentation of a group of Web sites found in a Web search, according to an embodiment of the invention.
FIG. 11 schematically illustrates a system for searching of Web sites, according to a preferred embodiment of the invention.
FIG. 12 schematically illustrates a method and system searching of Web sites, according to a preferred embodiment of the invention.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
In order to facilitate the reading of the description to follow, a number of terms and initials are defined below:
A Search engine is a system that searches for information that sustains some Search criteria. Regarding the Internet, a Search engine is a Web application that searches for Web sites that sustain some Search criteria. A search criterion is a rule for which Web pages of the Internet are checked. The rule is a mathematical expression combined of logical Operator(s) and Operand(s). The Operand(s) are word(s) and/or their synonyms. For example, if W 1 , W 2 and W 3 are words, the Search criterion can, for example, be the existence of the rule (W 1 or (W 2 and W 3 )) in the content of a Web site. Another example for a search criterion: (W 1 and (W 2 or W 3 )). A Heuristic method is a means for solving a problem that does not guarantee a good solution all the time, but generally does provide such. A Heuristic method is a group of rules, suggestions, guides, or techniques that may be useful in making progress toward the solution of a problem. Classification means assigning items to one of a set of predefined classes of objects based on a set of observed features. For example, one might determine whether a particular mushroom is “poisonous” or “edible” according to its color, size, and gill size. Classifiers can be learned automatically from a set of examples through supervised learning. Classification rules are rules that discriminate between different partitions of a database based on various attributes within the database. The partitions of the database are themselves based on an attribute called the classification label (e.g., “faulty” and “good”). Indexing is the operation of compiling a massive search-index of the sites of the Internet. Clustering is an approach to place objects into meaningful groups based on their similarity. Clustering, unlike classification, does not require the groups to be predefined. Alternatively, the clustering applies an algorithm to determine obvious or hidden groupings of data items. The object of applying clustering algorithms is to discover useful but unknown classes of items. Clustering methods are implemented, for example, in artificial intelligence and data mining. Data structure is the physical layout of data. Data fields, memo fields, fixed length fields, variable length fields, records, word processing documents, spreadsheets, data files, database files and indices are all examples of data structures. A Linked list is a group of data items, each of which points to the next item. It allows for the organization of a sequential set of data in noncontiguous storage locations. A tree structure is an algorithm for placing and locating data entities in a database. The algorithm finds data by repeatedly making choices at decision points called nodes. A node can have as few as two branches (also called “children”), or as many as several dozen. In a tree, records are stored in locations called leaves. This name derives from the fact that records always exist at end points; there is nothing beyond them. The starting point is called the root. The maximum number of children per node is called the order of the tree. The Internet, or WWW (World Wide Web), is a worldwide system of computer networks—a “network of networks” in which users at any one computer can, if they have permission, receive information from any other computer.
FIG. 2 schematically illustrates a theoretical example of a collection of Web sites that are related to the movie “The Matrix”. The Web sites are:
whatisthematrix.com, the official Web site of the movie (e.g., which is owned by the producer of the movie); upcomingmovie.com the Web site which contains information regarding the upcoming sequent movie; amazon.com the site where the book on which the movie is based on can be bought; jet-li.com the Web site of the director of the movie; carrieannmoss.com the Web site of the major actress; some corresponding amateur Web sites, and so forth.
As is well known, there are connections, generally called “links” or “hyperlinks”, which refer Internet users from one Web site to other Web site(s). Actually, links point from one Web page to another Web page, or even to the same Web page, however since Web sites comprise Web pages, we can assume that a link points from one Web site to another Web site, or even to the same Web site. For example, link L 1 refers users from the Web site Si, where L 1 resides on, to Web sites S 2 and S 3 . L 2 refer users to Web sites S 1 , S 3 and S 4 , etc. Generally, links are made to “connect” between Web sites. Furthermore, the more links point to a Web site, the higher its popularity. In other words, a Web site to which more links refer, maybe considered as more “important” than a Web site to which fewer links refer. In that sense, the Web site whatis.thematrix.com to which 3 links refer, is more “important” or “popular” than the Web site jet-li.com. Furthermore, all the Web sites of FIG. 2 form a virtual group “connected” by a somewhat common subject.
FIG. 3 schematically illustrates a theoretical example of the hyperlinks in three related groups of Web sites: Football, Basketball and Baseball. The number of hyperlinks pointing between the members of the group are:
The Football group: 5 hyperlinks point between the members of the group, and 3 hyperlinks to/from the other groups. The Basketball group: 11 hyperlinks point between the members of the group, and 3 hyperlinks to/from the other groups. The Baseball group: 5 hyperlinks point between the members of the group, and 2 hyperlinks to/from the other groups.
FIG. 4 schematically illustrates a theoretical example of a wider view of Web sites. The figure shows three major groups: Sport, Health and Business. The Sport group comprises three sub-groups: Football, Basketball and Baseball. Again, the presence of a group can be determined by counting the hyperlinks between a group and the hyperlinks pointing from/to a group and the outside world. It can be seen that most links in Web sites having a common subject remain in the group, and less point out of the group.
In this example, only three hyperlinks are pointing from/to the Sport group to the other groups, while the number of links pointing between the members of the group is much higher. The same is true at the Health and Business groups.
Indexing
Prior to carrying out a search, a great deal of the Internet Web sites should be indexed, by means of an indexing process. According to the present invention the indexing is carried out in two stages:
Clustering
The groups of the Web are determined according to the hyperlinks pointing to and out of the Internet sites. Since the grouping criteria is the hyperlinks (such as the number of hyperlinks, the density of hyperlinks, etc.), this is a totally objective process, in contrary to the prior art, where the groups are determined by a human factor or text-oriented, and hence the results were subjective. For a matter of fact, the clustering process is so indifferent to text, that even after the cluster formation, it is still unknown what is the topical common denominator of the new-formed group.
Determining the groups can be a lengthy process, since any possible combination of Web sites is to be checked. For example, if a set of 10 Web sites is checked, named as “A” to “J”, then any combination should be considered, such as A,B; A,C; A,D; A,B,C; A,B,D; A,B,E; A,B,C,D,E; A,B,C,D,F; and so forth in order to determine groups. The decision as to when a group is formed is subject to an automatic decision based on statistical and/or mathematical parameters such as variance and significance in the link's density, variance, direction, proportion, etc.
The problem of grouping objects (not necessarily web entities) is well known in the art, and many algorithms were developed in order to speed up the process. In the prior art, the grouping process is called “Clustering”.
Since the Internet comprises more than 100 millions of Web sites (billions of Web pages), automatic clustering of the Internet is long and heavy process, even when fast algorithms and fast computing machines are implemented. Therefore, according to the invention, the clustering is made prior to the carrying out of a search. The clustering is performed by a “clustering engine”, which also works in the background.
Labeling
Another aspect of the clustering problem is naming the determined groups, in order to determine what is their subject, since the link-oriented grouping is indifferent to text, and therefore can not relate a subject title to the new formed groups. The process of entitling a group is called herein “Labeling”. Such a process can be carried out by heuristic methods, with or without the assistance of a human factor.
Regarding the examples described in FIGS. 3 and 4 , frequent appearance of the word “football”, “basketball” and “baseball” in a cluster may lead to the conclusion that the cluster deals with a group of sport.
A step toward automatization of the Labeling process is carried out by determining the major words that appear in a cluster, and then relating the words to a subject.
Data Structure
FIG. 5 schematically illustrates an example of clusters organized in a tree structure, according to an embodiment of the invention. The “Sport” cluster (or “group”) contains several sub-clusters (or sub-groups)—Football, Basketball and Boxing sub-clusters, etc. The cluster “Charlie's Angels” appears as a sub-cluster of the TV Series cluster, as a sub-cluster of the movies cluster and as a sub-cluster of the boxing cluster (there is a boxing team that is called “Charlie's Angels”). The circles denote Web sites. A Web site can belong to several clusters.
The data structure created by the clustering process can also be seen as a map of the web, since every site in the web has a specific location in the tree.
Carrying Out a Search
The search process uses the search-index that was constructed in the indexing process. As much Web sites have been indexed, as much reliable the results of the search.
The process of searching starts from the major clusters of the search-index. For example, searching for Web sites regarding “Charlie's Angels” produces seventy Web sites in the Entertainment cluster and forty Web sites in the Sport cluster. If the subject is searched in relevance with entertainment, then the next search will be in the Entertainment cluster. Searching for Web sites regarding “Charlie's Angels” in the Entertainment cluster produces twenty Web sites in the TV Series cluster, forty Web sites in the Movies cluster, and ten Web sites in the rest of the clusters. The search is refined by selecting the movies cluster, and so forth.
FIG. 6 is a high-level flow chart of a process for carrying out a search for Web sites, according to a preferred embodiment of the invention. The process is divided to two parts: Indexing and Searching. The Indexing process totally distinct from the searching process. While the indexing is a process carried out in order to prepare, order, and cluster the Internet for the search, the searching is a process that is initiated by an Internet user, which accesses the search site, uses a search engine. The Indexing can be carried out before and during the Searching process. The output of the Indexing process is used for the Searching process.
Indexing:
Marked as 101 , is the process that is made by the searching facility that includes Clustering and Labeling. As a result, trees of Clusters are constructed. The Web sites of the Internet are scanned and the titles of the Web sites, the links and the addresses of the pages in which predefined keywords are found are stored in a database. Then, a Clustering algorithm is executed on the collected data in order to determine clusters. Then the detected Clusters are labeled by a Labeling process.
Searching:
The Searching, which is conducted by a user, starts at 102 .
At 103 , the user defines the search criteria.
At 104 , the database is scanned in order to find the clusters (as defined at 101 ) contain clusters that meet the criterion.
At 105 , the names of the clusters that contain instance(s) of the searched words are presented to the user. According to an embodiment of the invention, the tree of Clusters is such that each node contains, for example, about 8-10 branches.
At 106 , after the user assesses the results, if he wishes to refine the search, the process continues with 107 . Otherwise the process proceeds to its end at 109 .
At 107 , the user clicks on the pointing entity (usually a name or an icon presented on his display) associated with the desired cluster.
At 108 , the sub group of the selected cluster that contains instances of the searched words is displayed to the user, and then the process returns to 105 .
At 109 , the process ends. At this stage, a list of Web sites is displayed to the user, and he may select the Web site to browse by clicking its hyperlink. It is preferable that the list will contain no more than tens of links. The presentation of hundred of links would overwhelm and confuse the user.
It should be understood that the process of refining the search may also be carried out by using the pre-classifying of the Web sites.
It is to be clear that the Indexing is a preliminary stage, and it is not carried out each time a search is performed.
Visual Presentation of Web Site's Attributes
In the prior art, hyperlinks to Web sites that have been found in a search are presented as a list. Some search engines also provide a rating number. Other search engines provide the paragraph (of the Web page) that includes the searched words. As a matter of fact, this type of presentation is one-dimensional. In order to make the list of the found Web sites more understandable and easier to analyze, the presentation of the list of Web sites is preferably carried out as follows:
According to a preferred embodiment of the invention, the Web sites of the Internet are categorized by predefined attributes. Then, on the presentation, the attributes will have a visual expression.
The following example presents some attributes by which Web sites can be categorized:
Commercial/academic/private Comprises/does not comprise a virtual store; The amount of information Importance (which is determined by the number of links pointing to and from it). Etc.
Subjected Presentation
According to a preferred embodiment of the invention, the attributes of the Web sites found in a search are presented in a subjected visual presentation, possibly a 3D-dimensional. For example, according to one embodiment of the invention, all the Web sites are visualized in an urban form as follows:
The Web sites are presented as buildings in a street. The importance attribute is expressed in the height of the buildings. The width of a building may reveal the amount of content. A display-window in a building may represent the existence of an e-store. If the Web site is owned by an enterprise, then it may be represented by an office type building. If the Web site is owned by a private person, the building may appear as a house. If the Web site is of an educational institute, it may be presented as a campus. And so forth.
A user that carries out a search may focus on the relevant Web pages by several steps wherein the street presentation is the last one of them. The steps are equivalent to the levels in a tree of clusters. According to an embodiment of the invention, each level may be presented as a geographical entity: a continent represents the highest level (Entertainment and Sport in FIG. 7 ). The next levels can be countries, cities, streets and buildings).
According to this approach, the search begins in a conventional manner by specifying the keywords with or without the logical terms between them (And, Or, Not, etc.). As a result, the user receives an illustration of the “continents” where the searched words have been found.
FIG. 7 schematically illustrates an example of a presentation of the results of the first stage of a search, according to a preferred embodiment of the invention. The search was for the phrase “Charlie's Angels”. Optionally, the results are presented in a 2-D map on which the main clusters are displayed as continents: the Sport continent, the Entertainment continent, the Health continent, etc. The Clusters, in which the term “Charlie's Angels” appeared, are marked for the user. Of course alternatively this presentation can be a textual presentation or most preferably 3D presentation.
The size of the continent is preferably proportional to the number of Web sites included in that Cluster. Since the Entertainment cluster contains more Web sites than the Sport cluster, it is of greater size in this example.
After selecting the Entertainment “continent” (the selection being carried out by clicking the selected object), the user is presented with the “countries”—TV series, Movies, Plays, Music, etc. Again, The countries, in which the search subjects have been found, are being marked to the user (see FIG. 8 ). The size of the “country” is proportional to the number of the Web sites of this entity.
The relevance of an entity to the search criterion can be visually marked also. For example, as greater the relevance, as highlighted the entity.
After selecting the “country”, the user is presented with the “cities” in the selected “country”, as illustrated in FIG. 9 .
The last level of the focusing process is the presentation of a street, as described above. FIG. 10 schematically illustrates an example of a “street” presentation of a group of Web sites found in a Web search, according to an embodiment of the invention. The buildings, each represents a Web site, are numbered from 11 to 16 . Building 14 represents a Web site, which is owned by an enterprise, hence, its presentation is like an office building. Building 13 represents an amateur Web site and hence, it is presented like a private house. Building 16 represents a Web site that is owned by an academic institute, and therefore is presented like a campus. Building 11 represents a Web site that sells products, for example, it has an e-store, and thus it comprises a display-window. As mentioned above, the height of each building is relative to the number of hyperlinks pointing to and from the Web site represented by it. The width of the Web site represents, for example, the amount of information in the Web site. This parameter can be determined by the amount of words, pages, bytes, and so forth.
It should be noted that the parameters of each Web site, as well as the continents, which are formed according to clusters, are attained and prepared for display by the search engine facility prior to the search by the user, by a process independent of the user search, which is carried out in real time. The application described above is geographically oriented. However, other reference “worlds” may be implemented in order to emphasize the attributes of a Web site.
FIG. 11 schematically illustrates a system for searching of Web sites, according to a preferred embodiment of the invention.
Web sites 30 are a part of the Internet 21 . The Web sites list can be obtained by a Spider program.
The system 27 for providing the capability of searching of Web pages by users 25 is essentially a server with connection to the Internet. It concentrates the activities of indexing and searching. It comprises:
a Spider program 22 , for scanning the Web sites of the Internet; a Database 24 , for storing the information collected by the Spider program 22 ; an Indexing application 23 , for carrying out the clustering, labeling and classification of the Web sites. The indexing is a process, which is carried out independent of the search process, and its purpose is to organize all the Web sites of the Web prior to the search. For example, the indexing concerns organizing all the Web sites in clusters, classifying the Web sites according to predetermined properties, etc.; and a Seeker application program/server 28 for interacting with the users 25 , carrying out the search (by the appropriate queries to database 24 ) and for sending the results to the users 25 (usually as Web pages, which usually perform a visual presentation of user's Web browser).
FIG. 12 schematically illustrates a method and system searching of Web sites, according to a preferred embodiment of the invention. Two processes are carried out separately as follows:
Indexing of the Internet. Searching for Web sites that sustain provided criterion(s).
Indexing: According to an embodiment of the present invention, the Indexing 23 comprises the activities of Clustering, Labeling and Classification of the Web sites according to the predefined attributes, as described above. A Spider program 22 scans the Web sites of the Internet. The found Web sites are added to a database 24 . By implementing Clustering method(s) a tree of Clusters is obtained. The gathered information (tree of Clusters, and the list of Web sites and their classification) is stored in database 24 .
Searching: The search starts by a user determining the search criterion. Usually the determination is carried out by providing a list of words and the relation between them. The user generally provides the search criterion by interacting via a Web page.
Then a query is posted from the system to database 24 , and the results of the query are presented to the user. This stage is carried out by a Seeker program 32 . The results of the search may be presented in a textual form or, but preferably in a graphical form described above (marked as 33 ). If the user is not satisfied with the search results, then the system may interview the user in order to focus the search, and the system posts a new query to the database 24 .
The above examples and description have of course been provided only for the purpose of illustration, and are not intended to limit the invention in any way. As will be appreciated by the skilled person, the invention can be carried out in a great variety of ways, employing more than one technique from those described above, all without exceeding the scope of the invention. | The invention relates to a method for visually presenting a set of properties of a web site, which comprises: (a) predefining within a provider's search engine a set of properties and assigning to each property a visual symbol; (b) using a spider program, visiting by said provider's search engine each web site and determining those properties from said set that are characteristic to that web site; (c) associating by said provider's search engine with each web site those symbols corresponding to said determined properties; (d) forming for each web site a corresponding combined visual representation of the web site based on said associated symbols; and (e) when listing search results to a user, including the combined visual representation for each web site respectively. | 8 |
CROSS REFERENCE TO RELATED APPLICATION
[0001] This application claims priority from German Patent Application Nos. 103 15 136.2 and 103 49 407.3, which are incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] The invention relates to an apparatus at a spinning preparation machine, for example a cleaner, opener, carding machine or the like, for detecting waste which is separated out from fibre material, for example cotton.
[0003] The fibre material typically consists of foreign matter and good fibres, and may be collected in a collecting device, wherein there is provided an optical measuring device having a brightness sensor, which measuring device examines the waste. In a known apparatus (EP-A-0 399 315), the beater pins of a cleaning roller convey the fibre flocks over cleaning bars which are adjustable so that the intensity of cleaning can be varied. Below the cleaning bars, a brightness sensor measures the brightness as a measure of the contaminant content of the offtake (waste), which has been separated out by the cleaning bars and is collected in a funnel-like collecting device. At prespecified time intervals, the offtake is drawn off under suction by way of a suction conveyor arranged at the lower end of the collecting device. The brightness—measured by the brightness sensor—of the separated-out waste, in the form of a signal, is input into a control system and displayed on a display. One disadvantage is that the sensor serves only for detecting the contaminant content; the content of good fibres is not detected. It is furthermore disadvantageous that the determined degree of cleaning is investigated, by sensors, in the offtake chamber of the cleaning machine. Finally, the brightness, that is to say the degree of brightness—measured by the sensor—of the offtake is merely input into the control system without, however, any optimum operating point of the cleaning machine being derived therefrom.
[0004] It is an aim of the invention to provide an apparatus of the kind described at the beginning which avoids or mitigates the mentioned disadvantages and which especially makes it possible for the content of good fibres in the offtake to be detected by simple means and allows optimum adjustment of the composition of the offtake, especially to have a high content of foreign matter (trash) and a low content of good fibres.
SUMMARY OF THE INVENTION
[0005] The invention provides a spinning preparation machine in which waste can be separated from fibre material, having a sensor arrangement including a light source and a brightness sensor for examining waste, and further having a measurement element, wherein the waste can be conveyed past the sensor arrangement and the brightness sensor is arranged to receive light from the light source reflected by the waste, the received light being convertible into electrical signals which are measurable by the measurement element.
[0006] The measures according to the invention make it possible for the content of good fibres in the offtake to be detected automatically and allow optimum adjustment of the composition of the offtake (trash/good fibres) by simple means. The brightness sensor and the subsequent evaluation provide precise information relating to the content of good fibres in the offtake, that information being usable for adjustment of the separating elements. In the process, a continuous, objective and, accordingly, personnel-independent assessment of the separated-out waste can be carried out. It is, especially, possible to determine, and if necessary to influence, the amount of good fibres that are, undesirably, also separated out. Existing machine elements can be so adjusted in dependence upon the results obtained that a predetermined, desired waste composition is obtained automatically. It is especially advantageous that the variation in the brightness signal (coefficient of variation/standard deviation of light reflection) corresponds to the quantitative distribution curve of the waste (trash/good fibres), from which an optimum operating point can be derived for adjustment of the separating elements for the cleaning of the fibre material. The function between the coefficient of variation and, for example, the position of the adjustable guide vanes of the cleaning machine may exhibit a characteristic change in the gradient (gradient endpoint or range) which corresponds to the optimum operating point for cleaning. Determining the optimum operating point can be carried out by means of an arrangement that is very simple in terms of apparatus, which constitutes a further advantage.
[0007] The collecting device may be a pneumatic pipe-line. The collecting device may be a suction offtake hood.
[0008] Advantageously, the waste is moved through the collecting device. The brightness sensor may be arranged in the wall region of the pipe-line or suction offtake hood. The brightness sensor may be located in the region of an end face of the pipe-line or suction offtake hood. The brightness sensor may comprise at least one photoelectric element, for example, at least one photodiode. The brightness sensor may be capable of detecting changes in voltage caused by differences in brightness. Advantageously, the brightness sensor is connected to an electronic evaluation device. The light source may be a direct-current illuminator. The light source may be an alternating-current illuminator. The light source is advantageously arranged in the immediate vicinity of the brightness sensor, for example, next to the brightness sensor. Advantageously, the sensor system operates in incident light. Advantageously, the variation in the brightness of the good fibres is arranged to be determined. Advantageously the coefficient of variation of the brightness of the good fibres is arranged to be determined. Advantageously, the standard deviation of the brightness of the good fibres is arranged to be determined. Advantageously, detection and assessment of the waste are carried out automatically. Advantageously, detection and assessment of the waste are carried out continuously. Advantageously, the measurement results of the evaluation device are compared with prespecified quantities. Advantageously, in the event of a departure from prespecified quantities, the waste separation can be modified. Advantageously, at least one opto-electronic brightness measurer is integrated into the suction offtake lines through which the waste is taken off under suction. Advantageously, more than one electronic evaluation device is provided. Advantageously, more than one opto-electronic brightness measurer is connected to evaluation devices. Advantageously, the evaluated measurement results relating to the consistency of the waste are compared with prespecified values and used for automatically modifying machine elements influencing separation. Advantageously, the at least one evaluation device is in communication with the associated machine control. Advantageously, the evaluated measurement results of the separation procedures are shown on the machine operating and display unit. Advantageously, the evaluated measurement results of the separation procedures are passed on to other, possibly superordinate and central, systems. Advantageously, at least one opto-electronic brightness measurer is associated with each machine. Advantageously, at least one opto-electronic brightness measurer is arranged on each side of a machine. Advantageously, the at least two brightness sensors are in communication with a central evaluation device. Advantageously, different light sources are provided. Advantageously, light sources of different colours are provided, for example red light and infra-red light. Advantageously, at least one source of incident light is provided. Advantageously, the evaluated measurement results are used for adjusting at least one guide vane associated with the roller. Advantageously, the evaluated measurement results are used for adjusting at least one separating blade associated with the roller. Advantageously, the at least one electronic evaluation device (measuring element) is in communication with an electronic control and regulation device, for example a microcomputer. Advantageously, the machine elements such as guide vanes, separating blades and the like are arranged to be automatically adjusted in dependence upon the evaluated measurement results. Advantageously, the cleaning capability of the machine is modifiable in dependence upon the evaluated measurement results. Advantageously, the nature of the waste (amount, composition) is modifiable in dependence upon the evaluated measurement results. Advantageously, at least one separate brightness sensor is associated with each suction offtake location or guide vane. Advantageously, the brightness sensor is associated with a central waste-collecting line. Advantageously, a window for the brightness sensor is provided in each waste-collecting line. Advantageously, a window for an illumination device is provided in each waste-collecting line. Advantageously, the evaluated measurement results are used for determining the ratio of the good fibre content to the contaminant content. Advantageously, the evaluated measurement results are used for assessing the quality of the fibre material being processed. Advantageously, a machine is in communication with a central evaluation device, to which more than one brightness sensor is connected. Advantageously, the electronic control and regulation device, for example a computer, has a memory for comparison data. Advantageously, the evaluation device is in communication with a superordinate electronic evaluation system, for example KIT. Advantageously, the measurement values of the brightness sensor are convertible into electrical signals. Advantageously, the evaluated measurement results are used in a control and regulation circuit for optimising the cleaning of the fibre material. Advantageously, the illumination device or light source operates using visible light. Advantageously, the content of good fibres is arranged to be determined. Advantageously, at least one angle-measuring device is connected to the control and regulation device. Advantageously, at least one brightness sensor is connected to the control and regulation device. Advantageously, at least one actuating element is connected to the control and regulation device. Advantageously, the sensor arrangement is used for determining a blockage of fibre material in the collecting line. Advantageously, a blockage in a suction hood is determined. Advantageously, a static state of the electrical signal caused by the blockage is arranged to be detected. Advantageously, exceeding, or falling below, a limit value for the electrical signal caused by the blockage is arranged to be detected. Advantageously, the machine control issues an error message on the basis of the blockage.
[0009] The invention also provides an apparatus at a spinning preparation machine, for example a cleaner, opener, carding machine or the like, for detecting waste which is separated out from fibre material, for example cotton, and consists of foreign matter and good fibres and which is collected in a collecting device having a brightness sensor, which measuring device examines the waste, characterised in that the waste material is moved past at least one sensor arrangement responding to good fibres, and the sensor arrangement comprises a light source, the light reflected by the moving good fibres being detected by the brightness sensor and being converted into electrical signals, which are measured by a measurement element.
[0010] The invention also provides a method of monitoring waste in a spinning preparation machine, comprising conveying the waste past a location in which it can be examined by a sensor arrangement, so illuminating waste in said location that reflected light from the waste can be detected by a brightness sensor, converting data relating to the brightness of the waste to electrical signals, and evaluating the electrical signals to ascertain information relating to the composition of the waste.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] [0011]FIG. 1 a is a diagrammatic cross-sectional side view of a cleaning machine having several suction hoods for waste;
[0012] [0012]FIG. 1 b is a side view of the cleaner of FIG. 1 a having apparatuses according to the invention;
[0013] [0013]FIG. 2 is a cross-sectional front view, along I-I in FIG. 1 b , of a part of a cleaner similar to that of FIG. 1 b having an apparatus according to the invention arranged at a suction offtake channel;
[0014] [0014]FIG. 2 a shows an apparatus according to the invention arranged at a connection piece of a suction offtake arrangement;
[0015] [0015]FIG. 3 a shows a waste-separating location with a waste-separating arrangement having an adjustable guide vane;
[0016] [0016]FIG. 3 b shows the waste-separating arrangement of FIG. 3 a with the guide vane in a different position;
[0017] [0017]FIG. 3 c is a top view of a part of the waste-separating arrangement of FIGS. 3 a , 3 b , including the guide vane together with an actuating motor and an angle-measuring element;
[0018] [0018]FIG. 4 is a top view of a part of the cleaner according to FIG. 1 b ;
[0019] [0019]FIG. 5 is a generalised circuit diagram of an electronic control and regulation device having connected apparatuses according to the invention, an evaluation device, an angle-measuring device for guide vane angles, an operating and display device and an actuating device for guide vanes;
[0020] [0020]FIG. 6 is a diagrammatic side view of a feed device for a carding machine together with apparatuses according to the invention at suction waste-offtake hoods;
[0021] [0021]FIG. 7 shows the apparatus according to the invention comprising a photodiode, a light source and a measuring device for data collection at a waste pipe-line;
[0022] [0022]FIG. 8 is a graph showing the standard deviation (CV %) of the measurement voltage and the measurement voltage in dependence upon the guide vane position (or the width of the separation opening) and
[0023] [0023]FIG. 9 is a graph showing the waste composition in dependence upon the guide vane position (or the width of the separation opening).
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0024] With reference to FIG. 1 a , the fibre material to be cleaned (arrow F), especially cotton, in flock form, is fed to the cleaning apparatus, for example a CVT 4 cleaning apparatus made by Trützschler GmbH & Co. KG of Mönchengladbach, Germany, which is arranged in an enclosed housing. That is accomplished, for example, by means of a charging shaft (not shown), a conveyor belt or the like. The lap is fed, by two feed rollers 1 , 2 , with nipping, to a pinned roller 3 , which is rotatably mounted in the housing and rotates in an anti-clockwise direction (arrow A). Downstream of the pinned roller 3 there is arranged a clothed roller 4 covered by a sawtooth clothing. The roller 3 has a circumferential speed of about 10 to 21 m/sec. The roller 4 has a circumferential speed of about 15 to 25 m/sec. Roller 5 has a higher circumferential speed than roller 4 , and roller 6 has a higher circumferential speed than roller 5 . Downstream of rollers 3 and 4 there are successively arranged two further sawtooth rollers 5 and 6 , the directions of rotation of which are denoted by reference letters C and D, respectively. Rollers 3 to 6 have a diameter of about from 150 to 300 mm. The pinned roller 3 is enclosed by the housing. Associated with the pinned roller 3 is a separation opening 7 for removing fibre contaminants, the size of which opening is modified or modifiable according to the degree of contamination of the cotton. Associated with the separation opening 7 is a separating edge 12 , for example a blade. In the direction of arrow A there are provided, at the roller 3 , further separation opening 8 and a separating edge 13 . A separation opening 9 and a separating edge 14 are associated with the sawtooth roller 4 , a separation opening 10 and a separating edge 15 are associated with the sawtooth roller 5 , and a separation opening 11 and a separating edge 16 are associated with the sawtooth roller 6 . A suction offtake hood 17 to 21 is associated with each separating blade 12 to 16 . Reference letter E denotes the work direction of the cleaner.
[0025] In accordance with FIG. 1 b , a suction offtake line 22 , 23 , 24 , 25 and 26 is associated with each suction offtake hood 17 , 18 , 19 , 20 and 21 , respectively. The suction offtake lines 22 to 26 are in communication with a common suction offtake channel 27 . The rigid suction offtake lines 22 to 26 and the suction offtake channel 27 are of integral construction of, for example, sheet metal or plastics material. The lengths of the suction offtake lines 22 to 26 differ according to the distance between the suction offtake hood 17 to 21 and the suction offtake channel 27 . The cross-sections 27 I to 27 v of the suction offtake channel 27 —seen in the direction of flow (arrow K)—are located downstream of the entry of each suction offtake line 22 to 26 . The end of the suction offtake channel 27 is connected to a suction source (not shown). The directions of flow within the suction offtake lines 22 to 26 are shown by arrows L to P.
[0026] The mode of operation is as follows: The lap consisting of fibre flocks (F) is fed from the feed rollers 1 , 2 , with nipping, to the pinned roller 3 , which combs through the fibre material and takes up fibre tufts on its pins. When the roller 3 passes the separation opening 7 and the separating edge 12 , the centrifugal force, in dependence upon the circumferential speed and curvature of that roller and also upon the size of the separation opening 7 , which is matched to that first separation step, causes waste (short fibres and coarse contaminants) and a certain (per se undesirable) amount of good fibres to be flung out from the fibre material remaining on the roller; the material passes through the separation opening 7 into a suction offtake hood 17 (contaminants) in the housing. The fibre material pre-cleaned in that manner is taken off the first roller 3 by the tips of the clothing of the clothed roller 4 and is further opened out. When the rollers 4 , 5 and 6 pass the separation openings 9 , 10 and 11 , respectively, having separating edges 14 , 15 , and 16 , respectively, further contaminants are flung out from the system of fibres as a result of the centrifugal force.
[0027] Arrows B, C and D denote the directions of rotation of the clothed rollers 4 , 5 and 6 , respectively. Reference numerals 17 to 21 denote suction offtake devices for the contaminants leaving by the separation openings 7 to 11 , respectively. The directions of rotation A, B, C and D of rollers 3 , 4 , 5 and 6 , respectively, are different at adjacent rollers. At the end of the final roller 6 there is provided a pneumatic suction offtake device 22 for the cleaned fibre material (arrow H). The circumferential speed of each downstream roller is greater than the circumferential speed of the respective upstream roller. Reference numerals 23 ′ to 26 ′ denote adjustable air-guiding elements mounted at the air entry openings of the suction offtake hoods 18 to 21 , by means of which elements the amount of air drawn in can be adjusted. In the walls of the suction offtake channels 27 a , 27 b for the suction offtake hoods 17 to 21 there is mounted at each end face, that is to say coaxially with respect to the suction offtake hood 17 to 21 , a transparent pane 40 a to 40 e (see FIG. 2) so that it is possible to see into the suction offtake hood 17 to 21 from the outside. Associated with each of the panes 40 a to 40 e is a sensor arrangement 42 according to the invention (individual sensor arrangements being shown as 42 a to 42 g in the drawings), located outside the suction offtake channels 27 a , 27 b , by means of which the waste flowing through the suction offtake hood 17 to 21 and into the suction offtake channel 27 a , 27 b is detected by the sensor arrangement 42 . Reference numerals 139 , 140 and 141 indicate fixing devices.
[0028] In accordance with FIG. 2, the suction offtake hood 17 is arranged between the two frame walls 28 , 29 (housing walls); a connection piece 30 a , 30 b is provided outside the walls 28 , 29 at each end 17 a , 17 b of the suction offtake hood 17 so that the suction offtake hood 17 passes through two openings in the frame walls 28 , 29 . A resilient annular seal 32 , for example made from foamed material, is placed around the connection pieces 30 . In the arrangement of FIG. 1 b , one end region 22 a of the suction offtake line 22 opens out into the suction offtake channel 27 a ; the other end region 22 b of the suction offtake line 22 opens out into the suction offtake channel 27 b . Reference numeral 34 denotes a fastening element, for example a screw connection. The ends of the suction offtake channels 27 a , 27 b are connected to a common suction offtake channel 44 (see FIG. 4), which is connected to a suction source (not shown). The connection of the suction offtake line 22 a to the suction offtake hood 17 and the suction offtake channel 27 a corresponds to the connection of the suction offtake line 22 b to the suction offtake hood 17 and the suction offtake channel 27 b . On each outer face of the suction offtake channels 27 a , 27 b there is mounted a transparent pane 40 a and 40 b , respectively, with which there is associated a camera 41 a and 41 b , respectively, outside the suction offtake channels 27 a and 27 b , respectively, which camera is used for detecting the waste. In FIG. 4, only the sensor arrangements on channel 27 b are shown; the sensor arrangements on channel 27 a are of the same general construction but are not shown in FIG. 4. Arrows Q and R denote the flow directions of the suction offtake streams inside the suction offtake hood 17 .
[0029] The cleaning apparatus illustrated in FIGS. 1 a , 1 b and 2 has at openings 8 to 11 devices by means of which the amount and also, to some extent, the nature of the waste being separated (foreign matter, trash, neps, good fibres etc.) can be adjusted or influenced. Those devices are in the form of motor-adjustable guide vanes 37 a to 37 d (referred to collectively below as 37 ) mounted in the region of the opener and cleaning rollers 3 to 6 upstream of the separating blades. It is possible, by means of the angular position α of those vanes 37 to influence the amount and also, to a certain extent, the nature of the material separated 1 (FIGS. 3 a , 3 b ), a large angle of opening α resulting in a relatively large amount of separated material I and a small angle resulting in a correspondingly smaller amount. Stipulating the desired amount of separated material I at the same time determines very especially the cleaning action of the machine on the good material. Because it is generally the case that, with this kind of separation I, “good” fibre material will always be separated out as well, it is, in practice, necessary to find an acceptable compromise. This means that as much “bad material” as possible is separated out whilst, at the same time, separating out a minimum amount of good fibres. In order to be able to assess the waste 1 separated out and consequently to change the possible settings, the waste I is separated out, collected and, finally, visually assessed in the manner according to the invention.
[0030] In accordance with FIG. 2, a transparent pane 40 a is mounted in the wall surface of the suction offtake channel 27 b , the centre-point of which pane is aligned with the axis of the suction offtake hood 17 . Associated with the pane 40 a , on the outside of the suction offtake channel 27 b , is a sensor arrangement 42 a (brightness sensor) in the form of a photodiode (see FIG. 7). In addition, a light source 41 (see FIG. 7) is provided directly next to the photodiode.
[0031] In accordance with FIG. 2 a , a pane 40 g is arranged in the wall surface of the connection piece 33 b , which connects the suction offtake channel 27 b to the outlet from the suction offtake hood 17 . Associated with the pane 40 g , on the outside, is a brightness sensor 42 g.
[0032] In accordance with FIG. 4, the waste K 1 to K 8 from the individual separation locations is combined on each side of the machine to form combined streams M, N, drawn off continuously by means of a partial vacuum and conveyed to a central filtration and separation system 44 . In this case, in accordance with the invention, there is integrated in the waste channel 27 b , at the level of, that is to say aligned with, each suction offtake hood 17 to 21 , a brightness sensor 42 a to 42 d , together with appropriate illumination 41 a to 41 d (not shown in FIG. 4) and evaluation unit. The system is so arranged that fibres, foreign matter and other matter flying past in the line 27 b can be detected. The system is furthermore so arranged that it is possible to distinguish good fibres in the waste and to provide information relating thereto. In dependence upon corresponding specified requirements, the machinery influencing the composition of the waste I (e.g. the guide vanes 37 ) is then automatically adjusted until the desired waste quality has been achieved.
[0033] In accordance with FIG. 5, there are connected to an electronic control and regulation device 43 (machine control), for example a microcomputer, three sensor systems 42 a , 42 b , 42 c by way of three evaluation devices 44 a , 44 b , 44 c , an operating and display device 50 , three angle-measuring devices 46 a , 46 b , 46 c for guide vane angles α (FIGS. 3 a , 3 b ) and three vane-adjusting devices 45 a , 45 b , 45 c for adjustment of the guide vanes 37 a , 37 b and 37 c , respectively.
[0034] [0034]FIG. 6 shows a carding machine, for example a DK 903 high-performance carding machine made by Trützschler GmbH & Co. KG. There are provided, in the feed system of lickers—in 47 a , 47 b , 47 c , a suction waste-offtake hood 48 a , 48 b and 48 c at each roller, respectively, and also a connecting line 49 for the suction offtake hoods 48 a to 48 c . Associated with each of the suction offtake hoods 48 a to 48 c and with the connecting line 49 is a sensor system 42 a , 42 b , 42 c and 42 d (see FIG. 7).
[0035] In accordance with FIG. 7, there is provided in the wall surface of the waste line 27 an opening in which there are arranged a brightness sensor 42 in the form of a photodiode and a light source 41 in the form of a direct-current visible-light illuminator. The photodiode 42 (photovoltaic element) is a signal transducer. The photodiode 42 is connected, by way of lines 42 1 , 42 2 , with a measurement apparatus 44 for data collection (voltage measurement apparatus). The system is based on the detection and evaluation of changes in voltage or resistance caused by reflection differences (differences in brightness caused by a difference in reflection) in spaces containing moving waste. For that purpose there is required a direct-current illuminator or high-frequency alternating-current illuminator, which is mounted at the end face or tangentially on the pipe-line or suction offtake hood of the spinning or cleaning room machine. Directly next to or even inside that illuminator there is a photosensitive element which receives the light reflected by the good fibres, converts it into current and measures the variation in reflection. The reflection is always detected in reflected incident light. An image is not required so that the detection problems caused by honeydew and other contaminants are avoided. It is solely the variations in the level of reflection (which are dependent upon the content of good fibres) that are used because it is only the variance that provides reliable information relating to the correctness of the operating point and the associated separation element setting. The optimum operating point is achieved at maximum contaminant separation and, at the same time, minimum good-fibre separation. A large amount of good fibres produces a high variation in reflection so that the variation in the current produced is correspondingly high or the remaining resistance is correspondingly low. In dependence upon that level, the separating unit can then be appropriately adjusted in order to control the amount of good fibres in the waste (cf. FIGS. 3 a , 3 b ).
[0036] [0036]FIG. 8 shows the dependence of the voltage at the measurement apparatuses 44 a to 44 c and of the coefficient of variation of the voltage upon the guide vane angle. The coefficient of variation in % is defined as:
CV = 100 · s x _
[0037] CV=coefficient of variation
[0038] s=standard deviation
[0039] {overscore (x)}=mean
[0040] In operation, for a specific fibre material, the angle α of the guide vane 37 b is successively increased and the corresponding voltage values are detected at the measurement apparatus 44 . A large amount of good fibres in the waste results in a correspondingly high voltage value because of a correspondingly high light reflection. The voltage measurement values of the measurement apparatuses 44 a to 44 c and the guide vane angles α of the angle-measuring devices 46 a to 46 c are input into the computer 43 , which calculates the coefficient of variation (CV %) of the voltage and the functional dependence of the coefficient of variation on the guide vane angle α in accordance with the graph in FIG. 8. In the curve according to FIG. 8, at an angle α=13.1°, there is a characteristic change in the gradient which corresponds to the optimum operating point of the cleaning machine. At angle settings α>13.1°, the content of good fibres in the waste increases steeply, in undesirable manner, compared to the foreign matter and trash content (cf. FIG. 9). Then, by way of the actuating elements 45 a to 45 c , for example stepper motors, the inclination a of the guide vanes 37 a to 37 c is set to α=13.1° in accordance with the optimum operating point. The procedure described above is carried out automatically—during ongoing production or in a preliminary test run. The optimum operating point can be monitored and, in the event of departures therefrom, can be re-set automatically.
[0041] By means of the apparatus according to the invention, the irregularity of the stream of waste separated out is assessed in terms of its degree of opening. The irregularity is measured on the basis of the standard deviation of the light reflected by the individual items separated out. As a result of the incident light method, the contaminant content of the items is invisible to the sensor so that, with this measurement method, neither the contaminant content nor the brightness of the separated-out waste is assessed but rather only the variation in the brightness of the good fibres.
[0042] In order to measure the quantitative waste distribution (trash/good fibres) it is also possible, in principle, to use infra-red light because the trash content of the waste reflects strongly in the infra-red range. From the voltage (resistance) difference between white-light and infra-red illumination it is possible to calculate the contents of trash and good fibres. The area of use encompasses all fibre- and waste-conveying channels but not waste chambers containing waste that is at rest.
[0043] The sensor in accordance with the invention can advantageously used to determine a state of blockage in the suction offtake hood, in which case the machine control issues an error message. That may be advantageously accomplished by means of the fact that the normally dynamic signal changes to a static state as a result of the blockage, that static signal course being interpreted as an indication of a blockage, or by means of the fact that the signal exceeds or falls below certain limit values as a result of the blockage.
[0044] Although the foregoing invention has been described in detail by way of illustration and example for purposes of understanding, it will be obvious that changes and modifications may be practised within the scope of the appended claims. | In an apparatus at a spinning preparation machine, for example a cleaner, opener, carding machine or the like, for detecting waste which is separated out from fibre material, for example cotton, and consists of foreign matter and good fibres and which is collected in a collecting device, there is provided an optical measuring device having a brightness sensor, which measuring device examines the waste.
In order to make it possible, by simple means, for the content of good fibres in the waste to be detected and to allow optimum adjustment of the composition of the waste, especially with a high content of trash and low content of good fibres, the waste material is moved past at least one sensor arrangement responding to good fibres, and the sensor arrangement comprises a light source, the light reflected by the moving good fibres being detected by the brightness sensor and being converted into electrical signals, from which the good fibre content can be determined. | 3 |
This application is a continuation of U.S. patent application Ser. No. 12/759,227, filed Apr. 13, 2010, which claims the benefit of U.S. Provisional Application Ser. No. 61/168,749, filed Apr. 13, 2009, which are hereby incorporated by reference in their entirety.
FIELD OF THE INVENTION
Aspects of the present invention relate generally to saddles for anchoring and supporting insulated and uninsulated pipes.
BACKGROUND OF THE INVENTION
Metal components which are commonly known as “saddles” are typically used in building construction to anchor and support pipes to suspend the pipes from the structure of the building. Saddles typically spread the force of a hanger across a portion of the pipe to minimize the force applied to a particular spot. Arcuate saddles with 90° right angle corners along the edges ( FIG. 1 ) are well known in the art. An improved saddle is desired.
SUMMARY
Certain embodiments of the present invention relate to arcuate saddles typically used to anchor and suspend insulated or non-insulated pipes. Rounded corners on the saddles facilitate comfortably introducing and placing the saddles into hangers as well as improving use. Certain embodiments of the present invention involve methods of manufacturing arcuate saddles with rounded corners.
In one embodiment an arcuate saddle is formed for supporting pipe where the saddle has a length and a width. The saddle defines two parallel length sides and two parallel width sides, wherein the width is formed into an arc defined by a radius. The length sides are substantially perpendicular to the width sides and the intersections of the length sides with the width sides are formed with arcuate curves forming rounded corners.
In certain embodiments, a method for forming an arcuate saddle for supporting pipe includes forming a substantially rectangular flat saddle blank having a length and a width with two parallel length sides and two parallel width sides with corners. The length sides are substantially perpendicular to the width sides. Material is removed from the corners along a convex arcuate curve to form rounded corners tapered into the length and width sides; and the saddle blank is formed into an arcuate saddle shape defined by a radius.
In certain embodiments, a method for forming an arcuate saddle for supporting pipe includes: advancing a sheet of material; cutting convex arcuate curves into opposing edges of the material to form rounded corner portions; separating a blank with convex rounded corners defined by the rounded corner portions from the material; and forming the blank into an arcuate saddle shape. In certain options, the saddle is then ejected from the forming assembly.
In further embodiments, a progressive die assembly is provided for forming arcuate saddles for supporting pipe. The assembly include a bed defining a material path to receive a strip of sheet material advanced by a feeding mechanism. A pair of cutting pieces is aligned with the bed along opposing edges of the material path. The pair of cutting pieces is arranged in a compressive cutting relationship with the bed to cut convex arcuate curves into the material to form rounded corner portions. The bed includes a forward shearing edge. A lower stamping die with an arcuate portion is arranged along the material path forward of the forward shearing edge. An upper stamping die is arranged in a compressive relationship with the lower stamping die. The upper stamping die has a trailing shearing edge arranged adjacent the forward shearing edge of the bed to cut the material, thereby forming a separated saddle blank when the upper stamping die is compressed relative to the lower stamping die. The upper stamping die has an arcuate bending portion complimentary to the lower stamping die to stamp the saddle blank into an arcuate shape.
Objects, features and advantages of the present invention shall become apparent from the detailed drawings and descriptions provided herein.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a prior art saddle.
FIG. 2 is an example of a hanger assembly usable to suspend saddles according to embodiments of the present invention.
FIG. 3 illustrates a hanger assembly and saddle supporting a pipe according to a preferred embodiment of the present invention.
FIG. 4 is a perspective view of a saddle without ribs.
FIG. 5 is a perspective view of a saddle with 180 degree arcuate ribs.
FIG. 6 is a perspective view of a saddle with partial ribs.
FIG. 7 is a perspective view of the lower portion of a progressive die arrangement for stamping arcuate saddles according to certain embodiments of the present invention.
FIG. 8 is a cross-sectional view of the upper and lower portions of the progressive die arrangement of FIG. 7 .
FIGS. 9-11 are perspective views of one embodiment of a progressive die arrangement according to certain embodiments.
FIGS. 12A and 12B are perspective views of the lower and upper cutting pieces and profiles usable in the embodiments of FIGS. 9-11 .
FIGS. 13-15 are perspective views of the bending assembly of FIGS. 9-11 .
FIGS. 16-19 illustrate operative steps of the arrangement of FIGS. 9-11 .
FIGS. 20-22 illustrate an ejector assembly useable in the embodiments of FIGS. 9-11 .
FIGS. 23 , 23 A and 23 B illustrate perspective views of a cutting assembly usable in certain embodiments.
FIG. 24 is a perspective view of a roll bending arrangement usable in certain embodiments.
DESCRIPTION OF PREFERRED EMBODIMENTS
For the purposes of promoting an understanding of the principles of the disclosure, reference will now be made to the embodiments illustrated and specific language will be used to describe the same. It will nevertheless be understood that no limitation of the scope is thereby intended, such alterations, modifications, and further applications of the principles of the disclosure being contemplated as would normally occur to one skilled in the relevant art.
Embodiments of the present disclosure relate to arcuate saddles with rounded corners typically used to anchor and suspend insulated or non-insulated pipes. As illustrated in FIGS. 2 and 3 , in a typical assembly 10 a hanger assembly 20 wraps around a pipe or insulated pipe 15 with a saddle 30 situated between the lower portion of the hanger and the pipe. According to an embodiment of the present invention, saddle 30 includes rounded edge corners 60 , typically four, to facilitate introduction of the saddle into the hanger and to eliminate or minimize the ability of sharp corners of the saddle to catch upon or scratch a user, the hanger, a pipe, insulation, a vapor barrier or other materials during introduction or use.
Hanger 20 , for example the clevis hanger illustrated in detail in FIG. 2 , typically includes an upper portion or bracket 22 which can be suspended from a building structure, a lower bracket 24 for receiving and engaging the saddle and pipe and optionally includes a pivot 26 between the upper and lower brackets to allow some relative movement of the hanger portions, if necessary due to vibration, expansion or contraction. Alternately, the hanger can be one piece or a strap which suspends a pipe and saddle.
When putting together assembly 10 , an installer takes saddle 30 and slides it through lower bracket 24 of hanger 20 either independently or with the introduction of pipe 15 into the hanger. The vertical sides of saddle 30 have a width in a close tolerance with the interior of hanger lower bracket 24 to transfer suspension force from the pipe to the hanger once in place.
Certain embodiments include: non-ribbed saddles, 180° ribbed saddles or partial ribbed saddles, each with rounded corners as illustrated in FIGS. 4-6 . In 180° ribbed saddles or partial ribbed saddles, the ribs or partial ribs typically have a higher profile and larger radius than the interior of the hanger particularly on the sides. When ribbed saddles are mounted in place in the hangers, the ribs preferable inhibit or minimize relative sliding movement of the saddle with respect to the hanger.
FIG. 4 illustrates a non-ribbed saddle 30 with rounded corners 60 according to one preferred embodiment. Saddle 30 is formed typically from a rectangular blank of sheet metal 32 pressed or rolled into approximately a 180° arcuate bend about a radius R, forming a length L and a width W. Saddle 30 includes two ends 33 and 34 at opposing ends of the saddle length. Ends 33 and 34 are optionally slightly outwardly flared 35 to facilitate introduction of the pipe into the saddle and to minimize any abutment of sharp edges against the pipe or insulation. The exterior face of saddle 30 includes a generally lower portion or lower face 38 and opposing vertical sides 39 . “Vertical” and “lower” references herein refer to arcuate or curved portions of the saddle which may include generally vertical or horizontal tangents and are not intended to imply planar or flat portions.
The outer diameter or width W of saddle 30 is preferably sized to closely correspond to the inner diameter or width W C of the lower bracket 24 of hanger 20 while the saddle inner diameter corresponds to the outer diameter of the pipe and/or insulation. As examples, pipe and/or insulation sizes may range from 0.5 to 24 inches. More typical saddle sizes have diameters of 1.5 to 12 inches, optionally available in half-inch increments, although other diameter sizes can be made as desired. Example lengths are 8 or 12 inches.
An interior channel 42 extends through the interior of saddle 30 along a channel axis. In use, the interior diameter of channel 42 is sized to receive and engage an outer diameter of a corresponding pipe or insulated pipe.
In an option for certain embodiments, the saddle can be configured to adhere to the pipe or insulation surrounding the pipe to minimize relative movement of the saddle to the pipe or insulation. In one example of this, a double-sided adhesive strip may be mounted to the interior of the saddle longitudinally along interior channel 42 . In one embodiment, the adhesive strip is pre-mounted in the saddles and includes a peel-away cover which is removed to expose an inward facing adhesive face just prior to installation. In an alternate embodiment, an unmounted two-sided strip with two peel-away covers may be supplied with the saddle. In the two-sided version, a first face is first exposed and mounted either to the pipe assembly or the saddle. The second face is then exposed and adhered to the other of the saddle or pipe assembly when they are arranged respectively in a desired location. One or more adhesive strips may extend all or partially along the length of the saddle, and can be mounted between the interior lower portion of the saddle and a pipe assembly or along one or both side portions.
In the embodiments of FIGS. 5 and 6 , 180° ribs 150 or partial ribs 250 are defined on the lower face 138 and 238 of saddles 130 and 230 with rounded corners 160 or 260 . Ribs 150 and 250 typically have an arcuate bend corresponding in shape to the arcuate curve of lower face 138 and 238 . The ribs are generally transverse to the length L of saddle 30 and parallel to the width W. Ribs 150 and 250 preferably extend a sufficient height and width to inhibit saddle 130 or 230 from moving relative to the lower bracket 24 of hanger 20 once installed. When partial ribs are used, the partial ribs 250 are preferably primarily oriented on lower face 238 and do not substantially extend to side portions. In certain preferred embodiments, the arcuate bend of the partial ribs 250 is approximately 60° or less.
Ribs 150 and 250 each include a central peak section 152 or 252 and opposing slanted or curved sides extending from face 138 or 238 to peak 152 or 252 . Peak section 152 or 252 may be sharp, blunted or rounded. The ends of the partial ribs 250 may be sharply defined, but preferably are tapered into saddle 230 at each end to form a closed end. Ribs 150 or 250 could be mounted to lower face 38 with an attachment process, but preferably are formed into the metal.
In certain preferred embodiments of the present invention, arcuate saddles are made with rounded corners. Non-limiting examples of corner radii which may be used are ¼″, ⅜″ or ½″. Alternately a larger or smaller radius of curvature, or a non-constant radius may be used as desired. Preferably the rounded periphery at each corner is convex and smoothly tapers into the respective length and width edges of the saddle to eliminate sharp corners or discontinuities.
In one method of manufacture, rounded corners 60 , 160 or 260 are individually formed into a piece or “blank” of sheet metal either to be bent or in an already arcuately formed saddle. A blank is typically a flat, rectangular sheet of metal with a length corresponding to the desired length of the saddle and a width corresponding to the desired circumference of the saddle around the desired radius. The length forms two parallel length sides which are perpendicular to two parallel width sides. The corners of the blank or saddle may be individually formed by cutting or grinding. Examples of ways to cut or trim the corners include automated or manual trimmers or using a grinding machine to shape the blank or saddle to remove material and to form the rounded portion.
If the corners are cut or trimmed into a flat sheet metal blank, the blank may then be bent into an arcuate shape, for example using a stamping or rolling process. One method of roll bending saddles is to use a two or three roll bending machine, for example, using an Acrotech Model 1618 two roll bending machine. The roll bending machine may form a flat or ribbed blank into a non-ribbed saddle, a 180° ribbed saddle or a partially ribbed saddle, as desired, and may form flares on the edges as desired.
Alternate methods of manufacturing include forming the corners with an automated process, such as in a stamping machine which forms the corners by trimming a blank either simultaneously or as a separate step to forming the blank into an arcuate shape. A typical stamping machine compresses the blank between mating portions for bending and/or cutting.
In certain embodiments one or more stamping machines may be used with successive stamping steps and positions. In one embodiment, a first stamping position includes substantially flat male and female portions forming a cutting table to support a flat blank piece. Cutting punches extend from the male and/or female portions corresponding to each desired rounded corner. During compression, pressure is preferably applied so that the cutting punches penetrate and cut through the blank to remove material from the blank, forming rounded corners. Upon opening of the stamping machine, a substantially flat blank with rounded corners may be removed.
The flat blank with rounded corners is then automatically fed or manually transferred to a second stamping position of the same or a different stamping machine. In the second stamping position, the blank is arranged between a protruding male portion and receiving female portion formed in complementary arcuate shapes. When the stamping machine is compressed, the portions bend the blank into an arcuate saddle shape. Optionally, the stamping machine portions may also include protruding 180 degree or partial ribs which stamp corresponding rib sections into the saddle during the same step.
An example embodiment of a stamping machine and process is illustrated in FIGS. 7 and 8 . FIGS. 7 and 8 show an example of a progressive die having a lower die portion 300 and an upper die portion 400 . Lower die portion 300 includes a cutting portion 310 and a bending portion 350 . Upper die 400 includes a corresponding cutting portion 410 and bending portion 450 .
As illustrated in detail in FIG. 7 , cutting portion 310 of lower die 300 includes a bed portion 312 with an entry edge 314 , an upper edge 316 and a lower edge 318 . An exit edge 344 of the bed is formed with a replaceable cutting bar 340 mounted along the edge opposite entry edge 314 .
Cutting pieces or punches 325 are mounted in bed 312 . Cutting pieces 325 are preferably formed with two concave radius portions extending from each side of the cutting piece inward toward the center of the bed to an inner tip. The tips of the two cutting pieces are preferably aligned along a trim axis T-T. Optionally, cutting pieces 325 are selectively mountable in various locations relative to bed 312 to vary the width distance W 1 between axis T-T and the cutting edge 344 of bar 340 in certain preselected measurements. Optionally, cutting pieces 325 may also be mounted to bed 312 along the upper and lower edges forming side rails 316 and 318 as shown, or each may be moved inward along the length axis L 1 of bed 312 to engage a correspondingly shorter length of material. The length of dimension L 1 is intended to correspond to the desired length of the finished saddle piece, for example saddle lengths of 8 or 12 inches. The length dimension L 1 may correspond to the width measurement from the perspective of a metal strip or ribbon being supplied to die portion 300 , such as from a steel coil.
In correspondence with cutting portion 310 of lower die 300 , cutting portion 410 of upper die 400 is arranged with a cutting bed portion arranged to mate with lower bed 312 . Cutting or pierce punch pieces 425 which are complimentary in shape to cutting pieces 325 are mounted to upper portion 412 . As shown, cutting pieces 425 include two convex radius portions extending from outer edges inward towards the center of the bed to meet at a tip. Cutting portions 325 and 425 are preferably substantially equal in complimentary shapes with a slight tolerance difference in size so that upon compression of the die, a lower cutting portion 325 pushes upward on a piece of metal in the die a while upper cutting portion 425 pushes downward on the metal creating a shearing effect to cut a plug of material from the metal, leaving a shape in the metal matching the radius portions where the upper and lower cutting punches pass.
In an optional feature, upper bed 412 may include a compression plate 415 mounted on springs. When used, the compression plate typically would be the first portion of the upper cutting portion 412 to contact the metal material in the die and would provide a clamping force on the metal between the plate and lower bed 312 to hold the metal in place while the upper die continues its downward stroke. As the downward stroke continues, the springs compress to resiliently increase the clamping pressure on the metal in the die until the cutting portions have finished a cutting downward stroke. The clamping pressure releases and retracts as the upper die 400 moves in the reverse stroke.
Lower die 300 further includes bending portion 350 arranged to receive material exiting cutting portion 310 . Bending portion 350 includes a radiused male portion 360 forming a radius and diameter corresponding to the desired inner arcuate radius and curve of the saddle. The radius may extend for approximately 180°, or optionally may include a slight variation or be slightly oversized to accommodate expected spring back of the metal material being bent.
Male radius 360 typically includes a radiused face portion 362 forming a central portion of the bending surface. Optionally arranged on opposing sides of the center of central portion 362 are partial or full ribs 364 to press corresponding partial or 180° ribs into the metal blank being bent. The face of radius 360 preferably includes slightly tapered flared portions 367 at each end to impart a flare to the upper and lower edges of the blank being bent.
In certain embodiments, the face of radius 360 includes radiused sections 365 arranged outward along the length L 1 between upper edge 356 and lower edge 358 of bending portion 350 .
Optionally, the face of bending portion 350 can be arranged to accommodate a narrower blank corresponding to an arrangement where cutting portions 325 are spaced inward from upper edge 316 and lower edge 318 of bed 312 . For example, this can be used with a strip of metal having a length L 2 such as eight inches. In this arrangement, spacer plates (not shown) are placed over the outward radiused sections 365 so that a centered metal blank is fed between them in the area designated L 2 . The spacer plates optionally include flared portions along their central edges so that a blank bent in the L 2 region receives flared outer edges. The spacer plates preferably include radii to correspondingly fit snugly on radiused portions 365 when in place without interfering with compression of the die. The spacer plates may be mounted by resting in place or may optionally be secured with fasteners.
Upper die 400 has an upper bending portion 450 matching and complementary to lower bending portion 350 . As illustrated in a cross-section in FIG. 8 , bending portion 450 includes a cutting bar 440 , preferably replaceable, which forms a shearing relationship with lower cutting bar 340 to cut material in the die as the die compresses.
Bending portion 450 includes a concave female radius 460 complementary to male radius 360 . Female radius 460 may optionally include indentations or grooves allowing for partial or full ribs 364 to press ribs into the metal being bent. In some embodiments, male radius 360 and female radius 460 each include slight vertical wall sections 369 and 469 transitioned from the arcuate radius portions to allow the male and female portions to compress sufficiently to impart a full 180° radius to the metal being bent.
Preferably, the center of male bending portion 350 is spaced from the shear or cutting edge 344 of cutting bar 340 at a distance of ½ W 1 . The spacing corresponds to half of the distance W 1 between the punch 325 cutting tips along trim axis T-T and the shear edge 344 .
In operation of the illustrated progressive die, a ribbon or strip of metal is fed into bed portion 312 from the direction of intro edge 314 . The strip or ribbon of metal may have a width corresponding to the desired length of the saddle to be made, for example filling length distance L 1 of bed 312 . The thickness of the metal is preferably of a gauge designed to be cut by the height of punch pieces 325 and 425 . Prior to the introduction of the metal, cutting punches 325 and 425 are arranged at a distance W 1 from shearing edge 344 of cutting bar 340 where distance W 1 corresponds to the desired blank to be cut with a width to be formed into the desired circumference measurement of the saddle piece to be produced.
In a loading step, the leading edge of the metal with two rounded corners is advanced into bed 312 until the forward edge is adjacent the shear edge of cutting bar 340 . Optionally, the metal may be advanced further or less; however, a scrap portion will need to be cut and discarded in the first cycle or two of the die to create a leading edge with two rounded corners.
In a first cycle of operation, the male and female die portions compress to shear off any excess material extending beyond cutting bar 340 and also to punch radiused convex indentations along axis T-T into the metal material. Upon completion of the first compression and release cycle, the metal strip is advanced a distance W 1 through the die. In the next position, the portion of the metal in which the radiused indentations were made along axis T-T is aligned with the shearing edge of cutting bar 340 with the forward portion of the metal extending between the bending portions of the respective dies. Upon the next compression cycle, cutting bars 340 and 440 shear the material along axis T-T leaving a blank to be bent in the bending portions of the dies while also punching the next radiused indentations with punches 325 and 425 into the metal of material. Each compression and cutting cycle by punches 325 and 425 forms two rounded corners on one side of axis T-T and two rounded corners on the opposite side of axis T-T. When the metal is cut along axis T-T, these form rounded trailing corners of a prior blank and rounded leading corners on the edge of the next blank.
As the die closes in the second and successive iterations, the upper point of male radius 360 and the lower portions of upper bending portion 450 contact and hold the metal piece between them in a three point contact grasp. As the metal is cut and the dies continue to compress, the metal is bent around male radius 360 until the desired bend arc has been imparted to the blank. Typically the cutting portions and bending portions simultaneously compress and retract the same distance h 1 during a cycle.
During compression bending, the outer portions of the blank are pushed downward and slightly drawn inward to wrap around the male radius 360 . The lower edges of the female radius 460 preferably include a slight radius or taper 465 to facilitate the metal being bent rather than scraped as the female radius is forced downward to wrap the metal.
Upon completion of the compression cycle, the die portions are separated and the formed arcuate saddle may be removed from lower bending portion 350 . The metal strip or ribbon is then advanced a distance W 1 to provide the next portion of material to be cut off and bent in the bending portions and the next portion of material to be cut with indentations in the cutting portions of the die. The operation may then be repeated as desired to form multiple arcuate saddles with rounded corners.
In certain optional embodiments, the female bending portion 450 may include one or more retractable compression pins to contact the metal blank during the compression portion of the cycle. The pin or pins preferably push the saddle out to prevent it from sticking within the female bending portion during the upward stroke.
In certain optional embodiments, an embossing die may be arranged in the cutting or bending portions of the arrangement to emboss indicia such as size information or a brand name or logo into the inner or outer faces of the saddle being formed.
In one embodiment, the cutting portions and bending portions are mounted in a fixed distance relationship defined so that the distance between shear edge 344 and the center of bending portion 350 is one-half of the distance between the shearing edge 344 and the trim axis T-T. Alternately, the distance between the cutting portions and the bending portions can be varied at predefined intervals to maintain the relationship of W 1 to ½ W 1 as the cutting punches 325 are arranged within bed 312 to accommodate different width measurements W 1 . For example, different width measurements W 1 , would be used to accommodate the differences in circumference measurements between arcuate saddles of differing radii and diameters. In an alternate embodiment, the bending portion can be arranged to receive a cut blank with rounded portions from the cutting portions and to then automatically center the blank over the desired radius portion.
A further example embodiment of a stamping machine 500 and process is illustrated in FIGS. 9 through 22 . FIGS. 9-22 show an example of a progressive die arrangement having a cutting assembly 510 , a bending assembly 550 and an ejector assembly 590 .
As illustrated in detail in FIGS. 9-11 , cutting assembly 510 includes a lower portion with bed 512 . The top of bed 512 is closed with an upper plate 513 . Bed 512 includes a bed area with side rails which is covered by plate 513 to define a sheet metal path with entrance 514 sized to receive sheet metal material 235 fed, for example from a coil and advanced by a feeding mechanism. The bed ends in forward or shearing edge 544 ( FIG. 13 ). Upper plate 513 defines vertical edge slots 518 arranged along its longitudinal length and optionally a logo stamping slot 519 .
Bed 512 includes two cutting profiles 527 , as seen in FIG. 12A , aligned with edge slots 518 , which are complimentary in shape to and are mated to form a shearing arrangement with the cutting profiles of cutting pieces 525 . In the illustrated embodiment, the cutting profiles 527 within bed 512 have two convex radiused portions 528 extending from each side inward toward the center of the bed to a tip 529 . The tips of the two cutting profiles are preferably aligned along a trim axis T-T.
The upper portion of cutting assembly 510 includes an upper carrying plate 520 with cutting pieces or pierce punches 525 extending downward. As seen in FIG. 12B , cutting pieces 525 are preferably formed with a cutting profile having two concave radiused portions 526 extending from each side of the cutting piece inward toward the center of the bed to a tip 524 .
Cutting pieces 525 of the upper portion are aligned with longitudinal edge slots 518 in plate 513 and with the cutting profiles 527 of bed 512 . Cutting pieces 525 and cutting profiles 527 are preferably substantially equal in complimentary shapes with a slight tolerance difference in size so that upon compression of the die, the upper cutting portions push downward on the sheet metal, while the lower cutting profiles resist/push upward, creating a shearing effect to cut a plug of material from the metal, leaving a cutout shape 255 ( FIG. 16 ) in the metal 235 matching the radius portions where the cutting pieces and the cutting profiles pass.
Cutting pieces 525 and cutting profiles 527 are preferably selectively mountable in various locations along the length of edge slots 518 to vary the distance between axis T-T and the forward or cutting edge 544 of bed 512 . They optionally may also be mountable along the width of bed 512 . For example, two edge slots 518 are illustrated along one side of plate 513 . The cutting pieces on that side can be arranged in the inner or outer edge slots to accommodate metal widths corresponding to different lengths for example lengths L 1 and L 2 as discussed with respect to FIG. 7 .
If desired, an optional logo stamping piece 520 may be aligned with an optional logo stamping slot 519 . The logo stamping piece may be used to stamp the imprint of graphics or text into the sheet metal to apply a logo, sizing indicia or other information as desired.
Progressive die arrangement 500 further includes a bending assembly 550 illustrated in detail in FIGS. 13-15 . Bending assembly 550 is arranged adjacent the forward edge 544 of cutting assembly 510 , to receive sheet metal 235 advanced through bed 512 . Bending assembly 550 includes a lower die 560 and an upper die 580 . Upper die 580 is mounted on upper carrying plate 520 . Upper die 580 includes a cutting bar 584 , preferably replaceable, which forms a shearing relationship with a lower cutting bar 546 along edge 544 to cut extending sheet metal material into blanks as the die arrangement compresses.
Lower die 560 includes a radiused male portion forming a radius and diameter corresponding to the desired inner arcuate radius and curve of the saddle to be formed. The radius may extend for approximately 180°, or optionally may include a slight variation or be slightly oversized to accommodate expected spring back of the metal material being bent. Optionally arranged on lower die 560 are partial or full ribs 564 to press corresponding partial or 180° ribs into the metal blank being bent. Lower die 560 optionally but preferably includes slightly tapered flared portions 567 at each end to impart a flare to the width edges of the blank 230 being bent. Optionally, lower die 560 can be arranged to accommodate blanks of length L 1 or L 2 as discussed with respect to other embodiments herein.
Preferably, the center of the male bending portion is spaced from forward edge 544 at a distance corresponding to half of the distance between the cutting tips of the cutting pieces 527 along trim axis T-T and forward edge 544 .
Upper die 580 has an upper female radiused bending portion matching and complementary to the male bending portion of lower die 560 . The female bending portion allows, for example with indentations or grooves, for partial or full ribs 564 to press ribs of lower die 560 into the metal being bent.
In operation of the illustrated progressive die, shown in FIGS. 16-18 , a ribbon or strip of metal 235 is fed into bed 512 via entry slot 514 . Prior to the introduction of the metal, cutting pieces 527 and cutting punches 525 are arranged at a distance from shearing edge 544 corresponding to the width of the desired blank 230 to be cut and then formed into the desired circumference measurement of the saddle being produced. Ejector assembly 590 is not illustrated in FIGS. 16-18 for ease of reference.
In a loading step, the leading edge of metal 235 is advanced into bed 512 until the forward edge is adjacent the shear edge of cutting bar 546 . Optionally, the metal may be advanced further or less; however, a scrap portion will typically need to be cut and discarded in the first cycle or two of the die assembly to create a leading edge with two rounded corners.
In a first cycle of operation, trimming assembly 510 and bending assembly 550 compress concurrently to shear off any excess material extending beyond cutting bar 546 and also to punch radiused convex indentations as cut-out shapes 255 along axis T-T into the metal material. Upon completion of the first compression and release cycle, the metal strip is advanced a distance through the die. In the next position, illustrated in FIG. 16 , the forward or leading portion of the metal 235 has rounded corners. Additionally, the next portion in which the radiused indentations 255 were made along an axis T-T is aligned with the forward edge 544 and cutting bar 546 . The forward portion of the metal extends between lower die 560 and upper die 580 .
Upon the next compression cycle, carrying plate 520 is lowered to simultaneously lower cutting pieces 525 and upper die 580 . During the compression step, cutting bars 584 and 546 cut the metal material 235 along one axis T-T, leaving a separated blank 230 which is then bent between the upper and low dies 580 and 560 . Simultaneously, cutting pieces 525 are punching the next radiused indentations 255 into the metal of material 235 along the next axis T-T. Each compression and cutting cycle by punches 525 forms two rounded corners 260 on one side of an axis T-T and two rounded corners 260 on the opposite side of the axis T-T. When the metal is advanced and then cut along that axis T-T, these form rounded trailing corners of a prior blank and rounded leading corners on the edge of the next blank.
As the die closes in the second and successive iterations as illustrated in FIGS. 17 and 18 , the upper die 580 and the lower die 560 contact and hold the metal piece between them in a three point contact grasp. As the metal is cut and the dies continue to compress, the metal is bent around the male radius until the desired bend arc has been imparted to the blank.
Upon completion of a compression cycle, once the die portions are separated as seen in FIG. 19 , the formed arcuate saddle 230 may be removed from lower die 560 . The metal material is then advanced a distance to provide the next portion of material to be cut off and bent in bending assembly and the next portion of material to be cut with indentations 255 in the trimming assembly. The timing of compression cycles, removal of finished saddles and advancing material is preferably synchronized. The operation may be repeated as desired to form multiple arcuate saddles with rounded corners.
In certain preferred embodiments, an ejector mechanism such as ejector assembly 590 can be used to eject a formed arcuate saddle from lower die 560 , for example onto a gravity slide 599 into a collection area. Details of an example ejector assembly 590 are illustrated in FIGS. 19-22 among others. In the illustrated embodiment, ejector assembly 590 includes a longitudinal arm 592 extending alongside and parallel to the base of lower die 560 . In its lowered position, arm 592 lies between lower die 560 and bed 512 . Preferably a scraper portion 594 is formed with or attached to arm 592 , although alternately the arm can directly function as the scraper portion. Scraper portion is arranged along selected portions or entirely along the length of lower die 560 and extends closely adjacent the face of lower die 560 .
Ejector assembly 590 includes two radial legs 597 having outer ends formed with or attached to opposing ends of arm 592 and inner ends aligned along a longitudinal axis defined by a pair of pivot points. At least one of the inner leg ends is mounted to an axle portion 596 as a crank arm at a fixed angular relationship which allows and causes the radial legs 597 , arm 592 and scraper portion 594 to rotate around the pivot point and lower die 560 when the axle portion 596 is rotated. One end of ejector assembly 590 includes a rotation mechanism 598 operable to rotate axle portion 596 and thus ejector assembly 590 on demand. In one example embodiment, rotation mechanism 598 includes a compressed air powered cylinder which expands and contracts and corresponding rotates a crank arm or gearing inside rotation mechanism 598 to correspondingly rotate the axle and ejector arm 592 .
Preferably the closest separation distance between scraper portion 594 and the face of lower die 560 is less than the thickness of the sheet metal material being used. In one embodiment, when ejector assembly 590 is operated, scraper portion 594 impacts the lower edge of the finished saddle and propels the saddle off of the lower die and onto slide 599 directed to a collection point. The pivot axis may be aligned with the axis defined by the radius of die 560 . Alternately, scraper portion 594 may contact the surface or other aspects of the finished saddle and may follow a path not corresponding to the radius of the lower die, such as a radial path eccentric to the die or following a tangential approach path. In certain embodiments, engagement features such as rubber feet or pads may be used to allow the ejector assembly to contact and propel the saddle while not wearing on the lower die.
In certain preferred embodiments, compressive die assembly 500 and other arrangements herein include appropriate sensors and PLCs to monitor material within the assembly before, during and after compression cycles. Such sensors may signal operational readiness states. Preferably sensors may be used to detect whether material is within bed 512 and whether material is present and ready to be bent between lower die 560 and upper die 580 . Further a sensor and PLC preferably detects when an arcuate saddle has been formed and, upon sufficient separation of the dies, triggers the ejector assembly 590 to eject the finished saddle from lower die 560 . Completion of a compression cycle and ejection of a finished saddle preferably further is synchronized with a signal to an automated feed mechanism to advance the metal material the next desired distance within arrangement 500 for the next cycle.
A further example embodiment of a manufacturing arrangement is illustrated in FIGS. 23 , 23 A, 23 B and 24 . FIGS. 23 , 23 A and 23 B show a cutting assembly 610 and FIG. 24 shows a roll bending assembly 650 .
Cutting assembly 610 includes a bed 612 carried on a base plate 611 . A sheet metal path sized to receive sheet metal material is formed along bed entry 614 between side rails 616 . Bed 612 further includes two slide rails 618 along the metal path, which slightly raise the metal material as it is fed into the assembly. Bed 612 further defines an inset or lowered area 660 between slide rails 618 . A rib block 662 can be placed within inset area 660 . In certain embodiments, rib block 662 includes upward protruding rib portions 664 along all or a portion of the block length. Rib block 662 preferably can be mounted at selected desired positions within inset area 660 to corresponded to desired placement of rib indentations in the metal material.
In the illustrated embodiment, the tops of slide rails 618 are slightly taller than the height of protruding rib portions 664 so that material travelling over the slide rails travels above protruding rib portions 664 . In this arrangement, slide rails 618 are preferably mounted within slots in bed 612 . Specifically, slide rails 618 are resiliently supported by springs within the bed to allow slide rails 618 to depress under pressure during the compression cycle and to be biased to rise upward when the pressure is released.
The forward portion of bed 612 defines a lower cutting profile 680 . Lower cutting profile extends lengthwise across the width of bed 612 , and preferably corresponds in length to the width of the metal material to be cut. Lower cutting profile 680 has two convex radiused portions at each end. The radiused portions extend inward from the edges to a longitudinal channel connecting the radiused portions at opposing ends of the profile. An exit slide 699 is arranged along the path forward of cutting profile 680 .
The upper portion of assembly includes carrying plate 620 arranged in a compressive arrangement with bed 612 . Carrying plate 620 includes a stamping portion 626 arranged opposite slide rails 618 and ribs 664 . Stamping portions 626 includes clamping rails 628 arranged opposite sliding rails 618 . An upper rib block is mounted between clamping rails 628 and aligned opposite lower rib block 662 . The upper rib block defines rib portions complimentary to the rib portions in the lower rib block, such a grooves corresponding to and aligned with protruding rib portions 664 .
The forward portion of carrying plate 620 includes an upper cutting or punch portion 684 . Punch portion 684 is aligned with the placement and length of lower cutting profile 680 across the width of bed 612 , and preferably corresponds in length to the width of the metal material to be cut. Punch portion 684 is complementary in size and shape to lower cutting profile 680 , and defines two concave radiused portions at each end which are connected by a thin punch blade.
In operation, a coil or ribbon of metal material is fed into assembly 610 via entry 614 . As the metal is advanced, it slides upward and over sliding rails 618 and thus travels above protruding ribs 664 . In the loading cycle, the forward edge of the metal is advanced at least slightly forward of cutting profile 680 . Carrying plate 620 is then compressed downward. During the downward compression, clamping rails 628 contact the metal material and depress it, correspondingly depressing sliding rails 618 . Depression of sliding rails 618 , allows the metal material to bear against the protruding rib portions 664 which then stamps the metal between the protruding rib portions 664 and the corresponding rib portions in the upper rib block to form rib indentations. Upon upward motion of carrying plate 620 , sliding rails 618 rise, in turn raising the material above the protruding rib portions 664 , enabling the material to travel forward without hindrance by the rib portions.
Concurrently, with stamping rib indentations into the material, punch portion 684 engages the metal against lower cutting profile 680 in a shearing arrangement which cuts a piece of material from the metal. The cut shape forms convex rounded corners on the trailing edge of the metal material forward of cutting profile 680 and forms convex rounded portions on the leading edge of the material rearward of cutting profile 680 . Additionally, the blade of punch portion 684 cuts the material along the channel of profile 680 , separating metal material forward of cutting profile 680 from the material rearward of cutting profile 680 . The separated metal can then be removed from assembly 610 , for example by being pushed to fall along slide 699 .
After upward movement of carrying plate 620 , the metal material is advanced forward a predetermined distance corresponding to the circumferential width of the saddle to be formed. This places the metal material containing the rib indentations stamped in the prior cycle forward of cutting profile 680 . Upon the next compression cycle, cutting profile 680 and punch portion 684 forms convex rounded corners on the trailing edge of the metal material forward of cutting profile 680 and separate the material as a flat, ribbed blank of material with rounded corners. Currently, rib portions are stamped into the next portion of the metal material. The compression and advancement cycle can be repeated to create additional flat, ribbed saddle blanks.
In a separate step, using a manual or automated feed, the separated blank is fed into a roll bending assembly 650 which bends the blank into an arcuate shape. An example roll bending assembly 650 based on an Acrotech model 1618 machine, with a flared die, is illustrated in FIG. 24 .
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. | Certain embodiments of the present invention relate to arcuate saddles typically used to anchor and suspend insulated or non-insulated pipes. Rounded corners on the saddles facilitate comfortably introducing and placing the saddles into hangers as well as improving use. Certain embodiments of the present invention involve methods of manufacturing arcuate saddles with rounded corners. | 5 |
RELATED APPLICATION
[0001] This application claims the benefit of U.S. Provisional Patent Application Ser. No. 61/719,158 filed Oct. 26, 2012.
FIELD OF THE INVENTION
[0002] The present invention provides products including a least two reactants encapsulated in microdroplets which in turn are encapsulated by a coating of hydrophobic colloidal particles. The two reactants remain separately encapsulated up until the desired time of release at which time the reactants are released by mechanical action of the mixed colloidal particles such that when the two kinds of colloidal particles are mixed and mechanically treated, the reactants are released and whereupon the reactants react to form a desired product.
BACKGROUND OF THE INVENTION
[0003] In many fields of application including but not limited to laundry or hard surface cleaning, personal hygiene, cosmetics, hair care, oral care, paints and finishes and animal nutrition, it is often highly desirable to deliver reactive ingredients at the point of need in their active state, such that beneficial reactions may take place when and where desired.
[0004] Non-limiting examples of such reactions may be bleaching of stains, sanitizing of hands, or formation of hard-set surface finishes. In all cases, a common difficulty to be overcome is the protection of the reactive ingredients up to the point of need, then the controlled release or controlled reaction of the same when desired.
[0005] A number of methods have been taught to overcome these issues including the use of dual-component packaging containers (for example as disclosed in U.S. Pat. No. 3,685,645 or U.S. Pat. No. 5,881,869 to separate reacting materials prior to use, and the employment of a wide variety of encapsulating techniques including the use of encapsulating gels, polymers, waxes and films (see for example teaching disclosed in U.S. Pat. No. 5,258,132 or U.S. Pat. No. 6,248,364 or U.S. Pat. No. 7,491,687).
[0006] While initially effective, a significant drawback of the dual-component packaging approach is that it is expensive to manufacture, cumbersome to operate and difficult to maintain in optimum state; a very common drawback being the consumption of one part of the reacting formulation at a faster rate than the other, leaving an ineffective residual amount at the end of use.
[0007] The most significant drawback of the available encapsulating approaches is that while often effective in preventing degradation of the reacting ingredients during storage and before use, they are generally less effective at providing a sufficient release of the ingredients at the point of need. While this may not present a significant problem in some applications where steady release over a period of time is desired, for example fragrance release from fabric conditioning products as disclosed U.S. Pat. No. 4,446,032 or U.S. Pat. No. 7,491,687, it is a drawback in a range of applications where rapid release and reaction is required, for example bleaching fabrics or hard surfaces, treatment of hair or teeth, sanitization of hands, curing of paints and finishes and provision of nutrients.
[0008] Furthermore, it is often the case that in order to overcome the above described problems, product formulators have taken recourse to using either less effective, less safe or less desirable ingredients which present fewer challenges in stability or reactivity. One such non-limiting example of this approach is in the field of hand hygiene where typically either chemical based biocides such as triclosan or chlorohexidine gluconate (CHG) are employed, or alcohol based sanitizers are used.
[0009] While stable in storage, a drawback of both is that they are typically only available in liquid based form and presented either as a liquid, a gel or foam. This requires the storage and logistical movement of significant quantities of liquid, which is cumbersome, expensive and potentially hazardous.
[0010] A further significant drawback of the chemical-based products is that all of the known and available bactericides are potentially hazardous to humans and are persistent on the skin.
[0011] A further drawback of the alcohol-based products available is the risk of fire due to the inherent flammability of the substances used.
[0012] Hydrogen Peroxide is well known in the art as a safe and highly effective disinfectant and sanitizer, however its use in hand hygiene has been restricted in the past due to a lack of effective means to overcome storage stability and rapid release challenges associated with this ingredient.
[0013] The concept of “dry water” has been well described in the art including for example publications such as “Binks, B. P.; Murakami, M; “Phase inversion of Particle-stabilized Materials from Foams to Dry Water”, Nature Materials, Volume 5, November 2006” or disclosures such as U.S. Patent Publication No. 20030161855 or the earlier U.S. Pat. No. 5,122,518. Dry water is formed when aqueous droplets are finely dispersed and stabilized by a hydrophobic powder material such as hydrophobized fumed silica or finely dispersed metal oxides. The appearance of “dry water” is as a fine, flowable powder which can be storage stable when handled correctly and within which the aqueous medium is maintained in an isolated state.
[0014] The idea of using “dry water” to carry effective ingredients including a range of biocides has been taught within the art such as U.S. Pat. No. 5,122,518, however the compositions taught within are generally unstable over long periods of time. Further “dry water” mixtures including hydrogen peroxide are taught by U.S. Patent Publication No. 2009/0252815 wherein a range of hydrophobized silicas are proposed as the “protecting” phase and the resulting “dry water” powders are subsequently formulated within a range of cream formulations. Controlled, steady “time delayed” release of the hydrogen peroxide is well described by this teaching.
[0015] In both of the above and all other examples within the art however, no effective means to ensure rapid and effective release of the reacting ingredients are provided, such that while effectively “protected” during storage, no guarantee of rapid effectiveness at the point of need can be provided. Within U.S. Patent Publication No. 2009/0252815 for example, applications such as skin brightening or acne treatment are proposed wherein such “time delayed” release may be preferable, however this behavior would be wholly unsuitable and ineffective within the context of other applications such as skin sanitization or hard surface cleaning wherein a rapid “burst” of reaction is required.
[0016] U.S. Patent Publication No. 2003/0157188 provides a bactericide useful as a shelf life extender for produce and other food products. The bactericide is an aqueous solution formed from water, copper sulfate pentahydrate and a reagent, which can either be an acid or hydrogen peroxide. The bactericide is applied as a coating on the food product and is especially useful in extending the shelf life of fruits and vegetables. Other applications of the bactericide include treatment of drinking water, bacteria and algae control in pools and natural bodies of water, and as a disinfectant in cleansers. The bactericide may further comprise a concentration of phosphoric acid.
[0017] U.S. Patent Application Publication No. 2008/0041794 teaches methods of decontaminating water, catalysts therefor and methods of making catalysts for decontaminating water to neutralize contaminants including organic and non-organic contaminants, such as aromatic compounds and microorganisms, e.g. bacteria. A heterogeneous catalyst is formed by incubating a polymeric resin with a transition metal-salt solution, e.g. a CuSO 4 solution. The contaminated water is treated by immersing the resulting heterogeneous catalyst in the contaminated water with hydrogen peroxide. The use of the Fenton reaction for providing a bactericide is disclosed.
[0018] U.S. Pat. No. 4,311,598 relates to processes and compositions for the disinfection of aqueous media and particularly bacteria-containing aqueous effluents, e.g. treated municipal sewage or effluents from paper or food-processing industries, employing hydrogen peroxide-containing compositions as an alternative to chlorine. Specifically, the disinfectant comprises a combination of hydrogen peroxide, a soluble copper salt such as copper sulphate and an autoxisable reducing agent such as ascorbic acid or sodium sulphite, which can be employed in dilute concentrations at pH from 6 to 9, preferably 6.5 to 8. Particularly preferred combinations of the components are of mole ratios 1:1 to 60:1 of hydrogen peroxide:copper: and 5:1 to 1:1.2 copper:reducing agent.
[0019] U.S. Pat. No. 5,780,064 provides an aqueous germicidal composition and related method for the treatment or prevention of infectious diseases of the hoof in animals, comprising a copper salt (such as copper sulfate), a quaternary ammonium compound, and a peroxide is disclosed.
[0020] U.S. Pat. No. 5,681,591 discloses a composition useful for disinfecting a contact lens comprising a substantially isotonic, aqueous liquid medium containing hydrogen peroxide in an amount effective to disinfect a contact lens contacted with the aqueous liquid medium, and a hydrogen peroxide reducing agent dissolved in the aqueous liquid medium in an amount effective to enhance the antimicrobial activity of the aqueous liquid medium. Preferably, the composition further includes transition metal ions in an amount effective to further enhance the antimicrobial activity of the aqueous liquid medium and is substantially free of peroxidase.
[0021] U.S. Patent Publication No. 2010/0015245 describes a method of inhibiting biofilms by combinations of antimicrobials, particularly with their synergistic activity against biofilms. The antimicrobials include combination of copper ion and quaternary ammonium compound or combination of copper ion and peroxide. The invention also include methods for inhibiting biofilm-induced microbial corrosion or fouling.
[0022] U.S. Patent Publication No. 2010/0074967 teaches disinfectant or sterilant compositions, which are human safe, e.g., food grade or food safe. In one embodiment, an aqueous disinfectant or sterilant composition can comprise an aqueous vehicle, including water, from 0.001 wt % to 50 wt % of a peracid, and from 0.001 wt % to 25 wt % of a peroxide. Additionally, from 0.001 ppm to 50,000 ppm by weight of a transition metal based on the aqueous vehicle content can also be present. The composition can be substantially free of aldehydes. Alternatively or additionally, the transition metal can be in the form of a colloidal transition metal.
[0023] U.S. Patent Publication No. 2009/0252815 discloses pulverulent mixtures comprising hydrogen peroxide and hydrophobized, pyrogenically prepared silicon dioxide powder, preferably with a methanol wettability of at least 40. The pulverulent mixtures exhibit good storage stability and can be used for the controlled release of hydrogen peroxide and/or oxygen. The invention also includes methods of making these pulverulent mixtures and methods of using the mixtures in detergents, cleaning compositions, topical medications, antimicrobials and other products.
[0024] Methods are taught for the preparation of the pulverulent mixtures in which hydrogen peroxide is present in the form of drops of an aqueous solution which are enclosed by hydrophobized silicon dioxide. Such pulverulent mixtures can be produced by the intensive mixing of an aqueous hydrogen peroxide solution with hydrophobized silicon dioxide. Any mixing unit which can deliver sufficient energy to ensure a rapid division of the liquid into small droplets, which are then immediately surrounded by hydrophobized silicon dioxide powder, is suitable for this purpose.
[0025] U.S. Pat. No. 6,861,075 discloses a storage-stable biocidal aerated gel composition that comprises from 30 to 97% by weight of water, from 0.2 to 5% by weight of a gelling agent selected from xanthan gum, sodium alginate and neutralised carboxyvinyl polymer from 2 to 5% by weight of a fine particulate, hydrophobic silicone-treated silica having a surface area of from 80 to 300 m2/g and from 0.004 to 20% by weight. The composition is a biocide which is in the form of fine particles of an aqueous gel containing the water, gelling agent and the biocide, the surfaces of which are coated with a coating of the finely particulate hydrophobic silica. The biocidal aerated gel composition is recommended for use in controlling pests using one or more appropriate biocides in the composition.
[0026] U.S. Pat. No. 4,867,988 provides a stable oxygen-containing dentifrice in powder, paste or liquid form which contains a carrier and evenly dispersed therethrough a multiplicity of microencapsulated droplets of an oxygen releasing agent such as hydrogen peroxide. The walls of the microcapsules are rupturable upon mechanical manipulation of the dentifrice as it occurs during the toothbrushing action for releasing the oxygen-containing agent. The microcapsules are, however, not formed from hydrophobic silica, and are provided as a single component formulation only.
[0027] U.S. Patent Publication No. 2006/0276366 teaches a two-part hard surface treatment composition which is formed by the admixture of two aqueous compositions, particularly (a) an aqueous alkaline composition comprising a bleach constituent, with (b) an aqueous acidic composition comprising a peroxide constituent, which compositions are kept separate, but which are admixed immediately prior to use or upon use to form a foamed hard surface treatment composition.
[0028] U.S. Patent Publication No. US2006/0257498 provides an antimicrobial system having an amine part and an oxygen part, where the two parts are mixed prior to use to form an improved antimicrobial composition.
[0029] U.S. Patent Publication No. US2010/0143496 discloses a two-part disinfectant system which can be used to disinfect surfaces. The system includes a first chamber containing a first solution and a second chamber containing a second solution. The first solution can include an alcohol, an organic carboxylic acid, and from 0.01 ppm, to 1,000 ppm by weight of a transition metal or alloy thereof based on the first solution weight content. The second solution can include hydrogen peroxide. The system further includes a dispenser through which the system is configured to mix and dispense the first solution and the second solution immediately before being dispensed. A peracid composition is formed upon mixing of the first and second solutions.
SUMMARY OF THE INVENTION
[0030] Accordingly, it is an object of the present invention to provide a means of effectively encapsulating and storing a range of reaction reagents suitable for use in a wide variety of potential applications as illustrated through the non-limiting list given above. Furthermore, it is an object of this invention to provide with such encapsulating systems a means of rapid release and effective reaction of the reaction reagents at the point/time of use. Specifically this is achieved by the use of multi-component encapsulated powder systems wherein one reaction reagent is maintained in isolation from one or more other reaction reagents up to the point of need when these are brought together by mechanical action.
[0031] Thus, an embodiment of the present invention provides a system for storing and releasing complementary reaction reagents, comprising:
a first part comprising colloidal particles, the colloidal particles coating and encapsulating microdroplets, the microdroplets comprising an aqueous solution including a first reaction reagent to form a first encapsulate containing said first reaction reagent; at least a second part comprising colloidal particles, the colloidal particles coating and encapsulating microdroplets, the microdroplets comprising an aqueous solution including at least a second reaction reagent to form a second encapsulate containing said at least a second reaction reagent, said first and said at least a second reaction reagent being selected such that upon being mixed the first and at least a second reaction reagent chemically react to form reaction product; and wherein in use the first and at least second parts, being commingled together, are subjected to mechanical action causing breakage of the first and at least second encapsulates releasing and mixing the first and at least second reaction reagents to form said reaction product.
[0035] In an embodiment, the first and second colloidal particles are hydrophobized colloidal particles, which can be fumed silica.
[0036] The system can be formulated as a skin sanitization product, in which the first aqueous solution comprises a peroxide, a first acid and water, and wherein the second aqueous solution comprises a salt of a transition metal, a second acid and water; and
[0037] wherein in use said first and second parts are applied on a user's skin and upon being subjected to mechanical action said first and second encapsulates are broken, releasing and mixing said first aqueous solution with said second aqueous solution.
[0038] The first acid and said second acids can be independently selected from the following: phosphoric acid, phosphonic acid, citric acid, sulfonic acid, sulphuric acid, hydrochloric acid, itaconic acid, methanoic acid, alpha-hydroxy acid, maleic acid, gluconic acid, propanoic acid, butanoic acid, pentanoic acid, hexanoic acid, heptanoic acid, octanoic mono-acid, octanoic di-acid, octanoic tri-acid, beta-hydroxy-acid, sodium tripolyphosphate, ethylenediaminetetraacetic acid, diethylenetriaminepentaacetic acid, N-(hydroxyethyl)-ethylenediami-netriacetic acid, 2-hydroxyethyliminodiacetic acid, benzoic acid, salicylic acid, aminobenzoic acid.
[0039] The transition metal can be selected from the following: iron, copper, manganese, cobalt, vanadium, titanium, chromium, lead, aluminum, gold and silver.
[0040] The first acid can be present in the first part in a range from about 0.1% to about 10% by weight. The second acid can be present in the second part in a range from about 0.1% to about 10% by weight.
[0041] The peroxide can be hydrogen peroxide present in the first part in a range from about 0.1% to about 70% by weight.
[0042] The salt can be present in the second part in a range from about 0.1% to about 70% by weight.
[0043] The water can be present in the first part in a range from about 50% to about 99% by weight. The water can be present in the second part in a range from about 50% to about 99% by weight.
[0044] When present, fumed silica can be present, for example, within the first and second parts in an amount less than about 5% by weight.
[0045] In embodiments, the transition metal is present at substantially the same molar concentration in the first part as the peroxide is present in the second part.
[0046] The system can be formulated as a bleach system in which the first aqueous solution comprises water and one or combination of percarboxylic acid and bleach activator, and wherein the second aqueous solution comprises a salt of a transition metal and water. The one or combination of percarboxylic acid and bleach activator can be present in the first part in a range from about 1% to about 50% by weight. The salt can be present in the second part in a range from about 0.001 ppm to about 49% by weight. The system can further include a third part the comprises one or combination of surfactant, enzyme, salt, perfume, colourant, and dye transfer inhibition agent.
[0047] In an embodiment, the invention is a skin sanitization product, comprising:
a) a first part comprising first hydrophobized colloidal particles, said first hydrophobized colloidal particles containing first microdroplets, said first microdroplets comprising a first aqueous solution of a peroxide, a first acid and water to form a first encapsulate containing a first reaction element; b) at least a second part comprising second hydrophobized colloidal particles, said second hydrophobized colloidal particles containing second microdroplets, said second microdroplets comprising a second aqueous solution of a salt of a transition metal, a second acid and water to form a second encapsulate containing a second reaction element; and wherein in use said first and second parts are mixed together on a user's skin to form a mixture and upon being subjected to mechanical action said first and second encapsulates are broken, releasing and mixing said first and second reaction elements.
[0051] In a particular embodiment, the skin sanitization product includes a first part which comprises, by weight:
about 84% water; about 1% phosphoric acid (75%); about 12% hydrogen peroxide 50%; and about 3% fumed silica; and
a second part which comprises, by weight:
about 92.6% water; about 0.4% phosphoric acid (75%); about 4.0% copper sulphate; and about 3.0% fumed silica.
[0054] In invention provides a bleach product, comprising:
a) a first part comprising first hydrophobized colloidal particles, said first hydrophobized colloidal particles containing first microdroplets, said first microdroplets comprising a first aqueous solution of water and one or combination of percarboxylic acid and bleach activator, to form a first encapsulate containing a first reaction element; b) at least a second part comprising second hydrophobized colloidal particles, said second hydrophobized colloidal particles containing second microdroplets, said second microdroplets comprising a second aqueous solution of a salt of a transition metal and water to form a second encapsulate containing a second reaction element; and wherein in use said first and second parts are mixed together to form a mixture and upon being subjected to mechanical action said first and second encapsulates are broken, releasing and mixing said first and second reaction elements.
[0058] In an embodiment, the first part of the bleach product comprises, by weight:
about 93% water; about 4.0% sodium percarbonate; about 3% fumed silica; and the second part comprises, by weight: about 96.98% water; about 0.02% Mn(Bcyclam)Cl 2 ; and about 3.0% fumed silica.
[0061] The bleach product can further comprise a third part, wherein the third part comprises, by weight, about 50.0% zeolite; about 25.0% linear alkylbenzene sulphonate; about 15.0% C12-15 EO5 alcohol ethoxylate; and about 10.0% sodium silicate.
[0062] Also provided is a method for producing a system for storing and releasing complementary reaction reagents, comprising the steps:
a) dissolving at least one first reaction reagent in water to form a first aqueous solution; b) mixing and agitating said first aqueous solution with hydrophobized colloidal particles to form first colloidal particles encapsulating droplets of said first aqueous solution to form a first encapsulate; c) dissolving at least one second reaction reagent in water to form at least one second solution; d) mixing and agitating said second solution with said hydrophobized colloidal particles to form at least second colloidal particles encapsulating droplets of said second solution to form a second encapsulate; and e) mixing said first and second encapsulate without breaking said first and second encapsulates to form an inter-dispersed composition of said first and second encapsulates.
[0068] Steps b) and d) can be accomplished with one of a high-shear rotary mixer and a blender.
[0069] The hydrophobized colloidal particles can comprise fumed silica, which may be present within said first and second colloidal particles in an amount less than about 5% by weight. The hydrophobized colloidal particles comprise metal oxide powders.
[0070] The at least one first reaction reagent can comprise a peroxide, a first acid and water, and the at least one second reaction reagent can comprise a salt of a transition metal, a second acid and water. The transition metal in the salt can be selected from the group consisting of iron, copper, manganese, cobalt, vanadium, titanium, chromium, lead, aluminum, gold and silver.
[0071] The first acid can be dissolved in the first solution in a range from about 0.1% to about 10%. The second acid can be dissolved in said second solution in a range from about 0.1% to about 10%. The peroxide can be hydrogen peroxide dissolved in the first solution in a range from about 0.1% to about 70%, and the salt can be dissolved in the second solution in a range from about 0.1% to about 70%.
[0072] After step b), the water can be present in the first solution in a range from about 50% to about 99%. After step d), the water can be present in the second solution in a range from about 50% to about 99%.
[0073] The salt of a transition metal is preferably present at substantially the same molar concentration in the first colloidal particles as the peroxide is present in the second colloidal particles.
[0074] In embodiments, the at least one first reaction reagent comprises an aqueous solution of water and one or combination of percarboxylic acid and bleach activator, and the at least one second reaction reagent comprises an aqueous solution of a salt of a transition metal and water. The one or combination of percarboxylic acid and bleach activator can be dissolved in the first solution in a range from about 1% to about 50% by weight. The salt can be dissolved in the second solution in a range from about 0.001 ppm to about 49% by weight.
[0075] The method can further include the steps of:
mixing a third composition, comprising of one or combination of surfactant, enzyme, salt, perfume, colourant, and dye transfer inhibition agent; and mixing said inter-dispersed composition with said third composition.
[0078] A system of the invention can be as described above in which the first and second parts are included within a suitable carrier formulation selected from the group consisting of a cream, gel and paste.
[0079] The invention includes a method for delivering a skin sanitizing product, the method comprising:
(i) applying the product to the skin of a user, the product comprising a mixture of:
A) a first part comprising a first encapsulate comprising hydrophobized colloidal particles and microdroplets comprising an aqueous solution of a peroxide, a first acid and water; and B) at least a second part comprising a second encapsulate comprising hydrophobized colloidal particles and microdroplets comprising an aqueous solution of the salt of a transition metal, a second acid and water; and
(ii) subjecting the product to mechanical force by hand-rubbing the product on the user's skin with sufficient force to break open the first and second encapsulates to release and mix said components of the first and second parts with each other.
[0084] The hydrophobized colloidal particles of the first and second parts can comprise fumed silica.
[0085] The first acid and said second acid can each include, independently of the other, one or more of phosphoric acid, phosphonic acid, citric acid, sulfonic acid, sulphuric acid, hydrochloric acid, itaconic acid, methanoic acid, alpha-hydroxy acid, maleic acid, gluconic acid, propanoic acid, butanoic acid, pentanoic acid, hexanoic acid, heptanoic acid, octanoic mono-acid, octanoic di-acid, octanoic tri-acid, beta-hydroxy-acid, sodium tripolyphosphate, ethylenediaminetetraacetic acid, diethylenetriaminepentaacetic acid, N-(hydroxyethyl)-ethylenediami-netriacetic acid, 2-hydroxyethyliminodiacetic acid, benzoic acid, salicylic acid, and aminobenzoic acid.
[0086] The transition metal can be selected from the group consisting of iron, copper, manganese, cobalt, vanadium, titanium, chromium, lead, aluminum, gold and silver.
[0087] The first acid can be present in said first part in a range from about 0.1% to about 10% by weight. The second acid can be present in the second part in a range from about 0.1% to about 10% by weight. The peroxide can be hydrogen peroxide present in said first part in a range from about 0.1% to about 70% by weight.
[0088] The salt can be present in the second part in a range from about 0.1% to about 70% by weight. The water can be present in the first part in a range from about 50% to about 99% by weight. The water can be present in the second part in a range from about 50% to about 99% by weight.
[0089] The fumed silica can be present within the first and second parts combined in an amount less than about 5% by weight.
[0090] The salt can be present at substantially the same molar concentration in said first part as said peroxide is present in said second part.
[0091] In a particular embodiment of the method, the first part comprises, by weight: about 84% water; about 1% phosphoric acid (75%); about 12% hydrogen peroxide (50%); and about 3% fumed silica; and the second part comprises, by weight:
[0092] The invention includes a method for cleansing a surface, the method comprising the steps:
(i) applying the product to the surface, the product comprising a mixture of:
(I) a first encapsulate comprising hydrophobized colloidal particles encapsulating an aqueous solution of at least one first reaction reagent; and (II) a second encapsulate comprising hydrophobized colloidal particles encapsulating an aqueous solution of at least one second reaction reagent; wherein the first and second reagents chemically react when exposed to each other to form a cleansing agent;
(ii) subjecting the product to mechanical force by hand-rubbing the product on the surface with sufficient force to break open the first and second encapsulates to release and mix said first and second reaction reagents and thereby expose the surface to the cleansing agent.
[0098] Each of the first and second encapsulate can include hydrophobized colloidal particles comprising fumed silica and microdroplets of the aqueous solution formed by high-shear rotary mixing and blending. The fumed silica can be present within the first and second encapsulates in an amount less than about 5% by weight.
[0099] Each of the first and second encapsulates can comprise hydrophobized colloidal particles comprising metal oxide powders and microdroplets of the aqueous solution formed by high-shear rotary mixing and blending.
[0100] According to another aspect of the method, said at least one first reaction reagent comprises a peroxide, a first acid and water, and said at least one second reaction reagent comprises a salt of a transition metal, a second acid and water.
[0101] The first acid and said second acids can each be selected from the group consisting of phosphoric acid, phosphonic acid, citric acid, sulfonic acid, sulphuric acid, hydrochloric acid, itaconic acid, methanoic acid, alpha-hydroxy acid, maleic acid, gluconic acid, propanoic acid, butanoic acid, pentanoic acid, hexanoic acid, heptanoic acid, octanoic mono-acid, octanoic di-acid, octanoic tri-acid, beta-hydroxy-acid, sodium tripolyphosphate, ethylenediaminetetraacetic acid, diethylenetriaminepentaacetic acid, N-(hydroxyethyl)-ethylenediami-netriacetic acid, 2-hydroxyethyliminodiacetic acid, benzoic acid, salicylic acid, and aminobenzoic acid.
[0102] The transition metal in said salt can be selected from the group consisting of iron, copper, manganese, cobalt, vanadium, titanium, chromium, lead, aluminum, gold and silver.
[0103] The first acid can be dissolved in said first encapsulate solution in a range from about 0.1% to about 10%. The second acid can be dissolved in said second encapsulate solution in a range from about 0.1% to about 10%. The peroxide can be hydrogen peroxide dissolved in said first encapsulate solution in a range from about 0.1% to about 70%.
[0104] The salt can be dissolved in the second encapsulate solution in a range from about 0.1% to about 70%.
[0105] The water can be present in said first encapsulate solution in a range from about 50% to about 99%, and water can be present in the second encapsulate solution in a range from about 50% to about 99%.
[0106] The salt of a transition metal is typically present at substantially the same molar concentration in said first encapsulate as the peroxide is present in said second encapsulate.
[0107] The at least one first reaction reagent can comprise microdroplets of an aqueous solution of water and one or combination of percarboxylic acid and bleach activator, and the at least one second reaction reagent can comprise microdroplets of an aqueous solution of a salt of a transition metal and water. The one or combination of percarboxylic acid and bleach activator can be dissolved in the first solution in a range from about 1% to about 50% by weight. The salt can be dissolved in the second solution in a range from about 0.001 ppm to about 49% by weight.
[0108] An embodiment of the present invention provides a skin sanitization product comprising a mixture of two dry powder components, where each dry powder component is formed from a phase inversion process involving vigorous mixing. The dry powder is stabilized by colloidal fumed silica particles, which assist in generating stable “dry water” microdroplets. One dry powder component comprises encapsulates containing microdroplets comprising an aqueous solution of hydrogen peroxide, and the other dry powder component comprises encapsulates containing microdroplets comprising an aqueous solution of copper sulphate or another suitable source of a transition metal ion. When the hand sanitization product is agitated by rubbing together of ones hands, the encapsulates rupture and the two aqueous solutions undergo a Fenton reaction upon contact. The Fenton reaction is catalyzed to produce hydroxyl free-radicals that generate an effective bactericidal dose.
DETAILED DESCRIPTION OF THE INVENTION
[0109] Generally speaking, the embodiments described herein are directed to a system for storing and delivering two or more reaction reagents stored in microdroplets coated and encapsulated by hydrophobic colloidal particles to be released at the point and time of use by mechanical agitation of the stored reaction reagents in the encapsulates which are commingled such that the mechanical action releases the reagents which then react to give a desired reaction product. As required, embodiments of the present invention are disclosed herein. However, the disclosed embodiments are merely exemplary, and it should be understood that the invention may be embodied in many various and alternative forms. Some features may be exaggerated or minimized to show details of particular elements while related elements may have been eliminated to prevent obscuring novel aspects.
[0110] Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting but merely as a basis for the claims and as a representative basis for teaching one skilled in the art to variously employ the present invention. For purposes of teaching and not limitation, the illustrated embodiments are directed to a system for storing and delivering two or more reaction reagents stored in encapsulated microdroplets to be released at the point and time of desired use.
[0111] As used herein, the phrase “dry water” means the technology of microencapsulating water or aqueous solutions using hydrophobized colloidal silica particles described in the art including for example publications such as “Binks, B. P.; Murakami, M; “Phase inversion of Particle-stabilized Materials from Foams to Dry Water”, Nature Materials, Volume 5, November 2006” or disclosures such as U.S.
[0112] Patent Publication No. 2003/0161855 or the earlier U.S. Pat. No. 5,122,518. The particles adsorb at the air/aqueous interfaces formed during vigorous agitation such that the formed aqueous microdroplets are stabilised by the adsorbed layer in the form of a finely dispersed dry powder. A thin layer of the powder settles between the liquid and the surrounding air and allows the coated water to retain a spherical shape for the droplet.
[0113] As used herein, the phrase “hydrophobized colloidal particles” means particles of fumed silica or metal oxides characterized as those with a methanol wettability of at least 40 and a specific surface area of between 10 and 400 m 2 /g, preferably between 80 and 300 m 2 /g.
[0114] As used herein, the phrase “microdroplets” means the droplets of water or aqueous solution finely dispersed within and stabilised by the adsorbed coating of hydrophobized fumed silica or metal oxides within the “dry water” composition. No definition or restriction upon the size or polydispersity of these droplets is implied or should be inferred from the informal use of the term “micro”.
[0115] As used herein, the terms, “comprises” and “comprising” are to be construed as being inclusive and open ended, and not exclusive. Specifically, when used in this specification including claims, the terms, “comprises” and “comprising” and variations thereof mean the specified features, steps or components are included. These terms are not to be interpreted to exclude the presence of other features, steps or components.
[0116] As used herein, the coordinating conjunction “and/or” is meant to be a selection between a logical disjunction and a logical conjunction of the adjacent words, phrases, or clauses. Specifically, the phrase “X and/or Y” is meant to be interpreted as “one or both of X and Y” wherein X and Y are any word, phrase, or clause. The present invention relates to shelf stable skin sanitization and bleach products and methods of their preparation and use. Each of the product components as well and methods of their preparation are described in detail below.
[0117] Broadly speaking, the present invention provides a system for storing and releasing complementary reaction reagents at a desired time. This system generally comprises a first part comprising first colloidal particles, the first colloidal particles encapsulating first microdroplets, the first microdroplets comprising a first aqueous solution including a first reaction reagent to form a first encapsulate containing said first reaction reagent; at least a second part comprising second colloidal particles, the second colloidal particles encapsulating second microdroplets, the second microdroplets comprising a second aqueous solution including at least a second reaction reagent to form a second encapsulate containing said at least a second reaction reagent; said first and said at least a second reaction reagent being selected such that upon being mixed the first and at least a second reaction reagent chemically react to form a reaction product; and wherein in use the first and at least second parts, being commingled together, are subjected to mechanical action causing breakage of the first and at least second encapsulates releasing and mixing the first and at least second reaction reagents to form said reaction product.
[0118] In an embodiment of the system, the colloidal particles are hydrophobized colloidal particles and the microdroplets are aqueous microdroplets, thus the system is referred to a “dry water” system. In this embodiment, the storage stable “dry water” powders containing a range of reacting ingredients within the dispersed aqueous phase are disclosed. Two or more “dry water” powders are independently produced, each containing within the dispersed aqueous phase one reagent of a reaction mixture such that these ingredients are stored safely and effectively without reacting with each other. It is further disclosed that the independently produced “dry water” mixtures may be co-mixed with each other in a way that does not promote the breakdown of the dispersions, such that what is produced is a single, fully inter-dispersed powder containing all reaction reagents but wherein such reaction reagents remain isolated from each other such that stability is maintained.
[0119] The fully inter-dispersed, storage stable “dry water” mixture may then optionally be included within a suitable carrier formulation such as a cream, gel or paste according to the requirements of a given application. At the point of use, the fully inter-dispersed “dry water” powder is applied either solely or as part of a suitable formulation to the skin, fabric, hard surface or other point-of-use environment as required and through mechanical action such as rubbing or squeezing the inter-dispersed “dry water” powder is forced to break up allowing for the rapid and effective reaction of the stored reactive ingredients at the point of use. Each element of the invention is described in detail below. The colloidal particles may include, but are not restricted to, fumed silica.
[0120] In an embodiment of the invention, the water used in the aqueous solutions is purified to have a low electrical conductivity, for example less than about 50 microsiemens. This low conductivity promotes a longer shelf life for the encapsulated aqueous solutions. Methods for purifying water are well known in the art and may, for example, include reverse osmosis. It will be readily appreciated, however, that this discussion of water is purely didactic and should not limit the invention in any manner.
[0121] The present invention has application to many technical areas and is not restricted to any one in particular. For example, the present system is applicable to such areas including, but not limited to, laundry or hard surface cleaning, personal hygiene, pre-op skin disinfection, skin sanitization, surface disinfection, anti-dandruff treatment, cosmetics, hair care, oral care, paints and finishes and animal nutrition to mention just a few. The invention finds utility in those areas where it is desirable to deliver reactive ingredients at the point of need in their active state, such that the chemical reactions of interest take place when and where desired.
[0122] Non-limiting examples of such reactions may be bleaching of stains, sanitizing of hands, nutrition of teeth, conditioning of hair, oxidation of free-radicals in the skin or formation of hard-set surface finishes. In all cases, a common difficulty to be overcome is the protection of the reactive ingredients up to the point of need, then the controlled release or controlled reaction of the same when desired.
[0123] The present invention will now be illustrated with the following exemplary, non-limiting Examples.
EXAMPLES
[0124] The example compositions involve using hydrophobized colloidal particles and the microdroplets are aqueous microdroplets each containing different chemical reagents.
“Dry Water” Stabilizing Ingredient
[0125] The “dry water” mixtures described within the present invention comprise in general terms an aqueous phase within which are contained the reacting elements and a stabilizing ingredient which acts to stabilize the “dry water” dispersion and ensure isolation during storage of the reacting elements. Hydrophobized fumed silica (silicon dioxide) is proposed as a suitable stabilizing ingredient, for example, but not limited to, materials such as Aerosil R812, Aerosil R104, Aerosil R106 and Aerosil R812S all produced by Evonik Degussa GmBH of Essen, Germany.
[0126] Suitable hydrophobized fumed silica materials are characterized as those with a methanol wettability of at least 40 and a specific surface area of between 10 and 400 m 2 /g, preferably between 80 and 300 m 2 /g. Since the stabilizing ingredient is present only to provide suitable dispersion and storage stability, it is desirable to minimize the quantity in which it is present.
[0127] Accordingly, the stabilizing ingredient should be present within the final inter-dispersed “dry water” powder at levels of less than 10% by weight, preferably less than 5% by weight.
Reacting Ingredients
[0128] Within the invention, a range of application areas are identified, each requiring the use of different suitable reactions in order to effect desired benefits. In all cases, at least two distinct reacting ingredients are identified (a “reaction mixture”) and separated through manufacture and storage in order to ensure stability up to the point of use. It is within the scope of “reacting mixtures” that a broad range of chemistries and hence applications can be defined, thus we propose that non-limiting suitable and identified “reaction mixtures” include:
Example 1
Hydrogen Peroxide+Transition Metal Ions (the Fenton Reaction) for Hand Sanitising Compositions
[0129] In one embodiment, the system provides a skin sanitization product, wherein the microdroplets encapsulated by an adsorbed coating of the first colloidal particles comprise an aqueous solution of a peroxide, acid and water, and wherein the microdroplets encapsulated by an adsorbed coating of the second colloidal particles comprise an aqueous solution of a salt of a transition metal, acid and water.
[0130] The Fenton reaction involves the use of transition metal ions, such as ions of iron, gold, silver, titanium, lead, aluminium, cobalt, chromium, vanadium, manganese, or copper though others are also used, to promote the breakdown on hydrogen peroxide to hydroxyl free-radicals. This reaction significantly increases the rapid effectiveness of hydrogen peroxide as a bleaching, oxidizing or biocidal active as it rapidly accelerates this critical breakdown step (free-radical production).
[0131] Within one embodiment of the invention, suitable compositions for effective production of the Fenton reaction at the point of use include the presence of hydrogen peroxide within the aqueous phase of one fraction of the stabilized “dry water” mixture at levels of between 1% and 70% by weight and preferably between 3% and 50% by weight.
[0132] Hydrogen peroxide is stabilized at low pH, therefore it is desirable to also include within the same dispersed aqueous phase a suitable acid buffer which may be selected from the list including but not limited to phosphoric acid, phosphonic acid, citric acid, sulfonic acid, sulphuric acid, hydrochloric acid, itaconic acid, methanoic acid, alpha-hydroxy acid, maleic acid, gluconic acid, propanoic acid, butanoic acid, pentanoic acid, hexanoic acid, heptanoic acid, octanoic mono-acid, octanoic di-acid, octanoic tri-acid, beta-hydroxy-acid, sodium tripolyphosphate, ethylenediaminetetraacetic acid, diethylenetriaminepentaacetic acid, N-(hydroxyethyl)-ethylenediami-netriacetic acid, 2-hydroxyethyliminodiacetic acid, benzoic acid, salicylic acid, and aminobenzoic acid. The amount of acid buffer included may vary but should be added such that pH of the said aqueous phase should be between 1 and 5, preferably 1 and 3.
[0133] The presence of a suitable transition metal ion within the aqueous phase of a second, separately stabilized fraction of the “dry water” mixture is required to produce the Fenton Reaction at the point of use. Suitable transition metal ions include but are not limited to iron, copper, manganese, cobalt, lead, aluminum, gold, titanium, chromium, vanadium and silver. Suitable forms for delivery of the transition metal ion into the aqueous phase include but are not limited to simple salts, ligand bound, dissolvable metal powder or dissolvable complex salts including glasses.
[0134] The Fenton reaction requires a stoichiometric mixture of transition metal ion and hydrogen peroxide. Accordingly it is desirable to include the selected transition metal ion in the same molar concentration as the inclusion of hydrogen peroxide in the final mixture. Suitable compositions are therefore produced by the inclusion of the selected transition metal ion between 0.1% and 70% by weight and preferably between 3% and 50% by weight.
Example 2
Metal-Ion Catalysed Bleach Systems for Laundry or Dishwashing Applications
[0135] It is well known in the art, as disclosed in for example U.S. Pat. No. 6,306,812 that organic bleaches such as percarboxylic acids or other bleach activators may be made to perform considerably better in terms of stain bleaching on fabrics or hard surfaces in the presence of a suitable ligand-bound transition metal catalyst (of which several appropriate species are described in detail within U.S. Pat. No. 6,306,812). A well known drawback as described in U.S. Pat. No. 6,306,812 of this technology is the need to ensure that the catalytic reaction does not proceed on initial mixing but rather at the point of need.
[0136] Within one embodiment of the invention, suitable compositions for effective protection and subsequent delivery of transition metal catalysed bleaching of fabrics or hard surfaces at the point of use include the encapsulation of a suitable percarboxylic acid or bleach activator according to U.S. Pat. No. 6,306,812 within the aqueous phase of one fraction of the stabilized “dry water” mixture at levels of between 0.001% and 99.99% by weight and preferably between 1% and 50% by weight.
[0137] The encapsulation of a suitable ligand-bound transition metal ion according to U.S. Pat. No. 6,306,812 within the aqueous phase of a second, separately stabilized fraction of the “dry water” mixture is required to produce catalysis at the point of use. Suitable transition metal ions include but are not limited to ions of iron, copper, manganese, cobalt, chromium, vanadium, lead, aluminum, gold and silver. Suitable compositions are produced by the inclusion of the selected transition metal ion between 0.001 ppm and 49% by weight of the composition.
[0138] Preferably and optionally a third element of the composition should consist of suitable fabric or hard surface cleaning components selected from surfactants, enzymes, salts, perfumes, colourants, dye transfer inhibition agents and other suitable adjuncts. It is not necessary for these elements of the composition to be bound within either phase of the “dry water” encapsulates.
Method of Manufacture
[0139] In all embodiments of the invention, at least two separate “dry water” compositions are first independently produced and then mixed to form the inter-dispersed, stabilized “dry water” mixture. In some embodiments, more than two reacting elements may be included, or more than one reaction mixture may be included such that the total number of independently produced “dry water” compositions may be unlimited in number. For the purposes of simple disclosure of the method of manufacture, an example including only two such independently produced compositions (Part A and Part B) is described, though for clarity it is noted that in fact any number of such compositions (Part C, D, E, etc) are possible and fall within the spirit and scope of the invention. Part A is first produced independently by dissolving the first of the required reacting ingredients in water along with any required ancilliary ingredients. Using the example of the Fenton reaction composition given above, Part A would include the dissolution of hydrogen peroxide along with a suitable acid buffer ingredient to leave the composition at a suitable pH as defined above.
[0140] The aqueous solution of Part A is then mixed with a suitable amount of a selected stabilizing ingredient, such as hydrophobized fumed silica as defined above. Suitable mixing methods are high in energy and agitation and include the use of high-shear rotary mixers or blenders.
[0141] The resulting “dry water” powder represents “Part A” of the final composition and may be, for example, stored suitably in a plastic container until required later in the process.
[0142] Part B of the composition is then also produced independently by a method identical to Part A. In the example of the Fenton reaction given above, “Part B” would contain the transition metal ion reacting element, included at the same molar concentration as the hydrogen peroxide in “Part A” in order to produce a stoichiometric reaction. Part B is produced by first dissolving the required reacting elements and any ancillary ingredients in aqueous solution and then by mixing this solution with a suitably selected hydrophobized fumed silica stabilizing ingredient in a method identical to “Part A”. The resulting “dry water” powder represents “Part B” of the final composition.
[0143] Once formed independently, Parts A and B of the composition are combined in equal parts with gentle mixing and avoiding breakage of the powder encapsulates to form the final inter-dispersed “dry water” composition according to the invention. The final inter-dispersed “dry water” composition is a dry powder in appearance that is stable and can be stored suitably, for example, in a plastic container or sachet.
[0144] As noted above, optionally and within the spirit and scope of the invention, additional Parts C, D, E, etc may be produced independently and inter-dispersed according to the specific requirements of a given application. Furthermore, the final inter-dispersed “dry water” composition may be optionally blended into a suitable cream, gel or paste to produce a formulation with appearance and properties suitable for the chosen application (e.g. application to face, skin, hair, teeth, fabric, hard surfaces, etc.).
Method of Use
[0145] At the point of use, a suitable measure, according to the required application, of the final composition is applied to the location of use which may be skin (face, hands or other), hair, teeth, fabric, household hard surfaces or other locations as required and all within the spirit and scope of the invention.
[0146] When the final composition is applied to the location of use, a mechanical action is required such as that provided by simple patting, squeezing, rubbing, spreading, brushing, polishing or scrubbing such that the inter-dispersed “dry water” encapsulates are broken, releasing and mixing the isolated reacting elements and causing the desired reaction(s) to take place rapidly and completely. It will be readily appreciated that the final composition may be subjected to such mechanical action in a different location than at the location of use. For example, encapsulates may be broken by the hands and applied to a surface for cleaning.
[0147] Using the example of the Fenton reaction composition described in Example 1, this could include without limitation the use of such composition as a hand sanitizing powder wherein a suitable amount of the final inter-dispersed composition is deposited in the hands and then, through vigorous rubbing, the “dry water” encapsulates are broken, releasing and mixing the hydrogen peroxide and selected transition metal ions and promoting the rapid and effective Fenton reaction, leading to effective disinfection of the hands.
Example Compositions
[0148] 1. Fenton reaction composition suitable for use as a hand sanitizing powder
a. Part A of the formulation consists of:
[0000] Ingredient Percentage (w/w %) Water 84 Phosphoric Acid 75% 1 Hydrogen Peroxide 50% 12 Fumed Silica 3
b. Part B of the formulation consists of:
[0000] Ingredient Percentage (w/w %) Water 92.6 Phosphoric Acid 75% 0.4 Copper Sulphate 4.0 Fumed Silica 3.0
2. Bleach catalyst composition suitable for use as a fabric or hard surface cleaner:
a. Part A of the formulation consists of
[0000] Ingredient Percentage (w/w %) Water 93.0 Sodium Percarbonate 4.0 Fumed Silica 3.0
b. Part B of the formulation consists of:
[0000] Ingredient Percentage (w/w %) Water 96.98 Mn(BCyclam)Cl 2 0.02 Fumed Silica 3.0
c. Part C of the formulation (optionally encapsulated but not required) consists of:
[0000]
Ingredient
Percentage (w/w %)
Zeolite
50.0
Linear Alkylbenzene Sulphonate
25.0
C12-15 EO5 alcohol ethoxylate
15.0
Sodium silicate
10.0
[0149] It will be appreciated that while the above discussed examples are directed to the encapsulation system directed to skin cleansing, fabric cleaning and hard surface cleaning formulations respectively, the present invention is not restricted to this.
[0150] While a preferred form of this invention has been described above, it should be understood that the applicant does not intend to be limited to the particular details described above, but intends to be limited only to the scope of the invention as defined by the following claims. While the invention was developed for skin sanitization and bleach products, as noted above it may also be used with other types of cleansing products.
[0151] Therefore the foregoing description of the preferred embodiments of the invention have been presented to illustrate the principles of the invention and not to limit the invention to the particular embodiment illustrated. It is intended that the scope of the invention be defined by all of the embodiments encompassed within the following claims and their equivalents. | The present invention provides a multi-component encapsulated reactive formulation comprising a mixture of two or more dry powder components, where each dry powder component is formed from a phase inversion process involving vigorous mixing. The dry powder is stabilized by hydrophobic colloidal particles, which assist in generating stable “dry water” microdroplets. One dry powder component comprises hydrophobic colloidal particles encapsulating microdroplets comprising an aqueous solution of one reactant, and the at least one other dry powder component comprises hydrophobic colloidal particles encapsulating microdroplets comprising an aqueous solution of another reactant. When the encapsulated formulation is agitated such that the encapsulates are broken, the encapsulates rupture and the two aqueous solutions undergo a reaction upon contact. | 3 |
[0001] This is a continuation-in-part application of pending international patent application PCT/EP 2011/006162 filed 8 Dec. 2011 and claiming the priority of German Patent Application 10 2011 009 001.0 filed 19 Jan. 2011.
BACKGROUND OF THE INVENTION
[0002] The invention relates to a method for automatically stopping an internal combustion engine of a motor vehicle when certain conditions are met.
[0003] It is known that recent motor vehicles have so-called stop-start systems by means of which an internal combustion engine of the motor vehicle is automatically stopped and restarted after the engine has been started by a driver during a driving cycle. The automatic stopping generally takes place when the internal combustion engine is idling and no torque of the internal combustion engine is needed for propulsion of the motor vehicle or for an auxiliary drive. The automatic starting generally takes place when a torque request is made on the internal combustion engine, either by the driver via an accelerator pedal or by an auxiliary drive such as an air conditioner. Methods for automatically stopping and/or starting an internal combustion engine by means of a stop-start system therefore include these types of stop conditions and start conditions. In addition, methods of this type also include stop prevention conditions. Such stop prevention conditions prevent an automatic stop of the internal combustion engine even though the other stop conditions are met. One example of a stop prevention condition is the condition of an open hood; i.e., an automatic stop of the internal combustion engine is prevented for safety reasons under the condition that the hood of the motor vehicle is open. In this regard see DE 102 11 466 01, for example.
[0004] JP 2001-032734 A describes a method for automatically stopping an internal combustion engine of a motor vehicle, in which automatic stopping of the internal combustion engine is prevented under the condition that locking of the wheels of the motor vehicle by an antilocking system, for example, has been detected. This prevention of stopping is active as long as the locking is present. The aim of this stop prevention condition is to avoid a situation in which locked wheels of the motor vehicle, i.e., wheels having a wheel speed of zero, are misinterpreted by the stop-start system as a vehicle standstill. A vehicle standstill is a situation in which no drive torque is required, and thus, a situation in which a stop-start system preferably stops the internal combustion engine.
[0005] EP 1 647 707 A1 which relates to the same species, discloses a method for automatically stopping an internal combustion engine wherein, after an acute indication has ended, a risk status remains activated until a further condition is met in addition to the ending of the acute indication.
[0006] In the mentioned method there is the problem that safety aspects, in particular the aspect of a collision risk, is/are not taken into account. The object of the present invention, therefore, is to provide a method for automatically stopping an internal combustion engine of a motor vehicle, which allows improved performance of the motor vehicle in order to avoid collisions.
SUMMARY OF THE INVENTION
[0007] In a method for stopping an internal combustion engine of a motor vehicle, stop prevention conditions are established for preventing automatic stopping of the internal combustion engine even when all stop conditions are met but one of the stop prevention conditions is not met. One of the stop prevention conditions is for example an activated risk status (GS), the risk status (GS) being activated when an acute indication (AI) is present. After the acute indication (AI) has ended, the risk status (GS) remains activated until a safety indication (SI) is present, so that, due to the internal combustion engine remaining switched on, maneuverability of the motor vehicle is maintained at least until the safety indication (SI) is recognized.
[0008] Examples of the stop conditions include the following:
a coolant temperature of the internal combustion engine which is above a threshold, a vehicle speed which is below a threshold, a battery voltage which is above a threshold, an activation of a brake, wherein an activation rate is above a threshold.
[0013] A further condition for automatically stopping the internal combustion engine is an absence of a stop prevention condition. A stop prevention condition is present when one of the following criteria, listed by way of example, is met:
a hood is open, a vehicle door is open, a parking maneuver is underway.
[0017] When at least one of the criteria for the stop prevention condition is present, an automatic stop of the internal combustion engine is prevented according to the method, even if all of the above-mentioned stop conditions are met.
[0018] In addition to the above examples, according to the invention at least one of the criteria for the stop prevention condition is an active risk status.
[0019] The risk status is understood to mean status information which indicates whether or not a risk is present according to predefined assessment criteria. The risk status may assume two values: an active risk status indicates a recognition of the risk, and an inactive or deactivated risk status indicates absence of the risk. The risk is essentially a situation in which there is an increased probability that the motor vehicle will collide with another motor vehicle or with an obstruction, or that the motor vehicle will tip or roll over. From the start until the end of the risk situation, it is desirable that the drive force of the motor vehicle remains dynamically available. If the internal combustion engine were automatically shut off during the risk situation, the build-up of a required drive torque would be delayed by an automatic starting operation. During the risk situation, a driver of the motor vehicle as well as an automatic safety system of the motor vehicle may request a drive torque in order to avoid a collision or to change a motion of the vehicle. The aim of the invention is to ensure that such a torque request in the motor vehicle having a stop-start system is followed by a rapid build-up of torque of the internal combustion engine.
[0020] According to the invention, the risk situation is divided into two successive phases, namely, an acute phase and a latency phase. Both phases are defined according to suitable criteria. The acute phase is based on acute criteria, which indicate a very high probability of the presence of the risk, The latency phase is based on latency criteria, which indicate the presence of the risk with a lower probability than the probability for the acute phase, or which indicate with a very high probability a lower risk.
[0021] In the case of meeting the acute criteria, according to the invention an acute indication is activated. The acute indication is understood to mean status information which indicates whether or not an acute phase is present according to the acute criteria. When the acute criteria are not met, i.e., when no acute phase is present, the acute indication is deactivated; i.e., an acute indication is not present. When the acute criteria are met, i.e., when an acute phase is present, the acute indication is activated; i.e., an acute indication is present.
[0022] The risk status is activated when an acute indication is activated, and the risk status remains activated as long as the acute indication is active, Immediately after an acute phase, i.e., immediately after a deactivation of the acute indication, the risk status remains activated, since according to the invention at least one further condition besides the deactivation of the acute indication must be met in order to deactivate the risk status. This further condition is an activation of a safety indication. The safety indication is understood to mean status information which indicates whether a conclusion may be made with a very high probability, according to suitable safety criteria, that a risk is no longer present. The safety criteria include not only the negated acute criteria, but also the additional criteria. Presence of the safety indication means an active safety indication and an absence of the risk.
[0023] A first advantageous refinement of the method provides that the safety indication is present under the minimum prerequisite that the acute indication has ended and a predetermined period of time has subsequently elapsed. Immediately after the acute indication has ended, there is a certain probability that a state which caused the acute indication is once again occurring. This probability decreases after a certain period of time after the acute indication has ended. Therefore, for safety reasons it is meaningful to activate the safety indication only after the predetermined period of time after the deactivation of the acute indication. The predetermined period of time is meaningfully in the range of a few seconds, preferably 5 to 10 seconds.
[0024] Another advantageous refinement of the method provides that the safety indication is present under the minimum prerequisite that the acute indication has ended, and the motor vehicle has subsequently covered a specified distance. If the specified distance has been covered without the acute indication having been reactivated, it may be assumed with a high level of probability that the risk has permanently ended. A meaningful specified distance is in the range of a few hundred meters to a few kilometers.
[0025] The start of the acute phase, i.e., a change from a normal operating mode or normal operating environment of the motor vehicle to a hazardous operating mode or a hazardous operating environment of the motor vehicle, is advantageously deduced from measurable variables, wherein risk conditions are established as a function of the measurable variables, and these risk conditions are monitored. If at least one risk condition is present, the acute phase is present; i.e., the acute indication is activated. Different types of risks having particular risk conditions may be based on different types of acute indications. The acute indication is activated when one of the risk conditions is met. In addition, each type of risk advantageously has specific criteria for the activation of a
[0026] Another advantageous refinement of the method accordingly provides that one type of acute indication is an acceleration indication, the acceleration indication being activated under the minimum prerequisite that a magnitude of a vehicle acceleration in one direction is greater than a first acceleration limit value, and the safety indication is present under the minimum prerequisite that at least the magnitude of the vehicle acceleration in one direction is less than a second acceleration limit value, the second acceleration limit value being less than or equal to the first acceleration limit value. A risk situation is thus recognized based on an exceedance of the first acceleration limit value of the motor vehicle, A meaningful first acceleration limit value is 5 to 10 m/s 2 , particularly advantageously 8 m/s 2 . An end of the risk situation is recognized not when the acceleration value is less than the first acceleration limit value, but, rather, only when the acceleration value is less than the second acceleration limit value, for example 3 m/s 2 .
[0027] Another advantageous refinement provides that a further type of acute indication is a transverse acceleration indication, the transverse acceleration indication being activated under the minimum prerequisite that a magnitude of a vehicle transverse acceleration is greater than a first transverse acceleration limit value, and the safety indication is present under the minimum prerequisite that the magnitude of the vehicle transverse acceleration is less than a second transverse acceleration limit value, the second transverse acceleration limit value being less than or equal to the first transverse acceleration limit value. The transverse acceleration is understood to mean an acceleration of the motor vehicle transverse to the direction of travel.
[0028] A detection of a transverse acceleration of the motor vehicle which is greater than the first transverse acceleration limit value indicates a skidding or drifting motion of the motor vehicle, and is therefore a clear indication of a risk situation. A permanent end of this type of risk situation may be assumed with a particularly high level of probability when, after the acceleration value is less than the first transverse acceleration limit value, the acceleration value is also less than a second transverse acceleration limit value, the second transverse acceleration limit value being less than the first transverse acceleration limit value.
[0029] Another advantageous refinement provides that a further type of acute indication is a control indication, the control indication being activated under the minimum prerequisite that understeering or oversteering of the motor vehicle has been recognized, and the safety indication is present under the minimum prerequisite that no understeering and no oversteering of the motor vehicle is recognized for a predetermined period of time and/or
[0030] Another advantageous refinement provides that a further type of acute indication is to a steering indication, the steering indication being activated under the minimum prerequisite that a rapid steering movement at a high speed has been recognized, and the safety indication is activated under the minimum prerequisite that no rapid steering movement is recognized for a specified period of time. The steering indication is advantageously activated when the steering speed is less than a first limit value for a steering speed, and the safety indication is not activated until the steering speed is less than a second limit value of the steering speed.
[0031] Another advantageous refinement provides that a further type of acute indication is a target braking indication, the target braking indication being activated under the minimum prerequisite that radar-assisted target braking is carried out, Information concerning the presence of target braking may be obtained from appropriate known safety systems.
[0032] Another advantageous refinement provides that a further type of acute indication is a braking indication, the braking indication being activated under the minimum prerequisite that full braking and/or automatic braking is/are carried out. In the case of full braking or automatic braking, safety is increased in that, during the full braking or the automatic braking and for a certain period of time or distance afterward, a stop of the internal combustion engine does not occur on account of the stop prevention condition being activated, so that the vehicle maintains optimal maneuverability.
[0033] Another advantageous refinement provides that a further type of acute indication is a collision indication, the collision indication being activated under the minimum prerequisite that a collision risk is recognized. The collision risk may be a collision risk in the direction of travel, or may be a lateral collision risk. A collision risk may be recognized, for example, by a radar-assisted safety system of the motor vehicle.
[0034] It is also advantageous to activate the acute indication as a function of safety-relevant parameters of a vehicle dynamics control system or also of a collision avoidance system. These types of safety systems are designed to recognize various types of risk situations, and to activate a risk status when a risk situation is recognized.
[0035] The invention will be described below in greater detail in the following description of exemplary embodiments with reference to the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0036] FIG. 1 shows a motor vehicle for carrying out the method according to the invention,
[0037] FIG. 2 shows a flow chart for a stop function of a stop-start system,
[0038] FIG. 3 shows a flow chart for a risk status function, and
[0039] FIG. 4 shows a flow chart for a safety function.
DESCRIPTION OF EXEMPLARY EMBODIMENTS
[0040] FIG. 1 shows a motor vehicle 1 for carrying out the method according to the invention. The motor vehicle 1 has an internal combustion engine 2 , an engine control unit 3 for controlling and regulating the internal combustion engine 2 via control lines 9 and sensor lines 8 , and a safety system 4 . The safety system 4 has a vehicle dynamics control unit 5 and an anti-collision control unit 6 which are interconnected via a data bus system for purposes of data exchange. The safety system 4 is connected to the engine control unit 3 via the data bus system 7 . The engine control unit 3 is connected to further control units, not illustrated, via the data bus system 7 . The engine control unit 3 has a stop-start system, not illustrated in greater detail, by means of which the internal combustion engine 2 is automatically stopped and automatically started. The stop-start system of the engine control unit 3 receives safety parameters from the safety system 4 via the data bus system 7 , the safety parameters being used for a function of the stop-start system.
[0041] FIG. 2 shows a flow chart for an engine stop function of the stop-start system. The engine stop function for automatically stopping the internal combustion engine 2 begins with a start step 21 . The start step 21 includes preconditions, not illustrated, which must be met in order for the engine stop function to run properly. After the preconditions have been met, a stop condition 22 is checked. The stop condition 22 includes checking of multiple stop subconditions STB which must be met in order for an automatic stop of the internal combustion engine 2 to take place. When the stop condition 22 is met, a check is made as to whether a stop prevention condition 23 is met. The stop prevention condition 23 includes the checking of a risk status GS. If the risk status GS is not activated, a stop of the internal combustion engine 2 takes place in a stop command step
[0042] If the stop condition 22 is not met, a stop of the internal combustion engine 2 does not take place, and the engine stop function begins anew with the start step 21 after running through the return step 25 . If the stop prevention condition 23 is met, a stop of the internal combustion engine 2 likewise does not take place, and a return is made to the start step 21 .
[0043] FIG. 3 shows a flow chart for a risk status function. The risk status function for assessing the risk status GS begins with a start step 31 . The start step 31 includes further preconditions, not illustrated, which must be met in order for the risk status function to run properly. After the further preconditions have been met, an acute checking step 32 takes place. The acute checking step 32 includes a check of an acute indication AI. The acute indication AI is active when a risk is present. If the acute indication AI is active, this is followed by a risk display 33 in which the risk status GS is activated. After the risk status GS is activated, a return step 37 to the start step 31 takes place.
[0044] If a nonactive acute indication AI is identified in the acute checking step 32 , the next operation is a risk status check 34 as to whether the risk status GS has been activated from a prior run of the risk status function. If the risk status GS has not been activated, the return step 37 is carried out. If the risk status GS has been activated, a safety status check 35 is carried out. In the safety status check 35 a check is made as to whether a safety indication SI is activated. If the safety indication SI is activated, the risk status GS is deactivated in an risk absence display 36 , followed by the return step 37 . If it is determined in the safety status check 35 that the safety indication SI is not activated, the risk status GS remains activated, and the return step 37 is carried out for rerunning the risk status function.
[0045] FIG. 4 shows a flow chart for a safety function. A start step 41 of the safety function includes preconditions, not illustrated, which must be met in order for the safety function to run properly. After the preconditions have been met, an acute condition step 42 takes place. In the acute condition step 42 a check is made via an acute condition AI_Cond for the presence of a type of risk. If the acute condition AI_Cond has been met, the acute indication AI is activated in an acute display 43 , and at the same time the safety indication SI is deactivated. A return step 47 subsequently takes place for rerunning the safety function. If the acute condition AI_Cond has not been met, a deactivation 44 of the acute indication AI takes place. After the deactivation 41 of the acute indication AI, a safety condition step 45 takes place in which a safety condition SI_Cond is checked. If the safety condition SI_Cond is met, the safety indication SI is activated in a safety display 46 .
[0046] An acute indication AI, an acute condition AI_Cond, and a safety condition SI_Cond are associated with each type of risk. Several types of risk and their acute conditions AI_Cond and safety conditions SI_Cond are listed below by way of example:
The type of risk is an overacceleration, and the associated acute indication AI is an acceleration indication; in this case the acute condition AI_Cond is met when a vehicle acceleration in one direction is greater than a first acceleration limit value; in this case the safety condition SI_Cond is met when the vehicle acceleration is less than a second acceleration limit value, and when a specified period of time has elapsed after the deactivation 44 of the acceleration indication; the second acceleration limit value is less than the first acceleration limit value; Alternatively, the type of risk is a transverse acceleration, and the associated acute indication AI is a transverse acceleration indication; in this case the acute condition AI_Cond is met when a vehicle transverse acceleration is greater than a first transverse acceleration limit value; in this case the safety condition SI_Cond is met when the vehicle transverse acceleration is less than a second transverse acceleration limit value, and when a specified period of time has elapsed after the deactivation 44 of the transverse acceleration indication; the second transverse acceleration limit value is less than the first transverse acceleration limit value; Alternatively, the type of risk is an oversteering or understeering of the motor vehicle 1 , and the associated acute indication AI is a control indication; in this case the acute condition AI_Cond is met when an oversteering or understeering of the motor vehicle 1 has been recognized; in this case the safety condition SI_Cond is met when the oversteering or understeering of the motor vehicle is no longer present, and when a specified period of time has elapsed after the deactivation 44 of the control indication; Alternatively, the type of risk is an evasive maneuver of the motor vehicle 1 , and the associated acute indication AI is a steering indication; in this case the acute condition AI_Cond is met when a steering speed of the motor vehicle 1 is greater than a steering speed limit value, and a vehicle speed is greater than a vehicle speed limit value; in this case the safety condition SI_Cond is met when the steering speed of the motor vehicle 1 is less than the steering speed limit value, and the vehicle speed is less than the vehicle speed limit value; Alternatively, the type of risk is a first collision risk, and the associated acute indication AI is a target braking indication; in this case the acute condition AI_Cond is met when target braking is carried out by a safety system of the motor vehicle 1 ; in this case the safety condition SI_Cond is met when the target braking has concluded, and when a specified period of time has elapsed after the deactivation 44 of the target braking indication; Alternatively, the type of risk is a second collision risk, and the associated acute indication AI is an emergency braking indication; in this case the acute condition AI_Cond is met when carrying out of emergency braking is recognized by a safety system of the motor vehicle 1 ; in this case the safety condition SI_Cond is met when the emergency braking has concluded, and when a specified period of time has elapsed after the deactivation 44 of the emergency braking indication; Alternatively, the type of risk is a third collision risk, and the associated acute indication AI is a collision indication; in this case the acute condition AI_Cond is met when a collision risk, in particular a lateral collision risk, is recognized by a safety system of the motor vehicle 1 , for example via associated radar sensors; in this case the safety condition SI_Cond is met when the collision risk has passed, and when a specified period of time has elapsed after the deactivation 44 of the collision indication.
LISTING OF REFERENCE NUMERALS
[0000]
1 Motor vehicle
2 Internal combustion engine
3 Engine control unit
4 Safety system
5 Vehicle dynamics control unit
6 Anti-collision control unit
7 Data bus system
8 Sensor lines
9 Control lines
21 Start step of the engine stop function
22 Stop condition
23 Stop prevention condition
24 Stop command step
25 Return step of the engine stop function
31 Start step of the risk status function
32 Acute checking step
33 Risk display
34 Risk status check
35 Safety status check
36 Risk absence display
37 Return step of the risk status function
40 Sequence plan of the acute status function
41 Start step of the safety function
42 Acute condition step
43 Acute display
44 Acute deactivation
45 Safety condition step
46 Safety display
47 Return step of the safety function
STB Stop subconditions
GS Risk status
AI Acute indication
SI Safety indication
AI_Cond Acute condition
SI_Cond Safety condition | In a method for stopping an internal combustion engine of a motor vehicle, stop prevention conditions are established for preventing automatic stopping of the internal combustion engine even when all stop conditions are me but one of the stop prevention conditions is not met. One of the stop prevention conditions is for example an activated risk status (GS), the risk status (GS) being activated when an acute indication (AI) is present. After the acute indication (AI) has ended, the risk status (GS) remains activated until a safety indication (SI) is present, so that, due to the internal combustion engine remaining switched on, maneuverability of the motor vehicle is maintained at least until the safety indication (SI) is recognized | 5 |
CROSS REFERENCE TO RELATED APPLICATIONS
The present application discloses subject matter in common with applications Ser. No. 518,988 now U.S. Pat. No. 3,942,497, filed on Oct. 19, 1974 by Reinhard Schwartz, and Ser. No. 597,912 filed on July 21, 1975 by Gerhard Stumpp. These applications are assigned to the same assignee.
BACKGROUND OF THE INVENTION
The present invention relates to a diaphragm valve comprising as the movable valve part a flexible diaphragm, and more particularly, a plastic diaphragm, separating two chambers through which pressurized liquid flows.
Diaphragm valves of this type are already used in fuel injection systems in which the influence of temperature variations on the metered quantity of injection fuel is eliminated by means of diaphragms consisting of webbing like membranes. However, these membranes are subject to the disadvantage that the flexible membrane oscillates and effects undefined opening and closing movements about the valve seat, resulting in unwanted variations in the metered quantity of injection fuel.
OBJECTS AND SUMMARY OF THE INVENTION
It is, therefore, an object of the present invention to provide the existing state-of-the-art with an improved diaphragm valve of the type discussed above.
It is another object of the present invention to provide the existing state-of-the-art with a diaphragm valve of the type discussed above which fulfills the requirements of this type of valve and which ensures that the pressure of the pressurized liquid flowing through the system is controlled as accurately as possible in spite of the fact that a flexible membrane is employed.
These and other objects of the present invention are achieved by the provision of a valve plate, which is connected with the diaphragm and which cooperates with a valve seat, having a diameter which is as large as possible in relation to the clamping diameter of the diaphragm, more particularly approximately 4/5 of the clamping diameter; and by the provision of a stationary thrust ring concentrically disposed with respect to the valve seat, a knife-shaped front side of which is disposed in the same plane as the valve seat and has as large a diameter as possible which cooperates with the valve plate.
According to an advantageous feature of the present invention, the front side of the thrust ring is interrupted by transverse grooves.
Another advantageous feature of the present invention consists in that the diaphragm valve is in the form of a pressure-equalizing valve of a fuel metering and distributing unit.
A further advantageous feature of the present invention consists in that the diaphragm valve is in the form of a differential pressure valve of a fuel metering and distributing unit.
Other objects, features and advantages of the present invention will be made apparent in the following detailed description of a preferred embodiment thereof provided with reference to the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an axial sectional view of an exemplary embodiment of a fuel injection system which includes a diaphragm valve according to the present invention.
FIG. 2 is a cross-sectional view along the line II--II of FIG. 1.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The exemplary embodiment of the diaphragm valve is included in a fuel injection system as illustrated in FIGS. 1 and 2 for a four-cylinder internal combustion engine. The system includes a fuel metering and distributing unit having a housing 1, an intermediate plate 2 and a bottom cover 3 axially clamped together by means of bolts 4. Clamped between the housing 1 and the intermediate plate 2 is a flexible diaphragm 5 which serves to divide axial bores 14, 15 and 16, 17, uniformly distributed about the longitudinal axis of the housing, into chambers 14, 15 and 16, 17. The diaphragm 5 also serves as the diaphragm for diaphragm valves 6 and 7. Because the exemplary embodiment illustrated relates to a fuel metering and distributing unit for a four-cylinder internal combustion engine, there are four diaphragm valves, of which one is a differential pressure control valve 6 and the other three valves are pressure equalizing valves 7. In each of these valves, the diaphragm 5 forms a flat seat valve with a stationary valve seat 8. The valve seat 8 is mounted to valve seat carrier 9 which is threadedly engaged with the housing 1 and which serves as the connecting member for conduits 10 leading to the injection valves 11. A helical spring 12 having as flat a spring characteristic as possible is supported on the valve seat carrier 9 of the differential pressure valve 6. The helical spring 12 biases the diaphragm 5 in the opening direction via a valve plate 13 which is in the form of a spring rest and which is connected to the diaphragm 5. Thus, the differential pressure control valve 6 is open when inoperative. On the one hand, the diaphragm 5 serves firstly to divide a first chamber 14 from a second chamber 15 of the differential pressure control valve 6 and, on the other hand, to divide the first chamber 16 from the second chamber 17 of the pressure equalizing valves 7. A channel 18 leads from the first chamber 14 of the differential pressure control valve 6 to the second chamber 17 of a pressure equalizing valve 7. The second chambers 17 of the pressure equalizing valve 7 are interconnected by means of an annular channel 19.
Fuel is supplied from a fuel tank 24 by means of a pump 23 driven by an electric motor 22. The fuel passes through a conduit 25 and a connecting member 26 into the second chamber 15 of the differential pressure control valve 6. From the conduit 25 there extends a conduit 27, in which a pressure limiting valve 28 is disposed. When there is excessive pressure in the system the pressure limiting valve 28 allows fuel to flow back into the fuel tank 24.
An axial bore 30 formed in the housing 1, the intermediate plate 2 and the bottom cover 3 of the fuel distributing unit has a bushing 31 mounted therein. The bushing 31 is prevented from being axially displaced and rotated by means of an elastic sealing sleeve 32 which may be made of rubber. To achieve this the sealing sleeve is axially compressed by a plug 33 against a disk 34 disposed between the bottom cover 3 and the intermediate plate 2. This measure also prevents any fuel from leaking between the bushing 31 and the housing 1 and the intermediate plate 1.
A control slide 36 into which an annular groove 37 is formed is axially slidable against the force of a spring 35 in the bushing 31. In place of the spring 35, the restoring force exerted on the control slide 36 could also be produced by pressurized fluid controlled by a hydraulic pressure control system (not shown) exerting a force on the slide.
Longitudinal grooves 38 which communicate with the inner bore of the bushing 31 through exactly identical, axially parallel, longitudinal slots 39 (control slots) are located in the bushing 31. Thus, depending on the position of the control slide 36, the annular groove 37 opens or uncovers a section of the control slots 39 of greater or lesser length. Radial bores 40 which provide constant communication between the annular groove 37 and an annular channel 41 provided in the bottom cover 3 are also provided in the bushing 31. The annular channel 41 communicates with the second chamber 15 of the differential pressure control valve 6 by means of a channel 42. The longitudinal grooves 38 of the bushing 31 communicate with the first chamber 14 of the differential pressure control valve 6 of the first chambers 16 of the pressure equalizing valves 7 by means of bores 43. A longitudinal groove 38 and an associated control slot 39 are provided for each of the valves 6 and 7. The first chambers 14 or 16 are thereby separated from one another.
According to the present invention, fixed thrust rings 44 are concentrically disposed with respect to the valve seats 8. The knife-shaped front sides of these thrust rings are disposed generally in the same plane as the valve seats 8. The diameter of the knife-shaped front side of each thrust ring 44 is generally of uniform size, but is smaller than the diameter of the valve plate 13. The diameter of the valve plate 13 is as large as possible in relation to the clamping diameter of the diaphragm 5, and, in particular, it corresponds to approximately 2/3 to 4/5 of the clamping diameter. The front sides of the thrust rings 44 are interrupted by transverse grooves 45 which permit pressure equalization in the first chambers 14 or 16 when the valve plate 13 rests against the thrust ring 44.
The method of operation of the fuel injection system described is as follows:
The fuel supplied by the fuel pump 23 is delivered via the conduit 25 and the connecting member 26 to the second chamber 15 of the differential pressure control valve 6. From there it flows via the channel 42, the annular channel 41 and the radial bore 40 into the annular groove 37 of the control slide 36. The control slide 36 can be displaced in an axial direction, for example, by means of an air sensing element (not shown) disposed in the suction tube of the internal combustion engine, such that the annular groove 37 opens the control slots 39 to a greater or lesser extent. The fuel is metered by the control slots 39 and flows from the annular groove 37 into the longitudinal grooves 38. From there it flows through the bores 43 into the first chamber 14 of the differential pressure valve 6, and the first chambers 16 of the pressure equalizing valves 7. The first chamber 14 of the differential pressure control valve 6 communicates via the channel 18 with the second chambers 17 of the pressure equalizing valves which communicate with one another via the annular channel 19.
The force of the spring 12 of the differential pressure control valve 6 is such that when there is a variation in the pressure drop between the first chamber 14 and the second chamber 15, the flow passage cross section between the diaphragm 5 and the valve seat 8 is varied until this pressure drop is once again restored. In the case of the flat seat valve which is illustrated, this can be achieved in a very short time as the flow passage cross section changes considerably even when there is only minimal lifting of the diaphragm. On the other hand, the spring force is only minimally varied as a result of this minimal lifting action and thus the control system can operate extremely accurately. In other words, the pressure drop is virtually constant irrespective of the fuel quantities flowing through the system.
The throttling action on the fuel at the control slots 39 is approximately uniform and thus the fuel pressure is approximately uniform. Thus the fuel pressure in the first chamber 14 of the differential pressure control valve 6 and the first chambers 16 of the pressure equalizing valves 7 is approximately uniform. By virtue of the fact that the first chamber 14 of the differential pressure control valve 6 communicates with the second chambers 17 of the pressure equalizing valves 7, in the regulated state, the fuel pressure in the second chambers 17 is generally equal to that in the first chambers 16. The use of pressure equalizing valves offers the advantage that to obtain the desired pressure difference at the metering valves 37, 39, it is only necessary to adjust the spring 12 of the differential pressure control valve 6. There is no need to adjust the individual pressure equalizing valves 7.
The portion of the diaphragm 5 associated with each of the valves 6 and 7 comprises a reinforcing bead 46 near its clamped periphery. In this way the diaphragm operates in a flexible manner but does not exert force on the valve. In the operating state the valve plate 13 of the diaphragm 5 will rest on any place on the front side of the thrust ring 44. This place acts as a hinge permitting the friction-free mobility of the diaphragm with respect to the valve seat 8, while avoiding oscillation of the diaphragm.
The diaphragm valves according to the present invention comprising a supporting ring have the advantage that defined opening and closing movements can be obtained even in the case of diaphragm valves comprising flexible diaphragms, thus making it possible to obtain control capable of satisfying high requirements. | A diaphragm valve which may serve as an equal pressure valve or as a pressure equalizing valve of a fuel metering and distributing unit for an externally ignited internal combustion engine. The valve has a flexible diaphragm having a clamped diameter and to which a valve plate is connected. The valve plate operatively cooperates with a valve seat of the valve and has a diameter which is as large as possible in relation to the clamped diameter of the diaphragm. The valve also includes a stationary thrust plate which is concentrically disposed relative to the valve seat, which defines a knife-shaped edge which lies in a common plane with the valve seat and which operatively cooperates with the valve plate. The knife-shaped edge has a diameter which is as large as possible in relation to the diameter of the valve plate. | 8 |
RELATED APPLICATIONS
[0001] This application claims priority to U.S. Patent Application Ser. No. 62/127,071 filed Mar. 2, 2015 and claims priority to U.S. Provisional Patent Application No. 62/043,830 filed Aug. 29, 2014, both of which are incorporated herein by reference in their entirety.
BACKGROUND OF THE INVENTION
[0002] The invention relates generally to a decorative cushion that can provide massage, and other stimulation to various areas of the body.
[0003] Modern workers often suffer from fatigue of heads, necks, shoulders, cervical spines, etc. Some workers may even have cervical spondylosis and other forms of more serious diseases. In view of this problem, various massage devices have been developed to meet this problem.
[0004] However, to the casual observer, such devices appear visually to be pieces of equipment or medical instruments.
[0005] It is therefore an object of the present invention to provide a massage cushion that is visually decorative.
[0006] Another object is to provide a massage cushion that is easily controllable and without the look of a piece of equipment or medical instrument having gauges and control buttons.
[0007] It is yet another object to provide a massage cushion that can be easily cleaned.
[0008] It is yet another object to provide a massage cushion that provides comfortable use as a pillow support whether or not massage is being conducted by the cushion.
[0009] Massage devices can be divided into kneading type, percussion type, vibration type and rolling type. The embodiment described herein relates to the kneading type, referred to as Shiatsu massage.
BRIEF SUMMARY OF THE INVENTION
[0010] A decorative cushion provides a massage, for example, in areas of neck, shoulders, and back. The massage device includes a cushion core with a single, unitary foam structure and a massage unit placed off center in the bottom third of the massage device providing a massage movement. The massage device is located in a fabric pouch and then positioned relative to the cushion core. The massage movement may be of several types, as for example, a kneading massage movement. A cushion cover receives the cushion core, and in certain embodiments, the cushion cover includes fanciful decoration, embroidery and shapes for aesthetical purposes. The cushion cover provides a fabric icon for use as part of an ON/OFF switch connected with the massage unit so that a user can easily turn ON or turn OFF the massage device. The massage device may include an electrical wire/plug to be plugged into a conventional electrical outlet.
[0011] Alternatively, certain embodiments of the present invention may have self-powered electrical sources, such as a battery, positioned within the massage unit outside of the view of the user and others. These self-powered electrical sources can be easily recharged for repeated use.
[0012] The massage unit is positioned off center within the cushion so as to provide certain advantages. Such a position can provide a full-range massage to a user's neck, as well as to the lower cervical spine area. If a user wants to massage his or her shoulders or upper back, the massage device may be rotated so as to provide massage to those areas.
BRIEF DESCRIPTION OF SEVERAL VIEWS OF THE DRAWINGS
[0013] FIG. 1 illustrates a perspective view of a massage cushion according to the present invention.
[0014] FIG. 2A illustrates a side view of an inner core of the massage cushion of FIG. 1 .
[0015] FIG. 2B illustrates a top view of the inner core of FIG. 2A .
[0016] FIGS. 2C , 2 D, 2 E, 2 F, 2 G, and 2 H illustrate a massage compartment or pouch and a massage unit which is placed in the compartment, and together both are placed into the inner core of the massage cushion of FIG. 1 .
[0017] FIG. 3A illustrates a side view of the inner core of FIG. 2A which is partially covered with an inner cover.
[0018] FIG. 3B illustrates a top view of the inner cover of FIG. 3A which fully covers the inner core of FIG. 2A .
[0019] FIG. 4A illustrates a side view of the inner core of FIG. 2A , together with the inner cover of FIG. 3B in a closed position, which is partially covered with an outer cover.
[0020] FIG. 4B illustrates a side view of the massage cushion of FIG. 1 .
[0021] FIG. 4C illustrates a holding band 44 sewn in the outer cover of the massage cushion of FIG. 1 .
[0022] FIG. 5 illustrates a partial top view of the outer cover of FIG. 4A and more particularly, the lower left corner of the backside of the outer cover.
[0023] FIG. 6 illustrates a partial top view of the outer cover of FIG. 5 , folded upon itself to reveal the lower left corner of the inner cover of FIG. 2A .
[0024] FIG. 7 illustrates the inner cover of FIG. 3B , folded upon itself to reveal the corner of the inner core of FIG. 2A .
[0025] FIG. 8 illustrates the outer cover of FIG. 5 shown empty and in a flat position.
[0026] The foregoing summary, as well as the following detailed description of certain embodiments of the present invention, will be better understood when read in conjunction with the appended drawings. For the purpose of illustrating the invention, there is shown in the drawings, certain embodiments. It should be understood, however, that the present invention is not limited to the arrangements and instrumentalities shown in the attached drawings.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0027] Preferred embodiments of the invention will now be described with reference to the accompanying drawings, in which several embodiments are shown. Embodiments 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 examples of the invention, which has the full scope indicated by the language of the claims. Like reference numbers refer to like elements throughout.
[0028] Referring to FIG. 1 , a massage cushion 11 is constructed generally rectangular in shape having a bottom edge 13 , a top edge 15 , a right side edge 17 and a left side edge 19 . A massage unit (not shown) is housed within massage cushion 11 and provides a kneading type massage movement, referred to as a Shiatsu massage movement. The massage movement occurs at the back side 85 of the cushion and against which the user places his or her neck and shoulders, for example.
[0029] As an example, massage cushion 11 may be 18 inches long, 18 inches wide and 7 inches deep. Other configurations and dimensions may be used.
[0030] Referring to FIGS. 2A and 2B , an inner core 23 is the primary component of cushion 11 . Inner core 23 includes a first core section 25 having an outer dimension to dictate the shape of cushion 11 , and has a second core section 27 to hold a massage unit 29 into a fixed position relative to inner core 23 .
[0031] First core section 25 is made as a single unitary piece of a first compressible foam material. The foam material measures a hardness of between 20-30 degrees using a Durometer scale. For example, the foam material is polyurethane. First core section 25 has a consistent level of compressibility throughout its shape and has a firmness of 38 IFD. The degree of compressibility provides comfort to the user, as well as a soft pillow-like support and feel to the cushion.
[0032] Second core section 27 ( FIG. 2B ) is made as a single unitary piece of a second compressible foam material, which also is made from polyurethane, e.g., 38 LX-C(Normal Urethane). Second core section 27 is located in an aperture 31 ( FIG. 2B ) formed in the lower one-third portion 33 of the three one-third portions 33 , 35 , 37 of first core section 25 . Aperture 31 is positioned in the lower one-third portion 33 of inner core 23 . Aperture 31 is of a size to receive second core section 27 so that it fits snugly within first core section 25 . First core section 25 may be compressed to expand aperture 31 somewhat in order to receive second core section 27 in a tight fixed fashion.
[0033] Massage unit 29 may be secured to second core section 27 by polyurethane glue or any other suitable means. The compressible material of second core section 27 is more firm in compressibility than the compressible material of first core section 25 , such that massage unit 29 is held fixed relative to the second core section 27 . Second core section 27 is shaped so as to receive massage unit 29 and so as to allow its kneading components to rotate freely. In addition, second core section 27 aids in positioning unit 29 so as to provide massage action to back side 85 of the cushion.
[0034] Massage unit 29 may be, for example, a kneading massage unit of the type illustrated and described in U.S. Patent Publication No. 2012/0010544. Massage unit 29 may include two massage ball bodies 39 and two massage ball bodies 41 (referred to herein as Shiatsu balls). Massage ball bodies 39 , 41 are driven to rotate and so to be used to knead and massage a human body. Massage ball bodies 39 , 41 are rotated in reverse directions to one another (e.g., clockwise for bodies 39 and counterclockwise for bodies 41 ). Further, a timer (not shown) may be used to automatically switch the directions of rotation of the massage ball bodies after a predetermined time period. For example, after sixty seconds, bodies 39 may switch to rotate counterclockwise and bodies 41 may switch to rotate clockwise; then after another sixty seconds, bodies 39 may switch back to rotate clockwise and bodies 41 may switch back to rotate counterclockwise. Such a switching of rotational direction provides a pleasant effect to the user. The timer may include a program stored on an electronic chip which is accessed by a controller for driving bodies 39 , 41 . In addition, a thermal effect on the user may be generated by a heating element (not shown) which thermoelectrically heats massage ball bodies 39 , 41 . The two massage ball bodies 39 may be configured to different outer surface sizes (volumes) Likewise, the two massage ball bodies 41 may be configured to different outer surface sizes. The user may thus feel the gradational strength of the massage ball bodies. Other conventional types of massage devices may be used in the massage unit 29 , as will suggest itself.
[0035] Massage unit 29 includes a disconnectable power supply cord 43 which connects massage unit 29 to a source of electricity for powering the unit. Power supply cord 43 extends outwardly from massage unit 29 and is of a length to extend outside of the perimeter area of cushion 11 . Cord 43 terminates in an electrical connector 45 which is mateable with another electrical connector (not shown) of a second power cord (also not shown). Power may be supplied directly from the second power cord to massage unit 29 via cord 43 . As will suggest itself, alternatively, electrical connector 45 may be a conventional wall plug that may be plugged into a conventional electrical wall outlet.
[0036] A pair of passageways 47 , 49 may be formed or cut into respectively first core section 25 and second core section 27 of the compressible foam material. Passageways 47 , 49 provide a trough or channel to receive power supply cord 43 , and thus keep cord 43 away from the outer top surface of core sections 25 , 27 .
[0037] Alternatively, a battery (not shown) may be used to power massage unit 29 instead of electricity through cord 43 . Thus, cord 43 can be avoided. Alternatively, cord 43 may be used with a rechargeable battery to supply electricity for recharging of the battery. After the battery is charged, cord 43 may be removed.
[0038] Massage unit 29 also includes a ON/OFF switch 51 and an associated connection cord 53 . Cord 53 extends outwardly from massage unit 29 allowing ON/OFF switch 51 to be positioned at a convenient place for user actuation. ON/OFF switch 51 operates to turn massage unit 29 ON or OFF, as described more fully herein. A passageway 55 may be formed or cut into the compressible foam material of second core section 27 to provide a channel to receive cord 53 , and thus keep cord 53 away from the outer top surface of core section 27 .
[0039] Referring to FIG. 2C , a massage unit compartment or pouch 131 is provided in another embodiment. Pouch 131 is shaped and is of a size to receive and contain massage unit 29 . The massage unit 29 may fit snugly within the massage unit pouch 131 , such that, for example, no adhesive is required to hold the massage unit 29 in place within pouch 131 .
[0040] Pouch 131 may be constructed as a separate unit. In addition, pouch 131 may be sewn into a position on an inner cover 61 (described hereinafter) which receives the inner core 23 . Alternatively, pouch 131 may be constructed to include a portion 132 of inner cover 61 , and so firmly locate pouch 131 relative to inner core 23 .
[0041] Pouch 131 is openable along at least a portion of one of its sides by a zipper closure mechanism 133 having a zipper head 135 and a pair of zipper tracks 137 . Pouch 131 may be formed of cloth mesh material, for example, 100% polyester, and may be of a solid beige color. Such a cloth mesh material may be made from nylon material, for example. Such a cloth mesh material may assist with dissipating heat generated from the massage unit 29 . The massage unit pouch 131 provides additional support to hold the massage unit 29 in place relative to the inner core.
[0042] Referring to FIGS. 2D-2G , massage unit 29 is placed within massage unit pouch 131 ( FIGS. 2D , 2 E) and then pouch 131 is zipped closed retaining unit 29 within pouch 131 ( FIGS. 2E , 2 F). As shown in FIG. 2F , power cord 43 and connection cord 53 protrude from a hole 139 formed in pouch 131 . Finally, as shown in FIG. 2G , pouch 131 containing unit 29 is placed into an aperture or cavity 32 formed in first core section 25 . Cavity 32 may have a shape, as shown, similar to the shape of unit 29 . Thus, second core section 27 may not be used. Alternatively, aperture 32 may be formed in second core section 27 ( FIG. 2 ). Core section 27 may provide expansion to aperture 32 allowing it to act as a sponge cavity so that pouch 131 fits snugly within cavity 32 . The walls of cavity 32 hold pouch 131 containing massage unit 29 in place without need for glue or other adhesive. The mesh pouch provides additional support to hold the massage unit in place and prevents the massage unit from falling out of position while resting in cavity 32 .
[0043] Referring to FIGS. 3A and 3B , and FIG. 2H , inner core 23 is insertable within, and received by inner cover 61 . Inner cover 61 has the shape of cushion 11 and is openable along three of its sides by a zipper closure mechanism 63 comprised of a zipper head 65 and a pair of zipper tracks 67 . Zipper tracks 67 extend along the lower portions of the two sides of inner cover 61 and along the bottom side of inner cover 61 , as shown in FIG. 3B . Zipper tracks 67 may instead be placed at the upper portions of the two sides of the inner cover 61 and along the top side of inner cover 61 . Thus, locating the zipper tracks 67 at the upper portion of the inner cover 61 may prevent any interference between zipper tracks 67 and zipper tracks 79 ( FIG. 4B ) of an outer cover 73 , described below. Inner cover 61 is shown open in FIG. 3A and shown closed in FIG. 3B . Inner cover 61 may be formed of cloth material, for example, 100% polyester and may have a solid beige color. Such a cloth material may be made from nylon material, for example.
[0044] When zipper closure mechanism 63 is open fully (as shown in FIG. 3A ), inner core 23 may be inserted within inner cover 61 . Once inner core 23 is received into inner cover 61 , inner cover 61 may be closed by zipper closure mechanism 63 (as shown in FIG. 3B ). Power supply cord 43 is positioned so as to extend out through the zipper opening at a location 69 where zipper tracks 67 end. Thus, zipper head 65 will end its movement to close the inner cover immediately adjacent to cord 43 at location 69 . Should tracks 67 be located at the upper portion of inner cover 61 , zipper head 65 will likewise end its movement to close the inner cover at location 69 . ON/OFF switch 51 is secured to the underside surface 71 (as shown in FIG. 3A ) of inner cover 61 , as more fully described hereinafter.
[0045] As shown in FIG. 3B , zipper head 65 includes a small pull handle. However, inner cover 61 may be constructed to prevent or discourage removal of inner cover 61 from inner core 23 . For example, zipper head 65 may be turned over so as to travel with respect to the inside of the cover and the pull handle may be removed from the zipper head. The inner cover thus protects the inner components of the cushion as well as protects the user from easily gaining access to the inner components. The inner core also protects an outer cover 73 , described hereinafter, from wear and tear (friction) from massage unit 29 .
[0046] Referring to FIGS. 4A and 4B , inner core 23 (not shown) when covered with inner cover 61 ( FIG. 4A ) is inserted within and received by outer cover 73 . Outer cover 73 has the shape of the cushion 11 and is openable along three of its sides by a zipper closure mechanism 75 comprised of a zipper head 77 and a pair of zipper tracks 79 . Zipper tracks 79 extend along the lower portions of the sides of outer cover 73 and along the bottom of outer cover 73 . Outer cover 73 is shown open in FIG. 4A and shown closed in FIG. 4B . Outer cover 73 may be formed of cloth material, e.g., cotton, and carries a decorative pattern 81 on its front side 83 and is only colored white on its back side 85 . Such cloth material would be fabric used on conventional decorative pillows found on high quality living room furniture.
[0047] Zipper closure mechanism 75 runs along part of the right side edge 17 ( FIG. 1 ), the bottom edge 13 ( FIG. 1 ) and part of the left side edge 19 ( FIG. 1 ). When the zipper closure mechanism 75 of outer cover 73 is open fully (as shown in FIG. 4A ), the inner core 23 (which is covered with inner cover 61 ) may be inserted within outer cover 73 . Once inner core 23 (covered with inner cover 61 ) is inserted, outer cover 73 may be closed by the zipper closure mechanism 75 . Power supply cord 43 is positioned so as to extend out through the zipper opening at a position 87 ( FIG. 4B ) where zipper tracks 79 end. As shown in FIG. 4 C, an elastic band 44 may be sewn adjacent to zipper opening and adjacent to position 87 in order to hold electrical connector 45 (with its extended portion of power supply cord 43 ) and contain electrical connector 45 from dangling or flopping. Band 44 is rectangular in shape folded and having its two ends sewn to the zipper cover interface 80 . ON/OFF switch 73 (not shown in FIG. 4A ) is secured relative to the underside surface 89 of outer cover 73 , as described hereinafter.
[0048] As shown in FIG. 1 , decorative pattern 81 may be printed, embroidered, sewn or otherwise secured to front side 83 of outer cover 73 . Decorative pattern 81 may be a fancy, high quality design found on conventional decorative cushions. Back side 85 of cushion 11 is without decoration and is only a solid color. Front side 83 and back side 85 may be of one piece of material, or alternatively be connected together along their four sides 13 , 15 , 17 and 19 by a seam or stitching 70 ( FIG. 4B ) and by zipper tracks 79 . Zipper tracks 79 are disposed along the bottom edge 13 and partially along each of side edges 17 , 19 of cushion 11 , similar to the inner cover zipper closure mechanism 63 shown in FIG. 3B .
[0049] Referring to FIG. 8 , the backside 85 of outer cover 73 includes a decorative icon 91 . As shown in FIG. 5 , icon 91 has a circle shape, and may be formed of a separate piece of material sewn to the back side 85 . Alternatively, icon 91 may be a shape that is directly stitched or embroidered onto outer cover 73 . It is shown somewhat enlarged in FIG. 8 , but may have a diameter slightly larger than that of a hand thumb.
[0050] Icon 91 is located in the lower left corner of outer cover 73 ( FIG. 8 ) as viewed from the back side. The user presses firmly against icon 91 with his or her thumb in order to activate ON/OFF switch 51 ( FIG. 2A ). This action of pressing against icon 91 closes switch 51 , and thus turns ON the massage unit, or else the action deactivates ON/OFF switch 51 by opening switch 51 and thus turns OFF the massage unit. When massage unit 29 is ON, pressing icon 91 causes the massage unit to turn OFF. When massage unit 29 is OFF, pressing icon 91 causes the massage unit to turn ON.
[0051] In addition, heat may be applied from inside the massage cushion by a heater (not shown), e.g., a metal heating wire or blade, which receives electrical power via power supply cord 43 . The heater may turn ON when the massage unit is activated by the pressing of icon 91 .
[0052] Referring to FIG. 6 , outer cover 73 is shown pulled back onto itself to reveal underside surface 89 of outer cover 73 . Secured onto underside surface 89 is an attachment ring 93 . Attachment ring 93 is positioned directly beneath icon 91 (which is located on the backside 85 of outer cover 73 ). Attachment ring 93 is formed as one component of a Velcro attachment device (having hooks-and-loop material). That is, attachment ring 93 is formed from either one of the two Velcro components: typically two plastic sheets, one sheet covered with tiny loops and the other sheet covered with tiny flexible hooks, which two components adhere together when the components are pressed together. Ring 93 is circular in shape and is sewn to the underside surface 89 via thread stitches 95 which trace a circular pattern. Stitches 95 in a circular pattern are also shown on the backside 85 , in FIG. 5 , surrounding icon 91 .
[0053] As shown in FIG. 6 , another attachment ring 97 is secured to top surface 99 of inner cover 61 . Attachment ring 97 is formed as a Velcro hooks-and-loop material component, the opposite to component of ring 93 so as to adheringly mate with ring 93 . Ring 97 is circular in shape and of the same size as ring 93 , and is sewn to inner cover 61 by stitches 101 . Attachment ring 97 is located at a position on inner cover 61 so as to align with attachment ring 93 when the outer cover 73 is closed over inner cover 61 . The two attachment rings 95 , 97 mate together and attached to one another via the Velcro structure so as to maintain icon 91 securely positioned relative to inner cover 61 , i.e., relative to the position of sewn-on ring 97 .
[0054] Referring to FIG. 7 , inner cover 61 is shown pulled back onto itself to reveal the underside surface 71 of inner cover 61 . Secured onto underside surface 71 and vertically beneath the attachment ring 97 ( FIG. 6 ) is another attachment ring 105 . Attachment ring 105 is formed as a Velcro hooks-and-loop material component. Ring 105 is sewn to underside surface 71 of inner cover 61 via thread stitches 101 which trace a circular pattern. Thread stitches 101 in its circular pattern are also shown sewn on the ring 97 in FIG. 6 , as well. Stitches 101 secure both attachment rings 97 , 105 to inner cover 61 .
[0055] As shown in FIG. 7 , ON/OFF switch 51 includes and ON/OFF button 107 mounted to a button support structure 109 (which contains a conventional electrical switch) and a circular base 111 . Switch 51 is positioned against underside surface 71 of inner cover 61 and into a square shaped area generally designated by reference numeral 103 . Area 103 is defined by a square aperture 113 being formed in attachment ring 105 . Square shaped aperture 113 conforms to the square shaped top surface of button support structure 109 allowing the button support structure 109 to seat within square shaped aperture 113 .
[0056] Referring again to FIG. 6 , a square shaped aperture 115 ( FIG. 6 ) may be formed in attachment ring 93 to allow the button support structure 109 to seat also within square shaped aperture area 115 . Such a positioning aligns ON/OFF button 107 with decorative icon 91 ( FIG. 5 ). The aperture 116 of ring 97 may be circular, or other shape, of a size sufficient to allow button support structure 109 to seat into aperture 115 .
[0057] Referring again to FIG. 7 , an attachment ring 117 is made of a Velcro hooks-and-loop material and includes a central aperture 119 which is of a size to receive electrical wires 121 , 123 from the ON/OFF switch 51 . Ring 117 is of a size for mating with attachment ring 105 to hold and secure ON/OFF switch 51 in position against square shaped area 103 . Circular base 111 of switch 51 is of a diameter larger than central aperture 119 so that attachment ring 117 holds switch 51 firmly in place and against area 103 . Wires 121 , 123 form cord 53 ( FIGS. 2A , 2 B) and feed into inner core 23 and connect to massage unit 29 .
[0058] Referring again to FIG. 1 , in addition to decorative pattern 81 on the front side 83 of outer cover 73 , outer cover 73 may also include pointy ears 125 , as shown in FIG. 1 , at each of the upper corners of cushion 11 . Because the zipper opening of outer cover 73 is located at the bottom of cushion 11 , the fabric material at the top of outer cover 73 may be configured in a fashionable structure, e.g., to provide pointy ears 125 . In addition, extra fabric material may be allotted to outer cover 73 in the area adjacent to the massage unit so as to allow outer cover 73 to easily slip over the covered massage unit and thereafter be easily zipped closed. Further, stitched designs may mold the front side of the outer cover in fanciful shapes, as for example, a central diamond shape or other shape centrally located on the cushion. Further, inner core 51 may be molded to a particular shape that is visually evident from viewing of outer cover 73 ; the outer cover may be held tight against the inner core so as to provide a similar shape or an affected shape, to outer cover 73 .
[0059] Cushion 11 has a wide-range application in terms of providing massage by virtue of positioning massage unit 29 at the bottom section of inner core 51 . For example, massage unit 29 is capable of providing full-range neck massage to the user lying on top of the massage cushion. As another example, the massage cushion may be reversely positioned to provide massage to lower back areas of the human user. Further, the user may position the cushion in a location the user wishes in order to relieve minor aches and pains.
[0060] In addition, inner cover 61 need not be used in certain embodiments. Instead, outer cover 73 alone may directly receive the inner core 23 and directly receive attachment ring 117 of FIG. 7 and instead of attachment ring 97 of FIG. 6 .
[0061] While particular embodiments of the invention have been shown, it will be understood that the invention is not limited thereto since modifications may be made by those skilled in the art, particularly in light of the foregoing teaching. It is therefore, the appended claims that define the true spirit and scope of the invention. | A decorative cushion for providing therapeutic shiatsu massage. The decorative cushion includes a cushion core comprising of a foam structure. An electrically powered massage unit is placed off center in the bottom third of the cushion core. A fabric pouch contains the massage unit. A first cushion cover covers the cushion core. A second cushion cover covers the cushion core when covered with the first cushion cover. The second cushion cover includes various forms of decoration or embroidery for aesthetic purpose. | 0 |
This is a division, of application Ser. No. 699,536 filed June 24, 1976, now U.S. Pat. No. 4,096,093.
CROSS REFERENCE TO RELATED PATENT & APPLICATIONS
The following patent and applications are broadly concerned with somewhat similar catalysts:
Hwang & Grimmett U.S. Pat. No. 3,953,413 covering essentially chromium chelates of beta-dicarbonyl compounds as catalyst ingredients.
Hwang & Grimmett application Ser. No. 674,450, filed Apr. 7, 1976, which discloses modifying the catalyst support of U.S. Pat. No. 3,953,413.
My copending application Ser. No. 694,780, filed June 10, 1976 which discloses and claims catalysts and methods comprising low-valent chromium surface species as an active ingredient which are derived specifically from chromium carboxylates, aminocarboxylates or nitrogen-heterocyclic carboxylates.
The above patent and applications are assigned to the assignee hereof.
BACKGROUND OF THE INVENTION
The new and improved catalysts and methods of this invention are prepared by dispersing on a finely divided and difficult to reduce inorganic oxide selected from silica, alumina, thoria, zirconia, titania, magnesia and mixtures or composites thereof a reaction product of a chromium carboxylate reactant and an organic nitrogen compound reactant capable of forming a complex such as a chelate with the chromium and activating the resulting mixture by heating to and at an elevated temperature in a non-oxidizing atmosphere with a specific temperature range being within about 850°-2000° F. These reaction products are generally complexes of the reactants and in certain specific instances classifiable as chromium chelates.
SUMMARY OF THE INVENTION
In accordance with this invention, 1-olefins of 2 to 8 carbon atoms are polymerized or copolymerized with C 2 -C 20 1-olefins to form solid polymers or copolymers in the presence of the catalyst of this invention which comprises essentially low-valent chromium surface species as an active ingredient dispersed and supported on at least one difficult to reduce inorganic oxide.
More uniquely, the novel catalyst is prepared by dispersing on a finely divided inorganic support of the class consisting of silica, alumina, thoria, zirconia, magnesia, titania and mixtures and composites thereof an organic chromium-bearing compound or mixture formed by chelating or complexing reactions between a chromium (III) salt or derivative of a carboxylic acid and an organic nitrogen compound that is a diamine, polyamine, heterocyclic nitrogen base with at least two nitrogen atoms not directly linked to each other, or an aromatic amine and then activating the resulting mixture by heating to and at an elevated temperature of from about 850°-2000° F. in a non-oxidizing atmosphere.
Alternately, the catalyst may be prepared by dispersing on the finely divided inorganic oxide support a carboxylate or carboxylates of the chelated or complexed trivalent chromium wherein the chelating or complexing agent is a diamine, polyamine, a heterocyclic nitrogen base containing at least two nitrogen atoms not directly linked to each other, e.g., 2,2'-bipyridine, or an aromatic amine and then activating the resulting mixture by heating to and at an elevated temperature of from about 850°-2000° F. in a non-oxidizing atmosphere.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
In accordance with this invention polymerizable olefinic compounds and especially 1-olefins of 2 to 8 carbon atoms are polymerized or copolymerized with C 2 -C 20 1-olefins to form solid polymers and copolymers in the presence of the novel catalyst which is derived, as stated previously, from the reaction product of two types of reactants.
The first type of reactant comprises the chromium salts or derivatives of a carboxylic acid conforming to the formula ##STR1## wherein R is selected from hydrogen, alkyl, alkenyl, aryl, arylalkyl, cycloalkyl and cycloalkenyl radicals and combinations of these radicals with R containing 0-30 carbon atoms and a corresponding number of valence-satisfying hydrogen atoms, m is a whole number of 1 to 3, n is a whole number of 0 to 2, m plus n is 2 or 3 and X is an inorganic or organic negative group relative to chromium such as halide, alkyl, alkoxy and the like. Typical chromium compounds of this description are chromium (III) formate, chromium (III) acetate, chromium (III) propionate, chromium (III) butyrate, chromium (III) pentanoate, chromium (III) benzoate, chromium naphthenate and chromium oleate.
The second type of reactant comprises a wide variety of organic nitrogen compounds which are capable of forming a complex such as a chelate with the trivalent chromium and are essentially of the formulas ##STR2## wherein each R' is individually selected from hydrogen, alkyl, alkenyl, cycloalkyl, cycloalkenyl, aryl or arylalkyl radicals and containing 0-10 carbon atoms and a corresponding number of valence-satisfying hydrogen atoms, j is a whole number of 1 to 5, k is a whole number of 1 to 3, and Y is a divalent radical such as >CO, >NH, and >CH 2 .
One of the convenient and general methods of preparing these reaction products for use as a catalyst ingredient in this invention is to heat and evaporate to dryness an aqueous solution containing a nitrogen compound, just described, and a chromium carboxylate, previously defined, preferably at the mole ratio corresponding to their coordination stoichiometry. For example, in a system involving ethylenediamine and chromium (III) acetate, the preferred mole ratio is 3:1. Similarly, non-aqueous media may be used instead of the aqueous medium when one or both of the reactants are not soluble in water, or when the presence of water interferes with or unnecessarily complicates the formation of the desired reaction product. Under certain circumstances, a mixture of the reactants may be heated without solvent to or beyond the melting point to form a desired reaction product for use as a catalyst ingredient. In general, chelating or complexing reactions may be detected by color changes or by heat of reaction. The crude product obtained by various methods is in general further purified by a conventional method such as washing, rinsing, extracting, recrystallizing, etc.
The reaction product obtained by any of the above-mentioned methods is believed to contain generally a mixture of closely related N,N-type chelates or arylamine complexes of the trivalent chromium having various compositions which are essentially of the formula ##STR3## wherein Z is any of the nitrogen compounds defined earlier which are capable of chelating or complexing the trivalent chromium, p is a whole number of 1 to 3 if Z is bidentate but may be as high as 6 if Z is an arylamine, q is a whole number of 0 to 3 depending on Z, p, R and the conditions to which the reaction product is exposed, and X, R, m and n are the same as previously defined in connection with the reactants. A typical reaction product obtained by heating and evaporating to dryness an aqueous solution of ethylenediamine and chromium triacetate having the mole ratio of 3:1 appears to contain, among other things, tris(ethylenediamine) chromium triacetate, bis(ethylenediamine) chromium triacetate, bis (ethylenediamine) aquochromium triacetate, ethylenediaminediaquochromium triacetate, etc.
Logically, all or at least some of the chelated or complexed species found in said reaction product should be also suitable as catalyst ingredients in the present invention regardless of their origins or methods by which they are prepared. Among all the possible variants described in the preceding paragraph, the most suitable ones are those highly chelated by the nitrogen compound but less complexed by the water molecule and are essentially of the formula ##STR4## wherein Z, R and X are compounds or radicals as defined previously in connection with the reactants, p' is a whole number of 2 or 3 if Z is bidentate, e.g. ethylenediamine, but 1 or 2 if Z is tridentate, e.g. diethylenetriamine, q' is a whole number of 0 or 1, m is a whole number of 1 to 3, n is a whole number of 0 to 2, and m plus n is a whole number of 2 or 3. In the most preferred case, both q' and n are 0, p' is 3 if Z is bidentate and a typical compound in this case is tris(ethylenediamine)chromium triacetate.
CATALYST PREPARATION
In preparing a catalyst of this invention a series of steps are normally taken as follows, some being optional as indicated.
PRETREATMENT OF SUPPORT
Catalyst support, selected from silica, alumina, zirconia, thoria, magnesia, titania, or mixtures and composites thereof resulting from coprecipitation, impregnation, vapor-phase deposition, etc. may have surface areas ranging from a few m 2 /g to over 700 m 2 /g but preferably above 150 m 2 /g. Pore volume is preferably in excess of 0.5 cc/g if surface area is primarily related to micropores. A finely divided non-porous support with relatively high surface area such as "Cab-O-Sil" may also be used in this invention.
Although not required, pretreatment of the support prior to its impregnation with an appropriate organic chromium compound is often preferred. Such pretreatment typically consists of adjusting the moisture content of the support by drying at elevated temperatures or chemically modifying the support with compounds containing metallic elements such as zirconium, titanium, boron, vanadium, tin, molybdenum, magnesium, hafnium or the like. Chemical modification may include adding compounds such as ammonium hexafluorosilicate which can react with the support or with the organic chromium compound during activation. Chemical modification using metal alkyls which react with the support can also be used.
The chemically modified support, especially when involving the aqueous solution impregnation, is generally calcined at elevated temperatures to fix a modifier onto the support and also to expel an excess amount of moisture, much the same way as adjusting the moisture content in the unmodified support. The calcining or drying step is normally carried out at temperatures from 300° to 2000° F. and can be done by any process known in the art such as in a muffle furnace or in a heated fluidized bed using gases such as nitrogen, air, carbon monoxide, or other suitable reactive or inert gases are fluidizing gases.
DISPERSION OF THE CHROMIUM-BEARING COMPOUND OR MIXTURE ON THE SUPPORT
The dispersion of the chromium-bearing compound or mixture on the support can be readily accomplished by a conventional impregnation method using an aqueous or organic solvent such as methanol, acetone, toluene or hexane. Equally satisfactory dispersion is often achieved by a more convenient method which calls for dry-blending of the chromium-bearing compound or mixture with the support and effecting the final dispersion during the initial stage of activation. If such a dry-blending technique is used, the subsequent activation is best carried out in the fluid bed operation. The optimum chromium content of the catalyst is dependent on the support type, surface area and pore structure. With a typical support whose surface area is 100-800 m 2 /g and total pore volume is 0-3.0 cc/g, the chromium level may range from 0.05 to 10% with the preferred level somewhere around 0.1-2.0 weight percent on the dry basis.
THERMAL ACTIVATION OF THE CATALYST IN NON-OXIDIZING ATMOSPHERE
In accordance with this invention, the non-oxidizing atmosphere is provided either by inert gas such as nitrogen, helium, argon, etc., by reducing gas such as carbon monoxide, hydrogen, etc., or by evacuation to a sufficiently high vacuum. In the latter case, it is desirable to permit deliberate leak-in of a small amount of non-oxidizing gas. In all cases, a mixture of non-oxidizing gases may be used, if desired.
When the activation is carried out in non-oxidizing (inert or reducing) gas atmosphere, either fluid-bed or stationary-bed operation may be used. Experience, however, shows that fluid-bed operation is preferable. Normally, for economic reasons, deoxygenated nitrogen is used to fluidize the catalyst in an activator. It was experimentally established that even a minute contamination of oxygen during the activation generally has a detrimental effect on catalyst activity, and that such an adverse effect is greatly magnified when the chromium level is reduced to about 0.15% from a more typical 1 weight percent, often to the extent of completely deactivating the catalyst.
The activation step is usually carried out using a preselected heating cycle which includes heating the catalyst up to a specific temperature, usually in the range of 850°-2000° F., holding the catalyst at this temperature for a prescribed length of time, usually 30 minutes to 12 hours, followed by cooling to ambient temperature in nitrogen atmosphere. The heating cycle may also include one or more hold periods at temperatures below the maximum, as mentioned above, to permit diffusion of moisture, solvent or gaseous products from the catalyst pores, or to permit reactions such as decomposition of the surface organic chromium species to take place. The final activation temperature is usually selected on the basis of several factors, such as desired resin properties, support type, pretreatment, etc. The heat-up rate above 600° F. is generally not critical.
POLYMERIZATION PROCESSES
The novel catalysts of this invention may be used to produce polymers or copolymers in liquid-phase, solution or slurry processes or vapor-phase processes. In the liquid-phase operation, any C 3 -C 12 saturated liquid hydrocarbon may be used as a reaction medium or diluent. Other types of solvents including aromatic hydrocarbons and chlorinated solvents may also be used. The polymerization of 1-olefins may be carried out in batch or continuous process. The catalyst is generally charged into the reaction as a slurry in the continuous process, but as dry powder in the batch process. The mode of charging the solvent and olefin to the reactor system may follow any conventional practice applicable to batch or continuous operation, respectively. A vigorous agitation of the reaction medium is of course greatly preferred and so is the provision for efficient cooling to control the reactor temperature.
In liquid-phase processes, the olefin polymer or copolymer is normally recovered by flashing off solvent without any intervening steps for removal of the catalyst. The activity of the catalysts described in this invention is normally greater than 3000 pounds of polymer per pound of catalyst so that catalyst removal is unnecessary for practical purposes. Reactor conditions are dependent on the type of olefin as well as the desired polymer properties. In the case of ethylene, reactor pressures may range from 50 to 1000 psig, temperatures from 150°-500° F. and solid levels from 5-60% by weight.
The following examples illustrate the invention.
EXAMPLE 1
The reaction product of chromium (III) acetate and ethylenediamine used in this example was prepared by the following method. 15 grams of ethylenediamine and 19 grams of chromium (III) acetate were dissolved in 30 ml and 50 ml of demineralized water, respectively. These two solutions were then mixed, heated, and evaporated to dryness. The residue was dissolved in 300 ml methanol for removal of the insolubles. Finally, the filtrate was evaporated and 29 grams of reddish brown solid was recovered.
A catalyst was prepared by the following steps:
(1) About 10 pounds of Davison MS-ID silica gel, having about 350 m 2 /g surface area and 1.70 cc/g total pore volume, was dried in the pilot plant scale activator, essentially a 12" I.D. by 30" long cylinder equipped with a gas dispersing plate and encircling electrical heater. The actual drying was accomplished in the fluid bed maintained by 100 SCFH of air and held at 1300° F. for five hours.
(2) 30 grams of this predried silica was impregnated with a 90 ml methanol solution containing 2.4 grams of the above reaction product of chromium (III) acetate and ethylenediamine.
(3) Solvent was then evaporated off at 85°-150° F. by nitrogen sweep until the catalyst became free flowing. This drying step always followed the impregnation of the support using an organic solvent and therefore its mention will be omitted from the subsequent examples for simplicity.
(4) About 15 grams of this impregnated and partially dried catalyst was charged into a catalyst activator consisting of a 38mm O.D., 27 inch long Vycor glass tube, fitted with a fritted disc in the midsection of the tube for the purpose of fluidizing the catalyst and provided with tubular electrical heaters around the tube for adjusting the catalyst temperature. The catalyst was then fluidized with the flow of deoxygenated nitrogen, approximately 400 cc/minute, and activated according to the following heating cycle: (a) hold at 250° F. for one hour, (b) hold at 350° F. for one hour, (c) hold at 550° F. for one hour, (d) raise 200° F. every 15 minutes up to 1600° F., (e) hold at 1600° F. for 2 hours, and (f) cool down to ambient temperature in nitrogen atmosphere. The deoxygenated nitrogen that was used in this and subsequent examples was obtained by passing high purity nitrogen through a bed of reduced copper catalyst.
(5) The catalyst thus activated was transferred into a closed flask equipped with a hose-and-clamp at both openings without exposing it to air. This step was also followed in all the subsequent examples.
Evaluation of the activated catalyst for its ethylene polymerization activity was carried out in accordance with a general procedure as follows: The reactor, essentially an autoclave 5" I.D. and about 12" deep, was equipped with an agitator rotating at 560 rpm, a flush bottom valve, and three ports for charging catalyst, isobutane and ethylene, respectively. The reactor temperature was controlled by a jacket containing methanol which was kept boiling by an electrical heater encircling the jacket. The control mechanism involved the automatic adjustment of jacket pressures in response to either cooling or heating requirements.
To test a catalyst, the reactor was first thoroughly purged with ethylene at temperatures around 200° F. followed by the transfer of 0.05-0.5 g catalyst from a catalyst flask under nitrogen into the reactor via a transfer tube without exposing it to air. After the catalyst charge port was closed, 2900 ml of isobutane (dried and deoxygenated) was charged into the reactor, trapped ethylene was vented, and the reactor was allowed to warm up to 225° F. The reactor was then pressurized with ethylene which was regulated at 550 psig and which was permitted to flow into the reactor whenever the reactor pressure dropped below 550 psig. An instantaneous flow rate of ethylene was monitored by rotameters of various capacity. The duration of a test run was normally from 40 minutes to four hours depending on the polymerization rate or desired productivity.
At the end of a test run, ethylene flow was cut off, the flush bottom valve was opened, and the reactor content was dumped into a recovery pot, approximately 5" I.D. and 10" deep, where isobutane was allowed to flash off through a 200 mesh screen into the vent. Polymer particles left in the pot were recovered and weighed.
In this particular example, the activated catalyst was tested twice. The first run involved a catalyst charge of 0.2228 g, lasted for 60 minutes, and resulted in the recovery of 104 grams of polymer having the unmilled resin melt index of 0.11. The second run used a catalyst charge of 0.1830 g, was terminated after 60 minutes, and produced 80 grams of polymer whose melt index on an unmilled sample was 0.10. The resins in both runs were white to the naked eye.
EXAMPLES 2-5
The catalysts used in these examples were prepared essentially in the same manner as in Example 1 except for the final hold temperatures in the activation cycle which were 1700 and 1500° F., respectively, instead of 1600° F.
In accordance with the general procedure described in Example 1, each of these catalysts were tested and the following results were obtained.
______________________________________ Un-Act. Catalyst Run Polymer milledEx. Temp. Charge, Time Rec'd React. Melt ResinNo. ° F. g Min. g g/g/hr Index Color______________________________________2 1700 0.2074 60 89 429 0.17 White3 1700 0.1679 60 43 256 0.44 White4 1500 0.2203 60 102 463 0.24 White5 1500 0.1983 60 90 453 0.26 White______________________________________
EXAMPLES 6-7
These examples illustrate the invention with the reaction product of chromium (III) pentanoate and ethylenediamine.
The reaction product of chromium (III) pentanoate and ethylenediamine that was used in these examples was prepared by mixing 19.7 grams of chromium (III) pentanoate dissolved in 70 ml acetone and 10 grams ethylenediamine dissolved in 30 ml demineralized water, heating and then concentrating by evaporation to a tacky, dark red semi-solid. After the residue was dissolved in 400 ml acetone, the insolubles were filtered off and the filtrate was once again evaporated to tacky, dark red material weighing about 15 grams. The above-mentioned chromium (III) pentanoate was in turn prepared by the metathetical reaction between the intermediate sodium pentanoate and chromium trichloride as follows: 200 grams of valeric acid was first neutralized approximately to a pH of 9 using a 500 ml aqueous solution containing about 78 grams sodium hydroxide. 174 grams of chromium trichloride was dissolved in 500 ml water and then mixed with the above solution to form the precipitate. The precipitate was dissolved in 2100 ml benzene and washed in solution with a total of 1000 ml water. After filtration, the filtrate was evaporated until about 203 grams of thick, tacky, greenish-blue substance was obtained.
A catalyst was prepared by dispersing 3.1 grams of the above reaction product onto 30.0 grams of the predried 952 MS-ID silica described in Example 1 by solution impregnation using 90 ml acetone as the solvent. About 15 grams of this impregnated and partially dried catalyst was activated essentially in the same manner as in Example 1.
The catalyst thus activated was tested twice in accordance with the general procedure described in Example 1. For catalyst charges of 0.1797 (Example 6) and 0.1589 (Example 7) and a reactor run time of 60 minutes each, 117 and 88 grams of polymer were recovered in the two examples corresponding to the reactivities of 651 and 553 g/g cat/hr, respectively. The resin melt indices of the unmilled samples were 0.20 and 0.26, respectively. The resin color was relatively white in both runs.
EXAMPLE 8
This example illustrates the invention with the reaction product of chromium (III) formate and ethylenediamine.
The reaction product of chromium (III) formate and ethylenediamine used in this example was prepared by mixing two solutions, 15.7 grams of chromium (III) formate dissolved in 30 ml water and 15.0 grams of ethylenediamine dissolved in 50 ml water, heating and concentrating the resulting mixture to a tacky, red residue. After the residue was dissolved in 200 ml methanol, the insolubles were filtered off, and the filtrate was evaporated once again to a slightly tacky, red substance weighing about 16 grams.
2.2 grams of this reaction product was then dissolved in 90 ml methanol to impregnate 30.0 grams of the predried 952 MS-ID silica described in Example 1. About 20 grams of the impregnated and partially dried catalyst was then activated in the same manner as in Example 1.
According to the general test procedure described in Example 1, 92 grams of polymer was recovered after one hour with 0.2179 g of the catalyst in the polymerization. The resin melt index on an unmilled sample was 1.59.
EXAMPLES 9-10
These examples demonstrate the invention using higher homologs of ethylenediamine including in general 1,2-diaminoalkanes (e.g. propylenediamine), and 1,3-diaminoalkanes (e.g. 1,3-diaminopropane).
The reaction product of propylenediamine and chromium (III) acetate used as a catalyst ingredient in Example 9 was prepared by heating and evaporating to dryness the mixture of two solutions, one prepared by dissolving 15 grams of 1,2-diaminopropane in 30 ml water and the other by dissolving 15.5 grams of chromium (III) acetate in 50 ml water. The residue thus prepared was dissolved in 200 ml methanol. After removal of the insolubles, the filtrate was evaporated to recover 23 grams of red material.
The catalyst used in Example 9 was prepared by dispersing 2.6 grams of this reaction product onto 30.0 grams of predried 952 MS-ID silica as described in Example 1 using 90 ml of methanol as the solvent. About 15 grams of this impregnated and partially dried catalyst was then activated by the same method as in Example 1.
The reaction product of 1,3-diaminopropane and chromium (III) acetate used as a catalyst ingredient in Example 10 was prepared essentially by a similar procedure as in Example 9 except for minor differences in the amount of solvent used. About 18 grams of a slightly tacky, purple substance was recovered.
The catalyst used in Example 10 was prepared by using 2.7 grams of this reaction product and 30.0 grams of predried 952 MS-ID silica described in Example 1. The preparation procedure, including non-oxidative activation, was essentially identical to the one used in Example 9.
The two catalysts thus prepared in Examples 9 and 10 were then tested according to the general procedure described in Example 1 and the following results were obtained.
______________________________________ Polymer UnmilledExam. Catalyst Run Time Rec'd React. MeltNo. Charge,g Min. g g/g/hr Index______________________________________9 0.1865 60 20 107 0.2610 0.1648 60 66 402 0.72______________________________________
EXAMPLE 11
This example further illustrates the invention by using an aromatic diamine instead of aliphatic diamines which were used in the preceding Examples.
The reaction product of 3,4-diaminotoluene and chromium (III) acetate used in this example was prepared by blending two solutions, one containing 20 grams of 3,4-diaminotoluene in 50 ml water and the other 12.5 grams of chromium (III) acetate in 50 ml water, followed by heating and evaporating the mixture to dryness. The residue was then dissolved in 200 ml acetone, and the filtrate was evaporated to yield about 25 grams of a residue of a dark brown substance.
A catalyst was prepared by impregnating 30 grams of a predried 952 MS-ID silica described in Example 1 with 90 ml of acetone solution containing 3.2 g of this reaction product. About 15 grams of the impregnated and partially dried catalyst was activated in nitrogen by the same method as in Example 1.
For a catalyst charge of 0.1887 g and run time of 60 minutes, in accordance with the general test procedure described in Example 1, 55 grams of polymer was recovered having a resin melt index (unmilled) of 1.0.
EXAMPLE 12
This example demonstrates the invention using polyamines or condensed diamines such as diethylenetriamine.
The reaction product of diethylenetriamine and chromium (III) acetate used in this example was prepared by mixing two solutions, one containing 15 grams of diethylenetriamine in 50 ml water and the other 11.1 grams of chromium (III) acetate in 40 ml water, followed by heating and evaporating the mixture to an oily, purple, glue-like residue. This residue was dissolved in 300 ml methanol and after removal of the insolubles the filtrate was again evaporated to an oily, glue-like, purple substance weighing about 18 grams.
A catalyst was prepared by dispersing 3.2 grams of this reaction product onto 30 grams of the predried 952 MS-ID silica as described in Example 1 by impregnation using 90 ml methanol as solvent. About 15 grams of the impregnated and partially dried catalyst was then activated in deoxygenated nitrogen as in Example 1 in all essential respects.
The above catalyst was tested according to the general procedure described in Example 1. 34 grams of polymer was recovered having an unmilled melt index of 0.69 over a one hour period with a catalyst charge of 0.1335 g.
EXAMPLES 13-15
These examples demonstrate the invention with the reaction product of a chromium (III) carboxylate and a heterocyclic nitrogen base capable of chelating the trivalent chromium, e.g. 2,2'-bipyridine and 2,2'-dipyridylamine. ##STR5##
The chromium-containing reaction product used as the catalyst ingredient in Examples 13 and 14 was prepared by mixing two solutions, one containing 10 grams of 2,2'-bipyridine in 40 ml water and the other 4.9 grams of chromium (III) acetate in 30 ml water, followed by heating and concentrating the mixture to a slightly tacky residue of a brown material. This residue was dissolved in 300 ml methanol for removal of the insolubles. Upon evaporating the filtrate, about 9 grams of brown residue was obtained. 4.0 grams of this reaction product was then used to impregnate 30 grams of predried 952 MS-ID silica as described in Example 1 using 90 ml methanol as a solvent. About 15 grams of the impregnated and partially dried catalyst was then activated as in Example 1.
The chromium-containing product used as a catalyst ingredient in Example 15 was prepared by mixing two solutions, one containing 10 grams of 2,2'-dipyridylamine in 50 ml water and the other 4.5 grams of chromium acetate also in 50 ml water, followed by heating and evaporating the mixture to dryness. A violet-colored substance was leached out from the hard residue using a total of 500 ml water. After evaporating off the water, 4.6 grams of violet substance was obtained. A catalyst was then prepared by impregnating 30 grams of 952 MS-MD silica as received, without predrying, using a 90 ml aqueous solution containing 4.39 grams of the reaction product just described. The impregnated catalyst was dried in an oven at 230° F. for 2 hours and afterward at 400° F. for another 4 hours in the same oven. About 15 grams of this impregnated and dried catalyst was then activated in the same manner as in Example 1.
The catalysts of Examples 13, 14 and 15 were tested according to the general procedure described in Example 1. There were obtained the following results:
______________________________________ Run PolymerExam. Catalyst Time Rec'd Reactivity Resin MINo. Charge, g Min. g g/g cat/hr (Unmilled)______________________________________13 0.1752 60 59 334 0.4214 0.1735 60 61 352 0.3515 0.2041 60 113 554 1.06______________________________________
EXAMPLE 16
This example demonstrates the applicability of this invention to the reaction product of an aromatic amine, e.g. aniline, and chromium (III) acetate.
The reaction product used as a catalyst ingredient in this example was prepared by blending 12.3 grams of chromium acetate, 100 ml of water and 15 grams of aniline and heating the mixture to precipitate a tacky, black substance. The precipitate was washed with 100 ml water five times and then dissolved in 200 ml acetone for removal of the insolubles. The filtrate was evaporated to a tacky, black material weighing roughly 13 grams.
A catalyst was prepared by dispersing 2.9 grams of this reaction product onto 30 grams of the predried 952 MS-ID silica described in Example 1 by solution impregnation using 90 ml acetone as the solvent. About 15 grams of this impregnated and partially dried catalyst was activated by the method used in Example 1.
A test of ethylene polymerization activity by the general method described in Example 1 indicated that the reactivity was 261 g/g catalyst/hr and the unmilled resin melt index was 0.80.
Various theories have been presented as an aid in understanding the invention. It should be understood that the invention is not limited by any of these theories. | A new catalyst and method of making polymers therewith and the process of preparing the catalyst in which the catalyst is prepared by dispersing on a finely divided carrier material, particularly a difficultly reducible inorganic support such as silica, a reaction product of (1) a chromium carboxylate reactant and (2) an organic nitrogen cmpound reactant capable of forming a complex such as a chelate with the chromium and activating the resulting mixture by heating at an elevated temperature in a non-oxidizing atmosphere. | 2 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a continuation of pending U.S. patent application Ser. No. 09/389,862, filed Sep. 2, 1999 now U.S. Pat. No. 6,492,738.
TECHNICAL FIELD
The present invention relates to apparatus and methods of testing and assembling bumped die and bumped devices using an anisotropically conductive layer, suitable for testing, for example, flip chip die, chip scale packages, multi-chip modules, and the like.
BACKGROUND OF THE INVENTION
Bumped die and other bumped devices are widely used throughout the electronics industry. As the drive toward smaller electronics continues, the pitch (or spacing) of solder bumps on such bumped devices continues to decrease. The increasingly finer pitches of the solder bumps on bumped die and bumped devices raise concerns about the reliability of these devices. These concerns are being addressed by testing.
A die (or chip) is typically tested during the manufacturing process to ensure that the die conforms to operational specifications. Solder bumps (or balls) are then formed on bond pads of the die using a solder deposition device, such as a solder ball bumper. The solder bumps are typically formed with a height of from 25 μm to 75 μm. The bumped die are then tested by placing conductive test leads in contact with the solder bumps on the die, applying a test signal to the bumps via the test leads, and determining whether the bumped die responds with the proper output signals. If the bumped die tests successfully, it may be installed on a printed circuit board, a chip scale package, a semiconductor module, or other electronics device.
FIG. 1 is a cross-sectional view of a bumped die 10 engaged with a test carrier 20 in accordance with the prior art. In this typical arrangement, the bumped die 10 includes a substrate 12 with a plurality of bond pads 14 thereon. A solder bump 16 (or other suitable conductive material) is formed on each of the bond pads 14 . The test carrier 20 has a plurality of contact pads 22 thereon, each of the contact pads 22 being electrically coupled with a test lead 24 . For testing of the bumped die 10 , the solder bumps 16 engage the contact pads 22 of the test carrier 20 , and the appropriate test signals are applied to the bumped die 10 through some of the test leads 24 . Output signals from the bumped die 10 are monitored through other test leads 24 to determine whether the bumped die 10 is functioning to specifications. Test carrier apparatus of the type shown in FIG. 1 for testing unpackaged die are described in U.S. Pat. No. 5,519,332 to Wood et. al., incorporated herein by reference.
Testing of the bumped die 10 generally includes four levels of testing. A first or “standard probe” level includes the standard tests for gross functionality of die circuitry. A second or “speed probe” level includes testing the speed performance of the die for the fastest speed grades. A third or “burn-in die” level involves thermal cycling tests intended to drive contaminants into the active circuitry and to detect early failures. And a fourth or “known good die (KGD)” level includes testing to provide a reliability suitable for final products.
To ensure proper transmission of the test signals and output signals, the solder bumps 16 may be temporarily connected with the contact pads 22 by reflowing the bumps, thereby soldering the bumps to the contact pads. After the testing is complete, the solder bumps 16 may be reflowed to disconnect the bumps from the contact pads. Connecting and disconnecting the solder bumps 16 from the contact pads 22 , however, involve time consuming processes and may damage the solder bumps 16 or the contact pads 22 .
Another problem with soldering the solder bumps 16 to the contact pads 22 is that the coefficient of thermal expansion (CTE) of the bumped die 10 may be appreciably different from the CTE of the test carrier 20 . During burn-in die testing, the bumped die 10 and test carrier 20 are placed in a burn-in oven and subjected to temperature cycling (e.g. −55° C. to 150° C.) for a time period of from several minutes to several hours or more. Due to the different CTE of the bumped die 10 and the test carrier 20 and the rigidity of the solder connections, significant stresses may develop throughout the components. These stresses may result in delamination or other damage to the bumped die 16 or the test carrier 20 , and may degrade or damage the connection between the solder bumps 16 and the bond pads 14 .
An alternate approach to soldering is to simply compress the solder bumps 16 into engagement with the contact pads 22 . Ideally, only a small compression force is needed to engage the solder balls 16 against the contact pads 22 so that tests may be conducted. Methods and apparatus for testing die in this manner are fully described in U.S. Pat. No. 5,634,267 to Farnworth and Wood, incorporated herein by reference. The applied compression force, however, must be kept to a minimum because larger forces may damage the circuitry of the bumped die 10 or the test carrier 20 .
A problem common to both the solder reflow and the compression force methods of engagement is that the solder bumps 16 are not uniformly shaped. As shown in FIG. 1, the solder bumps 16 are usually of different heights. Using typical manufacturing methods and solders, the nominal variation between the tallest and shortest bumps (shown as a distance d on FIG. 1) is presently about 10% of the average solder ball height. Therefore, when the bumped die 10 is placed on the test carrier 20 , the shorter solder bumps may not touch the corresponding contact pads. In some cases, especially for very fine pitch solder bumps, the gaps between the shorter solder bumps and the contact pads may be too large to overcome using solder reflow (because of the small volume of solder in each bump) or by using compression force (because of possible damage to the bumped die).
The variation in solder bump height also creates uncertainty in the final assembly of electronics components that include bumped devices. As the number of bumps on the bumped device increases, the failure rate of the assembled package increases due to solder bump non-uniformity.
FIG. 2 is a partial cross-sectional view of the bumped die 10 of FIG. 1 engaged with another conventional test carrier 40 . The test carrier 40 includes a test substrate 42 having a plurality of pockets 44 disposed therein. As shown in FIG. 2, the pockets 44 have sloping sidewalls 46 , and a pair of contact blades 48 project from opposing sidewalls 46 into each pocket 44 . Conductive test leads 50 are formed on the test substrate 42 , including on the sidewalls 46 and contact blades 48 of the pockets 44 .
During testing, the solder bumps 16 at least partially engage the pockets 44 of the test carrier 40 with the sharp contact blades 48 partially penetrating the solder bumps 16 . The solder bumps 16 may also contact the sloping sidewalls 46 of the test carrier 40 . Thus, the desired electrical connection between the solder bumps 16 and the test leads 50 may be achieved despite the variation in the solder bump height.
Although the test carrier 40 having pockets 44 with contact blades 48 addresses solder bump height variation, testing solder bumps with the test carrier 40 has several disadvantages. For example, because the contact blades 48 penetrate the solder bumps 16 , the solder bumps may be cracked, chipped, or otherwise damaged by the contact blades. The solder bumps 16 may also become stuck to the contact blades 48 , requiring additional time and effort to disengage the bumped die 10 from the test carrier 40 . Furthermore, the test carrier 40 with the plurality of pockets 44 is relatively costly to fabricate and more difficult to maintain than alternative test carriers having flat contact pads.
FIG. 3 is a partial cross-sectional view of the bumped die 10 of FIG. 1 engaged with another prior art test carrier 60 . In this example, the test carrier 60 includes a test substrate 62 having a plurality of pedestals 64 formed thereon. Test leads 66 are disposed on the test substrate 62 , each test lead 66 terminating in a contact pad 68 on the top of each pedestal 64 . A plurality of projections 69 project from each contact pad 68 . Apparatus for testing semiconductor circuitry of the type shown in FIG. 3 are more fully described in U.S. Pat. No. 5,326,428 to Farnworth et. al., U.S. Pat. No. 5,419,807 to Akram and Farnworth, and U.S. Pat. No. 5,483,741 to Akram et. al., which are incorporated herein by reference.
To conduct a test of the bumped die 10 , the solder bumps 16 engage the contact pads 68 so that the sharp projections 69 at least partially penetrate the solder bumps 16 . The projections 69 may be properly sized to penetrate into the taller solder bumps, allowing the shorter solder bumps to at least contact the projections of the corresponding contact pad 68 .
One of the drawbacks of testing bumped die using the carrier 60 having projections 69 is that the projections (like the contact blades 48 described above) may damage the solder bumps 16 . Furthermore, the projections 69 are relatively expensive to manufacture, particularly when the projections must be sized to account for a nominal 10% variation in the solder bump height.
SUMMARY OF THE INVENTION
The present invention is directed toward apparatus and methods of testing and assembling bumped devices using anisotropically conductive layers. In one aspect of the invention, a semiconductor device comprises a bumped device having a plurality of conductive bumps formed thereon, a substrate having a plurality of contact pads distributed thereon and approximately aligned with the plurality of conductive bumps, and an anisotropically conductive layer disposed between and mechanically coupled to the bumped device and to the substrate. The anisotropically conductive layer electrically couples each of the conductive bumps with a corresponding one of the contact pads, providing electrical contact between the conductive bumps and the contact pads despite variation in conductive bump height, and without damaging the conductive bumps.
In another aspect, an apparatus for testing a bumped device having a plurality of conductive bumps includes a substrate having a plurality of contact pads distributed thereon and substantially alignable with the plurality of conductive bumps, and an anisotropically conductive layer disposed on the first surface and engageable with the plurality of conductive bumps to electrically couple each of the conductive bumps with a corresponding one of the contact pads. Alternately, the test apparatus may also include an alignment device. In another aspect, the test apparatus may include a bumped device handler. The test apparatus provides for rapid and efficient engagement, testing, and disengagement of the bumped device.
In another aspect of the invention, a method of forming a semiconductor device includes providing a bumped device having a plurality of conductive bumps formed thereon, providing a substrate having a plurality of contact pads distributed thereon, forming an anisotropically conductive layer between the conductive bumps and the contact pads, approximately aligning the plurality of conductive bumps with the plurality of contact pads, and engaging the plurality of conductive bumps and the plurality of contact pads with the anisotropically conductive layer to electrically couple each of the conductive bumps with a corresponding one of the contact pads.
In yet another aspect of the invention, a method of testing a bumped device includes engaging a plurality of contact pads with an anisotropically conductive layer, engaging the plurality of conductive bumps with the anisotropically conductive layer substantially opposite from and in approximate alignment with the plurality of contact pads, forming a plurality of conductive paths through the anisotropically conductive layer so that each of the conductive bumps is electrically coupled to one of the contact pads, and applying test signals through at least some of the contact pads and the conductive paths to at least some of the conductive bumps. Alternately, the method further includes at least partially curing the anisotropically conductive layer. The method advantageously reduces the time, effort and expense involved in connecting and disconnecting the conductive bumps from the contact pads, reduces the potential for damage to the conductive bumps or the contact pads, and accommodates variation in the heights of the conductive bumps.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a cross-sectional view of a bumped die engaged with a test carrier in accordance with the prior art.
FIG. 2 is a partial cross-sectional view of the bumped die of FIG. 1 engaged with an alternate embodiment of a test carrier in accordance with the prior art.
FIG. 3 is a partial cross-sectional view of the bumped die of FIG. 1 engaged with another embodiment of a test carrier in accordance with the prior art.
FIG. 4 is a partial cross-sectional view of the bumped die of FIG. 1 engaged with a test carrier in accordance with an embodiment of the invention.
FIG. 5 is a partial cross-sectional view of the bumped die of FIG. 1 engaged with a test carrier in accordance with an alternate embodiment of the invention.
FIG. 6 is a partial cross-sectional view of the bumped die of FIG. 1 engaged with a test carrier in accordance with another alternate embodiment of the invention.
FIG. 7 is a partial cross-sectional view of the bumped die of FIG. 1 engaged with a test carrier in accordance with yet another embodiment of the invention.
DETAILED DESCRIPTION OF THE INVENTION
The following description is generally directed toward apparatus and methods of testing and assembling bumped die and bumped devices using anisotropically conductive layers. Many specific details of certain embodiments of the invention are set forth in the following description and in FIGS. 2-7 to provide a thorough understanding of such embodiments. One skilled in the art, however, will understand that the present invention may have additional embodiments, or that the present invention may be practiced without several of the details described in the following description.
Throughout the following discussion, apparatus and methods in accordance with the invention are described in relation to the testing and assembly of bumped die. It is understood, however, that the inventive apparatus and methods may be used to test and assemble any number of bumped devices, including chip scale packages, chip modules, or any other bumped devices. To simplify the following discussion, however, the inventive apparatus and methods are described in relation to testing and assembly of bumped die with a test carrier or a printed circuit board, allowing the reader to focus on the inventive aspects.
FIG. 4 is a partial cross-sectional view of the bumped die 10 of FIG. 1 engaged with a test carrier 100 in accordance with an embodiment of the invention. In this embodiment, the test carrier 100 includes a test substrate 102 having a plurality of contact pads 104 coupled with a plurality of test leads 106 . An anisotropically conductive layer 160 having conductive particles 162 distributed in a suspension material 164 is formed on the test substrate 102 and contact pads 104 .
The anisotropically conductive layer 160 is formed such that electrical resistance in one direction through the layer 160 differs from that measured in the other directions. Typically, electrical conductivity is provided in one direction (e.g. the “z” direction) while high resistance is provided in all other directions. The conductivity in the one direction may be pressure sensitive, requiring that the material be compressed in that direction to achieve the desired conductivity.
One type of anisotropically conductive material suitable for forming the anisotropically conductive layer 160 is known as a “z-axis anisotropic adhesive.” In the z-axis anisotropic adhesive, the conductive particles 162 are distributed to a low level such that the particles do not contact each other in the xy plane. Compression of the layer 160 in the z direction, however, causes the conductive particles 162 to contact each other in the z direction, establishing an electrically conductive path. The conductive particles 162 may be formed from any suitable electrically conductive materials, such as gold, silver, or other electrically conductive elements or compounds. Similarly, the suspension material 164 may be include, for example, a thermoset polymer, a B-stage (or “pre-preg”) polymer, a pre-B stage polymer, a thermoplastic polymer, or any monomer, polymer, or other suitable material that can support the electrically conductive particles 162 .
Z-axis anisotropic adhesives may be formed in a number of ways, including, for example, as a film or as a viscous paste that is applied (e.g. stenciled, sprayed, flowed, etc.) to the contact pads 104 . The anisotropically conductive adhesives may then be cured. Curing may be performed in a variety of ways, such as by subjecting the materials to certain environmental conditions (e.g. temperature, pressure, etc.), or by the removal of solvents or suitable curing compounds, or by irradiation/exposure to ultraviolet or ultrasonic energy, or by other suitable means.
For example, z-axis anisotropic adhesives are commercially available in both a thermoplastic variety or a thermosetting variety. Thermoplastic anisotropic adhesives are those that are heated to soften for application to the test substrate and then cooled for curing, and include, for example, solvent-based hot-melt glue. Conversely, thermosetting anisotropic adhesives are suitable for application to the test substrate at normal ambient temperatures, and are heated for curing at temperatures from 100° C. to 300° C. for periods from several minutes to an hour or more. Suitable z-axis anisotropic adhesives include those available from A.I. Technology, Inc. of Trenton, N.J., or Sheldahl, Inc. of Northfield, Minn., or 3M of St. Paul, Minn.
As best seen in FIG. 4, the anisotropically conductive layer 160 is formed on the test substrate 102 , and the bumped die 10 is positioned adjacent to the layer 160 with the solder (or conductive) bumps 16 approximately aligned with the contact pads 104 . The bumps 16 may alternately be formed of any suitable, electrically conductive material. For bumped die 10 having solder bump pitches of at least 32 μm, conventional mechanical alignment devices may be used. For finer pitches, however, more advanced optical alignment systems may be necessary, such as the type of alignment apparatus shown and described in U.S. Pat. No. 4,899,921 to Bendat et. al., incorporated herein by reference.
In the test carrier 100 , the solder bumps 16 are compressed into the anisotropically conductive layer 160 prior to the curing of the layer 160 so that the solder bumps 16 become embedded in the layer 160 . The compression of the solder bumps 16 into the anisotropically conductive layer 160 compresses the conductive particles 162 into contact with each other and creates an electrically conductive path 166 between each of the solder bumps 16 and its corresponding contact pad 104 .
In the test carrier 100 , the solder bumps 16 become attached to the test carrier 100 during the curing of the anisotropically conductive layer 160 . For example, in one embodiment, an anisotropically conductive layer 160 having a B stage polymer as the suspension material 164 is applied to the test carrier 100 . A bumped die 10 is pressed into the layer 160 until the solder bumps 16 are “tacked” in position, and then the bumped die 10 and test carrier 100 are placed in an oven and heated to 150° C. At this temperature, the polymer is fully cross-linked, curing the layer 160 to a hardened consistency.
One or more test signals are then transmitted to the bumped die 10 through one or more of the test leads 106 , through the contact pads 104 , across the conductive paths 166 , through the solder bumps 16 , and into the bumped die 10 . Output signals from the bumped die 10 are then communicated from the solder bumps 16 back across the conductive paths 166 to the contact pads 104 and other test leads 106 , and are monitored to determine whether the bumped die 10 is functioning to the desired specifications.
After testing, the bumped die 10 may be removed from the test carrier 100 by detaching the solder bumps 16 from the anisotropically conductive layer 160 . This may be accomplished in a number of ways depending upon the properties of the anisotropically conductive layer 160 , including, for example, by heating the layer 160 until it softens, or by applying solvents to dissolve the layer, or by other suitable means. After the bumped die 10 is removed, the test carrier 100 may be used to test another bumped die 10 .
Alternately, FIG. 4 may represent a cross-sectional view of the bumped die 10 attached to any electronic component, such as a printed circuit board 100 . In that case, the bumped die 10 may be aligned with the contact pads 104 and attached with the anisotropically conductive layer 160 as described above, except that the bumped die 10 is not removed and remains secured to the printed circuit board 100 .
Although the anisotropically conductive layer 160 is shown in FIG. 4 as being a single, continuous layer covering the entire test substrate 102 , it is not necessary that only one layer be used, or that the layer be continuous. Rather, the anisotropically conductive material may be formed on a plurality of contact pads 104 of the test carrier (or printed circuit board) 100 in a variety of patterns, including, for example, in strips covering rows of contact pads, or in a checkerboard pattern covering regions of contact pads.
Furthermore, it is not necessary that the anisotropically conductive layer 160 be formed on the test carrier (or printed circuit board) 100 , but rather, the layer 160 might be formed on the solder bumps 16 of the bumped die 10 . After the layer 160 is applied to the solder bumps 16 , the test carrier 100 may be engaged with the layer to form the desired electrical connections for testing of the die.
The anisotropically conductive layer 160 advantageously improves the process of testing and assembling of bumped die 10 and other bumped devices. The process of attaching (and detaching) the bumped die 10 to the test carrier (or printed circuit board) 100 using the anisotropically conductive layer 160 may be less time consuming and more economical than the prior art process of soldering (and unsoldering) the solder bumps 16 to (and from) the contact pads 104 because the rework temperatures of the anisotropically conductive layer 160 (typically 80° C. to 150° C.) may be less than the typical reflow temperature of solder (183° C.). Thus, less time and energy may be needed to bring the temperatures of the bumped die 10 and test carrier 100 up to the temperature necessary for detachment, and the potential for damaging the solder bumps 16 or the contact pads 104 may be decreased due to the reduced rework temperatures.
Another advantage of the test carrier (or printed circuit board) 100 having the anisotropically conductive layer 160 is that a more flexible connection may be provided between the solder bumps 16 and the contact pads 22 than is obtained using solder. If the bumped die 10 and test carrier 100 are subjected to a large range of temperatures or repeatedly thermal cycling during the testing (e.g. burn-in tests), the flexibility of the layer 160 may relieve stresses that might otherwise occur due to the differences in the CTE of the bumped die 10 and the test carrier 100 . Depending upon the anisotropically conductive materials used, the anisotropically conductive layer 160 may advantageously expand and contract during such testing to prevent delamination or other damage to the bumped die 16 or the test carrier 100 , or to prevent damage from occurring at the connection between the solder bumps 16 and the bond pads 14 .
An additional advantage of the anisotropically conductive layer 160 is that satisfactory electrical contact may be achieved between the contact pads 104 and the solder bumps 16 despite the variation in the heights of the solder bumps 16 . Because the tallest solder bumps 16 become embedded in the layer 160 , if the layer 160 is properly sized, even the shortest solder bumps 16 may be brought into contact with the layer 160 to form an electrical path 166 between the solder bumps 16 and the contact pads 104 . The anisotropically conductive layer 160 may therefore improve the electrical connection between the short solder bumps and the contact pads.
The anisotropically conductive layer 160 may also reduce the compression force needed to bring the short solder bumps 16 into electrical contact with the contact pads 104 . Because the compression force is reduced, the potential for damaging the bumped die 10 or the test carrier (or printed circuit board) 100 is reduced.
Yet another advantage of the anisotropically conductive layer 160 is that the solder bumps 16 of the bumped die 10 may be easily cleaned of any residual amounts of the anisotropically conductive material following testing. Some anisotropically conductive materials are commercially available that are readily dissolvable using solvents for ease of removal and cleanup. One solvent that may be suitable (depending upon the anisotropically conductive material used) is RS 816 available from AI Technology, Inc. of Princeton, N.J. Thus, the time consuming task of flux cleaning associated with traditional soldering may be avoided.
FIG. 5 is a partial cross-sectional view of the bumped die 10 of FIG. 1 engaged with a test carrier 100 b in accordance with an alternate embodiment of the invention. In this embodiment, the test carrier 100 b includes an anisotropically conductive layer 160 b that has a flexible outer surface 168 . The flexible outer surface 168 may be formed, for example, by at least partially curing the anisotropically conductive layer 160 b prior to engagement with the bumped die 10 . The flexible outer surface 168 may be a resilient surface.
To test the bumped die 10 using the test carrier 100 b , the die is positioned over the layer 160 b with the solder bumps 16 approximately aligned with the contact pads 104 . The solder bumps 16 are then compressed against the flexible outer surface 168 causing localized compression of the anisotropically conductive material 160 b in the region near each of the solder bumps 16 . The conductive particles 162 are brought into contact by the compression forces to form the conductive paths 166 between each of the solder bumps 16 and the corresponding contact pads 104 . Test signals are then transmitted to the bumped die 10 through some of the test leads 104 and the conductive paths 166 , and output signals from the bumped die 10 are transmitted from the solder bumps 16 through the conductive paths 166 to the test carrier 100 b as previously described above.
After the bumped die 10 has been tested, it is disengaged from the test carrier 100 b by simply moving the solder bumps 16 away from the flexible outer surface 168 of the anisotropically conductive layer 160 b . If the flexible outer surface 168 of the layer 160 b is a resilient surface, the localized compression areas near each of the solder bumps 16 will spring back to their uncompressed shape.
The test carrier 100 b having the layer 160 b with the flexible outer surface 168 may further improve the process of testing of the bumped die 10 by reducing or eliminating the time and effort involved in detaching the solder bumps 16 from the anisotropically conductive layer 160 b . Because the solder bumps 16 are not embedded in the layer 160 b , it is not necessary to reheat the bumped die 10 or the test carrier 100 b to the rework temperature of the anisotropically conductive layer 160 b in order to disengage the die from the test carrier. The time, effort, and expense associated with disengaging the solder bumps 16 from the anisotropically conductive layer 160 may therefore be reduced or eliminated.
Similarly, because the solder bumps 16 are not embedded in the anisotropically conductive layer 160 b , the time, effort, and expense associated with cleanup of any residual anisotropically conductive material deposited on the solder bumps 16 may also be reduced or eliminated. Depending upon the anisotropically conductive material used, the transfer of material to the solder bumps 16 may be minimized or eliminated so that the solder bumps 16 may be clean enough for immediate use after testing.
FIG. 6 is a partial cross-sectional view of the bumped die 10 engaged with a test carrier (or printed circuit board) 200 in accordance with another alternate embodiment of the invention. In this embodiment, the test carrier 200 includes a test substrate 202 having a plurality of pockets 244 disposed therein. A plurality of test leads 206 are formed on the test substrate 202 , each test lead 206 terminating in a contact pad 204 that is formed within each of the pockets 244 . An anisotropically conductive layer 260 is formed on the test substrate (or printed circuit board) 202 covering the contact pads 204 and test leads 206 . The anisotropically conductive layer 260 includes a plurality of conductive particles 262 contained with a suspension medium 264 , and an outer surface 268 .
In operation, the solder bumps 16 of the bumped die 10 are at least partially disposed within the pockets 244 of the test carrier 200 . The solder bumps 16 may be embedded in the anisotropically conductive layer 260 prior to the curing of the layer, or alternately, the layer 260 may be at least partially cured so that the outer surface 268 is a flexible surface and the solder bumps 16 do not penetrate the outer surface 268 or become attached to the layer 260 . In either case, a compression force may be applied to the bumped die 10 (or to the test carrier 200 ) to compress the anisotropically conductive material to form a conductive path 266 between each solder bump 16 and each contact pad 204 . Testing may then be performed on the bumped die 10 . After testing is complete, the bumped die 10 may be disengaged from the test carrier 200 in one of the ways described above. Alternately, in the case of the bumped die 10 being attached to the printed circuit board 200 , the bumped die 10 is not disengaged.
The test carrier 200 having the pockets 244 and the anisotropically conductive layer 260 further improves the testing of the bumped die 10 by providing the desired electrical contact between the solder bumps 16 and the contact pads 204 without penetration of the solder bumps 16 using contact blades 48 or the like (see FIG. 2 ). Despite the variability of the size and shape of the solder bumps 16 , the anisotropically conductive layer 260 provides the necessary electrical contact along the conductive paths 266 between the solder bumps 16 and the contact pads 104 . Because the contact blades 48 may be eliminated, fabrication and maintenance of the test carrier 200 is simplified compared to the prior art test carrier 40 shown in FIG. 2 . Also, the potential for the solder bumps 16 to be cracked, chipped, or otherwise damaged due to penetration by the contact blades 48 is eliminated.
Similarly, when the bumped die 10 is engaged with the printed circuit board 200 having pockets 244 and the anisotropically conductive layer 260 , the electrical contact between the bumps 16 and the contact pads 204 is improved. As shown in FIG. 6, electrical contact between the solder bumps 16 and the sidewalls 204 is achievable over a larger contact area due to the anisotropically conductive layer 260 , providing improved electrical contact compared with the contact blades 48 of the prior art device (FIG. 2 ). Also, because the contact blades 48 may be eliminated, the manufacturing the pockets 244 is simplified. The pockets 244 may be formed, for example, by masking the areas surrounding the locations of the pockets 244 with a hard mask, and then etching the substrate using an etchant (e.g. KOH).
FIG. 7 is a partial cross-sectional view of the bumped die 10 engaged with a test carrier (or printed circuit board) 300 in accordance with yet another embodiment of the invention. In this embodiment, the test carrier 300 includes a test substrate 302 having a plurality of pedestals 364 projecting upwardly therefrom. Test leads 306 are formed on the test substrate 302 , each test lead 306 terminating in a contact pad 304 formed on at the top of each pedestal 364 .
A magnet 380 having a north pole 382 and a south pole 384 is positioned near the test substrate 302 . A plurality of magnetic flux lines 386 (only two shown in FIG. 7) emanate from the magnet 380 . An anisotropically conductive layer 360 having a plurality of conductive particles 362 and an outer surface 368 is formed on the test substrate 302 . An optical alignment system 390 (such as the type of alignment apparatus shown and described in U.S. Pat. No. 4,899,921 to Bendat et. al.) is positioned proximate the solder bumps 16 to ensure the alignment of the solder bumps 16 with the contact pads 304 . A die handler 392 is engaged with and controllably positions the bumped die 10 . Numerous types of die handlers 392 are suitable for this purpose, including, for example, those shown and described in U.S. Pat. No. 5,184,068 to Twigg et. al., U.S. Pat. No. 5,828,223 to Rabkin et. al., and the IC handlers available from Verilogic Corporation of Denver, Colo.
During the formation of the anisotropically conductive layer 360 , the conductive particles 362 align with the magnetic flux lines 386 to form conductive columns along the flux lines which form a conductive path 366 between each solder bump and its corresponding contact pad. If the magnetic flux lines 386 are strong enough, some of the conductive particles 362 may be induced to protrude from the surface 368 of the layer 360 (as shown in FIG. 7 ). Suitable anisotropically conductive materials that form conductive paths 366 when exposed to a magnetic field include, for example, the Elastomeric Conductive Polymer Interconnect (ECPI) materials available from AT&T Bell Laboratories of Murray Hill, N.J. For testing of the bumped die 10 , the solder bumps 16 may either be embedded in the anisotropically conductive layer 360 prior to the curing of the layer, or alternately, the layer 360 may be at least partially cured so that an outer surface is a flexible surface that is not penetrated by the solder bumps 16 . In either case, the solder bumps 16 are engaged with the anisotropically conductive layer 360 using the die handler 392 and the optical alignment system 390 so that each of the solder bumps 16 are electrically coupled to a corresponding one of the contacts pads 304 by at least one of the conductive paths 366 . Testing may then be performed on the bumped die 10 , and the bumped die 10 may be disengaged from the test carrier 300 in one of the ways described above.
An advantage of the test carrier 300 having the pedestals 364 and the anisotropically conductive layer 360 is that the desired electrical contact between the solder bumps 16 and the contact pads 304 is provided without penetration of the solder bumps 16 using the projections 69 (see FIG. 3 ). Because the projections 69 may be eliminated, fabrication of the test carrier (or printed circuit board) 300 is simplified compared to the prior art test carrier 60 shown in FIG. 3 . Also, the potential for the solder bumps 16 to be cracked, chipped, or otherwise damaged due to penetration by the projections 69 is eliminated.
Another advantage is that the bumped device 10 may be engaged with the test carrier 300 , tested, and disengaged rapidly and efficiently. The anisotropically conductive layer 360 eliminates the time and expense associated with reflowing the solder bumps 16 , and provides the desired electrical contact despite variation in the heights of the solder bumps 16 .
Although the above described embodiments of the anisotropically conductive layers have been described with specific reference to anisotropically conductive materials that form electrically conductive paths when subjected to a compression force, some anisotropically conductive materials do not require a compression force to form conductive paths. For such materials, the desired electrical contact between the solder bumps and the contact pads of the test carrier may be formed without applying a compression force.
Suitable anisotropically conductive materials that do not require a compression force to form conductive paths include, for example, Elastomeric Conductive Polymer Interconnect (ECPI) materials available from AT&T Bell Laboratories of Murray Hill, N.J. Conductive paths are formed in AT&T Bell's ECPI materials by subjecting the materials to a magnetic field.
The detailed descriptions of the above embodiments are not exhaustive descriptions of all embodiments contemplated by the inventors to be within the scope of the invention. Indeed, persons skilled in the art will recognize that certain elements of the above-described embodiments may variously be combined or eliminated to create further embodiments, and such further embodiments fall within the scope and teachings of the invention. It will also be apparent to those of ordinary skill in the art that the above-described embodiments may be combined in whole or in part with prior art apparatus and methods to create additional embodiments within the scope and teachings of the invention.
Thus, although specific embodiments of, and examples for, the invention are described herein for illustrative purposes, various equivalent modifications are possible within the scope of the invention, as those skilled in the relevant art will recognize. The teachings provided herein of the invention can be applied to other apparatus and methods of testing and assembling bumped devices using anisotropically conductive layers, and not just to the apparatus and methods described above and shown in the figures. In general, in the following claims, the terms used should not be construed to limit the invention to the specific embodiments disclosed in the specification and the claims, but should be construed to include all apparatus and methods of testing and assembling bumped devices using anisotropically conductive layers that operate within the broad scope of the claims. Accordingly, the invention is not limited by the foregoing disclosure, but instead its scope is to be determined by the following claims. | The present invention is directed toward apparatus and methods of testing and assembling bumped die and bumped devices using an anisotropically conductive layer. In one embodiment, a semiconductor device comprises a bumped device having a plurality of conductive bumps formed thereon, a substrate having a plurality of contact pads distributed thereon and approximately aligned with the plurality of conductive bumps, and an anisotropically conductive layer disposed between and mechanically coupled to the bumped device and to the substrate. The anisotropically conductive layer electrically couples each of the conductive bumps with a corresponding one of the contact pads. In another embodiment, an apparatus for testing a bumped device having a plurality of conductive bumps includes a substrate having a plurality of contact pads distributed thereon and substantially alignable with the plurality of conductive bumps, and an anisotropically conductive layer disposed on the first surface and engageable with the plurality of conductive bumps to electrically couple each of the conductive bumps with a corresponding one of the contact pads. Alternately, the test apparatus may also include an alignment device or a bumped device handler. In another embodiment, a method of testing a bumped device includes engaging a plurality of contact pads with an anisotropically conductive layer, engaging the plurality of conductive bumps with the anisotropically conductive layer substantially opposite from and in approximate alignment with the plurality of contact pads, forming a plurality of conductive paths through the anisotropically conductive layer so that each of the conductive bumps is electrically coupled to one of the contact pads, and applying test signals through at least some of the contact pads and the conductive paths to at least some of the conductive bumps. | 7 |
This invention was made with Government support under DE-FG03-90ER80898 awarded by the Department of Energy. The Government has certain rights in this invention.
BACKGROUND OF INVENTION
1. Field of Invention
The present invention relates to a process using electromagnetic energy in the radiofrequency region to catalyze selective chemical reactions that remove sulfur and nitrogen oxides from flue gas.
2. Background
Coal is a major energy resource of the United States and must be utilized in increased amounts if energy independence is to be a viable goal. A major problem associated with coal combustion is the resulting emissions of sulfur dioxide (SO 2 ) and nitrogen oxides (NO x ) into the atmosphere. Current flue gas removal technologies are not only expensive and cumbersome, but also produce troublesome waste products. High volumes of chemicals currently are required for SO 2 removal while NO x removal often uses expensive platinum catalysts. High conversions remain a difficult goal for these current technologies for the convenient chemical reactions require high activation energies, and thus, high temperatures.
Quantum radiofrequency (RF) physics is based upon the phenomenon of resonant interaction with matter of electromagnetic radiation in the microwave and RF regions, since every atom or molecule can absorb, and thus radiate, electromagnetic waves of various wavelengths. The detection of the radiated spectrum to determine the energy levels of the specific atoms or molecules is called radiofrequency spectroscopy. Often the so called "fine lines" are of interest, and these are created by the rotational and vibrational modes of the electrons. For instance, refer to L. Stepin, Quantum Radio Frequency Physics, MIT Press, 1965.
In the subject invention, the inverse is of interest, that is the absorption of microwave and RF wavelengths by the energy bands of the atoms or molecules resulting in a heating of the nonplasma material and the excitation of valence electrons. This lowers the activation energy required for desirable chemical reactions. In this sense, RF energy can be thought of as a form of catalysis when applied to chemical reaction rates. For instance, refer to Kirk-Othmer, Encyclopedia of Chemical Technology, 3rd Edition, Volume 15, pages 494-517, Microwave Technology.
The electromagnetic frequency spectrum can be conveniently divided into ultrasonic, microwave, and optical regions. The microwave region runs from 300 Mhz (megahertz) to 300 Ghz (gigahertz) and encompasses frequencies used for much communication equipment. For instance, refer to N. Cook, Microwave Principles and Systems, Prentice-Hall, 1986. A narrow part of this microwave region, 915 to 5000 Mhz, is commonly employed for selective heating purposes. Microwave ovens are a common household item and operate normally using 2450 MHz, which is a good frequency for exciting water molecules. However, this type of microwave heating often goes by the common name "RF Heating" and is actually a misnomer for most actual radiofrequencies lie in the what is now called the ultrasonic region. Yet, this concept of using the symbol RF to indicate a catalytic heating action for chemical reactions, regardless of the actual frequencies employed, continues to be commonly found.
Much energy related research was performed in the decade of the 1970s, and a number of U.S. patents were issued. These include:
______________________________________No. Inventor Year______________________________________3,502,427 Johswich 19703,565,777 Lauer 19713,656,441 Grey-1 19723,765,153 Grey-2 19733,869,362 Machi-1 19753,887,683 Abe 19753,960,682 Baranova 19763,981,815 Taniguchi 19763,997,415 Machi-2 19764,004,995 Machi-3 19774,076,606 Suzuki 19784,175,016 Lewis 19794,940,405 Kelley 1990______________________________________
Referring to the above list, Johswich discloses an acid treated activated carbon, giving a higher porosity, for use in removing sulfur, sulfur oxides and nitrogen oxides from flue gases. Lauer discloses a process to decompose sulfur dioxide by first electrically charging water used for absorption and then exposing to an ultraviolet light catalyst to enhance sulfur formation. Grey-1 discloses a cyclone wall-film wash for flue gas components that is enhanced by an electrostatic corona discharge. Grey-2 discloses equipment for an electrostatic ionizing process within a cyclone system that removes flue gas components. Machi-1 discloses a process for removing SO 2 and NO x by employing ionizing radiation or ultraviolet light at specific compositions to enhance their decomposition. Abe discloses a process for the removal of nitrogen oxides by injecting ammonia and absorbing on activated charcoal with a vanadium oxide catalyst. Baranova discloses a process for handling waste gas containing sulphurous-acid anhydride using an inorganic manganese salt as catalyst. Taniguchi discloses a process for removing sulfur dioxide and nitrogen dioxides by using ionizing radiation to form a removable aerosol. Machi-2 discloses an improvement over Machi-1 by employing contaminated air as part of the process. Machi-3 discloses an improvement over Machi-1 by employing high dose rate electron beam irradiation. Suzuki discloses a process for decomposing nitrogen dioxide using microwave irradiation. Lewis discloses a radiolytic-chemical process for gas production employing nitrogen oxides to inhibit secondary reactions.
In a later patent Kelley discloses a two stage furnace pulsed combustor where the first combustor forms soot that is employed to reduce SO 2 and NO x in the second combustor where calcium is added to react with the sulfur.
Some additional comment is needed concerning Suzuki which uses the standard microwave frequency to decompose NO x in the presence of typical exhaust gas constituents, such as SO 2 , CO 2 and others. Additionally Suzuki works with only homogenous decomposition of NO x where the microwave energy catalyzes the breakdown of N 2 and 2NO allowing other subsequent reactions to occur. Suzuki provides no information on heterogenous reactions.
Microwave heating was employed in other activities. For instance, Wall et.al. retorted shale oil with a standard microwave source in "Retorting Oil Shale by Microwave Power," 183 Advances in Chemistry Series 329, American Chemical Society, 1979.
The present invention removes NO x and SO 2 from gas stream but employs pyrolytic carbon or char in conjunction with RF microwave heating to catalyze a series of heterogeneous reactions that allow removal of said constituents. The above prior art, although representing interesting background material, employs significantly different concepts.
SUMMARY OF INVENTION
The objectives of the present invention include overcoming the above-mentioned deficiencies in the prior art and providing a potentially economically viable process for the removal of NO x and SO 2 from stack gases and further recover usable byproducts.
The subject invention utilizes radiofrequency catalysis to enhance desirable chemical reactions between carbon and NO x and SO 2 resulting in their elemental breakdown. A two step process is employed whereby step one adsorbs the subject gases onto pyrolytic carbon and step two employs RF catalysis to decompose them.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows the flow diagram for RF catalyzed flue gas cleanup.
DETAILED DESCRIPTION OF INVENTION
Radiofrequency heating is a versatile form of energy that is applicable to enhance rates of chemical reactions. Particularly reactions that proceed by free-radical mechanisms are often catalyzed to higher rates because their initial equilibrium thermodynamics is unfavorable. A second class of catalyzed reactions are those whose reaction kinetics appear unfavorable at desirable temperature conditions.
Pyrolytic carbon is an excellent RF energy absorber. Further, it has good properties for the reduction of NO x and SO 2 . When char, which contains a high percentage of carbon as shown in Table 1, is placed in a RF microwave field, its temperature rapidly increase setting up a large temperature gradient between the surface of the char and its surrounding bulk gas phase. If this gas phase comprises oxygen-containing molecules, the carbon will react and capture these oxygen atoms. Because the RF energy has heated the char surface, it asks as a catalyst for these heterogenous reactions to proceed with a relatively low bulk gas temperature of below approximately 300° F.
Flue gases containing NO x and SO 2 contact the RF energized carbon from char, carbon black, or other elemental carbon containing substance, the following chemical reactions potentially proceed:
C+2NO----(RF)→CO.sub.2 +N.sub.2 ; (1)
C+NO----(RF)→CO+1/2N.sub.2 ; (2)
C+SO.sub.2 ----(RF)→CO.sub.2 +S; (3)
2C+SO.sub.2 ----(RF)→2CO+S; (4)
where ----(RF)→ implies that RF microwave energy catalyzes the reaction to proceed in the direction indicated.
TABLE 1______________________________________Elemental Composition of CharComponent Weight %______________________________________Carbon 77.1Hydrogen 2.3Nitrogen 1.2Sulfur 0.4Oxygen 10.1Ash 8.9______________________________________
TABLE 2______________________________________Composition of Gas Produced from CharComponent volume %______________________________________H.sub.2 39.27CO 53.59CH.sub.4 3.67CO.sub.2 3.48______________________________________
Reactions (1) and (3) are exothermic and are favored at low temperatures. Reactions (2) and (4) are endothermic and naturally occur at only at elevated temperatures. Further, reaction (1) has a much higher heat of reaction than does reaction (3); therefore, NO can be decomposed selectively by close control over the pyrolytic carbon-bed temperature.
As noted in reactions (3) and (4), sulfur is the reaction product and not sulfuric acid. Yet, because of the oxygen and water in the flue gas, the actual reaction mechanism is more likely:
SO.sub.2 +1/2O.sub.2 +H.sub.2 O→H.sub.2 SO.sub.4 (sorbed);(5)
2C+H.sub.2 SO.sub.4 ----(RF)→S+CO+CO.sub.2 +H.sub.2 O;(6)
where `sorbed` implies that the reaction occurs on the surface of the particle char as the initial SO 2 is likely adsorbed on the pyrolytic carbon and the formed H 2 SO 4 remains on the surface and within the char particles. In reaction (6) the temperature-dependent equilibrium between the reaction products containing oxygen will vary the actual amounts of each that could be potentially detected especially in a flow system.
As shown in Table 1, the char contains a number of constituents beside carbon, and the RF microwave energy does decompose it. Typical components are:
Char----(RF)→H.sub.2 +CO+C+Ash; (7)
where this occurs even at the low bulk gas temperatures. The nitrogen is not included herein since it often is employed as a sweep gas for such a reaction. Table 2 gives a typical gas analysis obtained by heating char with RF energy, and shows that some product carbon and hydrogen combine to form methane.
In a practical sense, the char is present much in excess and is largely recycled after the adsorbed components, such as sulfur, are stripped off by high temperature, approximately 900° F., and recovered separately; this largely leaves product activated carbon to reclaim.
FIG. 1 shows the flow sheet of a system practicing the subject invention. Char 43 enters the adsorption reactor 42 that operates as a fluidized bed 44 where the flue gas 40 acts as the fluidizing gas and also contains SO 2 and NO x that is adsorbed on the fluidized char 43. Any source of pyrolytic carbon containing a large surface area, such as carbon black, could be employed in place of the char. The cleaned flue gas 41 with the SO 2 and NO x removed leaves the adsorption reactor 42. Depending upon the actual design, some removal of potentially entrained char dust may be necessary. An adequate cooling apparatus 54 is employed to keep the fluidized bed temperature to generally below about 300° F.
The char containing the adsorbed SO 2 and NO x 45 leaves the adsorption reactor 42 and enters the decomposition reactor 53 where a recycled gas 49 powered by a blower 52 provides a medium moving the char in the form of an entrained-bed reactor. The char passes upward through the reactor where it is heated by radiofrequency energy 55 through an appropriate wave guide 54 where the RF energy is reflected down the reactor chamber and heats the up-flowing char 57. In the presence of the reactive pyrolytic carbon, this RF energy 55 catalyzes the reduction of SO 2 and NO x as well as decomposes the char. Since the system is recycled, only a small part of the total needs to react in any cycle. The residence time of the char generally governs the reaction rates. The extra gas 56 generated is bled off the recycle gas stream 49. The post RF treated char 58 enters a separator 48, such as a cyclone, where the char 46 is recycled back to the adsorption reactor 42 and the separated gas 49 recycles through a cooler 50 and enters 51 the blower 52. Some of the char 47 from the separator 48 is bled-off to be further processed. Sulfur and activated carbon are potential products recovered from this bled-off char 47.
EXAMPLE 1
To check out the performance of the subject invention in carrying out reactions (1)-(7) a laboratory system was employed. A RF energy source at the standard microwave frequency of 2450 MHz and reasonable power was used with a special wave guide constructed to surround the reaction tube of 1/4 to 3/8 I.D. Vycor, a material that was essentially transparent to microwave energy. RF connection were made through mitre plates that allow needed access.
Load impedance matching can be employed if desired, and was often used with laboratory systems since the reaction chamber was physically small. However, in most industrial applications the reaction chamber and wave guides will be large and reflected microwaves became eventually absorbed by the moving bed of char; thus, load impedance matching becomes unnecessary.
Table 1 gives a typical composition of char obtained from mild gasification of subbituminous Western coal. Char from other sources would expect to have a somewhat different composition, but behave in the subject invention in a similar expected manner. Applying RF energy to the char alone at approximately 400° F. using a nitrogen carrier gas produced a gas composition as shown in Table 2.
The sulfur ends up adsorbed on the char and was not released at this reaction temperature. The char can absorb from approximately 5.9 to 10.1 weight percent SO 2 depending upon whether it was RF pre-treated. In an actual operating reactor using recycled char, some pretreatment likely occurs, but untreated char normally was added as makeup. This adsorption was usually adequate to keep nearly all the SO 2 on the surface of the char to then take part in chemical reactions (3) and (4).
Adsorption of NO was not as great as SO 2 , but what actual form the NO x might be, was unknown. Usually the large driving force in temperature between the char surface and nitrogen oxides in the bulk stream was sufficient to cause chemical reactions (1) and (2) to proceed, especially since the char was much in excess.
EXAMPLE 2
To investigate chemical reaction (1) 10 gram pyrolytic carbon black was inserted into the reaction tube and a gas containing 550 ppm NO and 99.95% N 2 was introduced into the top of the reactor. When the RF field was energized to approximately 350 watts, measurements of the NO level reduced to essentially zero. When the RF field was turned off, the measurements quickly returned to the previous input concentration.
A similar test was performed with a inlet composition of 1500 ppm SO 2 and 99.85% N 2 . The reaction kinetics for this chemical reaction (3) were not as fast, indicating a longer needed reaction residence time, yet the SO 2 concentration was lowered to approximately 100 ppm. In practice this longer residence time was obtained because of the better ease of adsorption of SO 2 on the char. A further test using variable RF wattage showed that the maximum reaction conditions for these tests appeared at approximately 550 watts.
EXAMPLE 3
The subject invention applied to a larger system would produce excellent results. Data from approximately a small sized power plant is shown in Table 3. Besides the previous steps as shown in FIG. 1 for the subject invention, pretreatment and char feed is desirable as well as recovery of the sulfur and activated charcoal.
Table 3 also shows the composition of the clean stack gases as they leave the adsorption reaction, while Table 4 gives the gas composition leaving the decomposition reactor.
TABLE 3______________________________________Processed Typical Flue Gas Inlet Stack Gas Outlet (Clean) Stack GasComponent Vol % Vol %______________________________________N.sub.2 68.10 68.70CO.sub.2 8.20 8.27H.sub.2 O 17.52 17.34O.sub.2 5.80 5.69SO.sub.2 0.33 0NO.sub.x 0.05 0Total 100.00 100.00______________________________________
TABLE 4______________________________________Produced Gas from Decomposition Reactor Volume %Component Wet Basis Dry Basis______________________________________CO.sub.2 59.54 95.43N.sub.2 2.85 4.57H.sub.2 O 37.61 --Total 100.00 100.00______________________________________
The following material composition occurs with the decomposition reactor:
______________________________________ wt % wt %______________________________________IN: Saturated char: 95.5 OUT: Recycle char: 86.9Recycle gas: 4.5 Gas: 9.7 Char to 3.4 S-Reactor______________________________________
In this decomposition reactor some of the char is decomposed according to chemical reaction (7) adding to the gas material balance. The S-reactor, or sulfur producing reactor, recovers the products from the process in the mass proportion of about 56% sulfur and 44% activated charcoal. This S-reactor operates at greater than 90° F. in order to strip the sulfur away in gaseous form from the residual activated carbon and allow its later condensation. The char that passes to S-reactor is made up by additional feed char to the adsorption reactor.
In an actual production facility, many steps would be taken to recovery residual heat from the various processes. Further, the hot gases from the char decomposition can be used for an additional energy source.
The foregoing description of the specific embodiments will so fully reveal the general nature of the invention that other can, by applying current knowledge, readily modify and/or adapt for various applications such specific embodiments without departing from the generic concept, and therefore such adaptations or modifications are intended to be comprehended within the meaning and range of equivalents of the disclosed embodiments. It is to be understood that the phraseology or terminology herein is for the purpose of description and not of limitation. | This process to remove gas oxides from flue gas utilizes adsorption on a char bed subsequently followed by radiofrequency catalysis enhancing such removal through selected reactions. Common gas oxides include SO 2 and NO x . | 1 |
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is a Continuation-In-Part of U.S. patent application Ser. No. 13/788,355 filed Mar. 7, 2013, now U.S. Pat. No. 8,894,460 issued, Nov. 25, 2014, which claims the benefit of priority to U.S. Provisional Patent Application Ser. No. 61/647,910 filed May 16, 2012 and U.S. Design patent application Ser. No. 29/447,627 filed Mar. 5, 2013, now U.S. Design Pat. No. D711,485 issued Aug. 19, 2014. The entire disclosure of each of the applications listed in this paragraph are incorporated herein by specific reference thereto.
FIELD OF INVENTION
[0002] This invention relates to toys, and in particular to toy surfboard devices, apparatus and methods of playing a game with a figurine mounted on a surfboard and a hydrofoil rudder underneath the board for allowing the surfboard to ride incoming waves back to a shoreline.
BACKGROUND AND PRIOR ART
[0003] Popular marketed water toys over the years have generally included balls and blow up toys which may be fun to some but would have limited fun to surfers. Traditional many toys, such as dolls and the like, may also sink in the water or float out to sea, both of which would not be desirable. The inventor is not aware of any marketed surfboard toys that would be popular with surfers and beachgoers that is able to take advantage of the direction and power of incoming waves found along ocean and large lake shorelines.
[0004] A check of the U.S. Patent Office database has shown that some patents on toy type surfboards have been proposed in years past. See for example, U.S. patents: Des. 312,491 to Roland; Des. 324,706 to Gibson, and U.S. Pat. No. 4,923,427 to Roland.
[0005] Although both Roland patents reference having heavy keels/fins, these toys are primarily for show. The downwardly protruding keels/fins would have difficulty in balancing the toy surfboard and keeping the surfboard in an upright position in the water.
[0006] Gibson '706 shows a surfer doll on top of a toy surfboard. The large mass of the doll compared to the thin toy board and single fin would not be able to balance in the water and would not be able to ride waves coming to shore at a beach. The top heavy doll would undoubtably cause the toy to capsize if used in the water without someone's hand holding the toy upright.
[0007] Furthermore, there is a good chance that Gibson '706 and possibly the Roland products would end up floating away and not being able to return to the shoreline which could result in the loss of these toys.
[0008] Thus, the need exists for solutions to the above problems with the prior art.
SUMMARY OF THE INVENTION
[0009] A primary objective of the present invention is to provide toy surfboard devices, apparatus and methods of playing a game with a figurine mounted on a surfboard and a hydrofoil rudder underneath the board for allowing the surfboard to ride incoming waves back to a shoreline.
[0010] A secondary objective of the present invention is to provide toy surfboard devices, apparatus and methods of playing a game, having a buoyant surfboard with a weighted hydrofoil which offsets the weight of a figurine mounted on the board which is able to continuously float on water in an upright position.
[0011] A third objective of the present invention is to provide toy surfboard devices, apparatus and methods of playing a game, having figurines that can interchangeably be mounted to the top of the surfboard.
[0012] A fourth objective of the present invention is to provide toy surfboard devices, apparatus and methods of playing a game with a figurine mounted on a surfboard and a hydrofoil rudder underneath the board, where players can simultaneously toss or throw respective surfboard toy devices, and determine a winner of the first surfboard toy to reach the shoreline.
[0013] A fifth objective of the present invention is to provide toy surfboard devices, apparatus and methods, which turns right-side up, points toward the shore after being put into a incoming shore wave, and returns to the shore each time it is used where the toy surfs the wave to the shore.
[0014] A sixth objective of the present invention is to provide toy surfboard devices, apparatus and methods, which takes advantage of the waves at a beach, instead of being overwhelmed, where a figurine on the toy stays upright and surfs the waves all the wave to the shore.
[0015] A seventh objective of the present invention is to provide toy surfboard devices, apparatus and methods, having a figurine, surfboard, skeg and wing (hydrofoil) which can be in separate pieces that easily snap together when assembled.
[0016] An eighth objective of the present invention is to provide toy surfboard devices, apparatus and methods, having a figurine and upper portion of a skeg with mateable attachment points to one another through holes that pass through the board.
[0017] A ninth objective of the present invention is to provide toy surfboard devices, apparatus and methods, having figurines with rounded, and non sharp tip edges (such as on hair ends and hand ends) that will not easily break off, and are safe to use.
[0018] A tenth objective of the present invention is to provide toy surfboard devices, apparatus and methods, with a hydrofoil (wings) that do not break off when the toy surfboard is stepped upon.
[0019] An eleventh objective of the present invention is to provide toy surfboard devices, apparatus and methods, having separate figurine, board, skeg and wing main that when separated can easily be packaged together taking up less space than a fully assembled or partially assembled surfboard toy.
[0020] A twelfth objective of the present invention is to provide toy surfboard devices, apparatus and methods, that can perform tricks similar to real surfers in surf and waves through its unique weighting and balancing.
[0021] 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
[0022] FIG. 1 is a top right perspective view of surfboard toy with mounted figurine and hydrofoil.
[0023] FIG. 2 is a top left perspective view of the surfboard toy of FIG. 1 .
[0024] FIG. 3 is a bottom left perspective view of the surfboard toy of FIG. 1 .
[0025] FIG. 4 is a bottom right perspective view of the surfboard toy of FIG. 1 .
[0026] FIG. 5 is a side view of the surfboard toy of FIG. 1 .
[0027] FIG. 6 is a top view of the surfboard toy of FIG. 1 .
[0028] FIG. 7 is a bottom view of the surfboard toy of FIG. 1 .
[0029] FIG. 8 is a rear view of the surfboard toy of FIG. 1 .
[0030] FIG. 9 is a front view of the surfboard toy of FIG. 1 .
[0031] FIG. 10 is a top exploded perspective view of the surfboard toy of FIG. 1 .
[0032] FIG. 11 is a bottom exploded perspective view of the surfboard toy of FIG. 1 .
[0033] FIG. 12 shows a user on the back-swing of throwing a surfboard toy of FIG. 1 into the breaking surf from a shoreline.
[0034] FIG. 13 shows the person in FIG. 12 throwing a toy into the breaking surf.
[0035] FIG. 14 shows the toy of FIG. 13 just after landing upside-down in the breaking surf.
[0036] FIG. 15 shows the beginning of the self righting ability of the toy in FIG. 14 .
[0037] FIG. 16 shows the toy of FIG. 15 fully upright. Floatation zone is noted.
[0038] FIG. 17 shows the toy of FIG. 16 floating in the breaking surf with its side to the oncoming waves.
[0039] FIG. 18 shows the toy of FIG. 17 just being caught by a breaking wave. The front three quarters of the board float free of the water allowing the assembly to rotate about the floatation zone as the wave exerts its influence. This naturally points the nose of the floatation board in the direction of wave travel.
[0040] FIG. 19 shows the toy of FIG. 18 continuing to rotate influenced by the breaking wave.
[0041] FIG. 20 shows the toy of FIG. 19 has full oriented itself with its nose in the direction of wave travel and is “surfing” on the breaking wave.
[0042] FIG. 21 is an enlarged view of an alternative figurine that can be mounted on the surfboard toy of FIG. 1 .
Second Embodiment
[0043] FIG. 22 is an exploded view of another embodiment of the surfboard toy with figurine, board, skeg and main wing (hydrofoil).
[0044] FIG. 23 is a side assembled view of the surfboard toy with figurine, board, skeg and main wing of FIG. 22 .
[0045] FIG. 24 is a front view of the assembled surfboard toy of FIG. 23 .
[0046] FIG. 25 is a rear view of the assembled surfboard toy of FIG. 23 .
[0047] FIG. 26 is a cross-sectional view of the assembled surfboard of FIG. 23 along arrows 26 X.
[0048] FIG. 27 is a side cross-sectional view of the assembled surfboard of FIG. 24 along arrows 27 X.
[0049] FIG. 28 is an enlarged perspective view of the separated figurine of FIGS. 22-27 .
[0050] FIG. 29 is a side view of the figurine of FIG. 28 .
[0051] FIG. 30 is a front view of the figurine of FIG. 28 .
[0052] FIG. 31 is a rear view of the figurine of FIG. 28 .
[0053] FIG. 32 is an enlarged perspective view of the separated surfboard of FIGS. 22-27 .
[0054] FIG. 33 is a top view of the surfboard of FIG. 32 .
[0055] FIG. 34 is a bottom view of the surfboard of FIG. 32 .
[0056] FIG. 35 is an enlarged perspective view of the separated keel/strut member (skeg) of FIGS. 22-27 .
[0057] FIG. 35A is a bottom view of the skeg of FIG. 35 along arrow 35 X.
[0058] FIG. 36 is a side view of the skeg from FIG. 35 assembled to the separate wing of FIGS. 22-27 .
[0059] FIG. 37 is a top view of the separate wing of FIGS. 22-27 and 36 .
[0060] FIG. 38 is a bottom view of the wing of FIG. 37 .
[0061] FIG. 39 is a side view of the wing of FIG. 37 along arrow 39 X.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0062] 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.
[0063] In the Summary above and in the Detailed Description of Preferred Embodiments and in the accompanying drawings, reference is made to particular features (including method steps) of the invention. It is to be understood that the disclosure of the invention in this specification includes all possible combinations of such particular features. For example, where a particular feature is disclosed in the context of a particular aspect or embodiment of the invention, that feature can also be used, to the extent possible, in combination with and/or in the context of other particular aspects and embodiments of the invention, and in the invention generally.
[0064] In this section, some embodiments of the invention will be described more fully with reference to the accompanying drawings, in which preferred embodiments of the invention are shown. This invention may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein. Rather, these embodiments are provided so that this disclosure will be thorough and complete, and will convey the scope of the invention to those skilled in the art. Like numbers refer to like elements throughout, and prime notation is used to indicate similar elements in alternative embodiments.
[0065] A list of the components referenced in the figures will now be described.
10 Surfboard toy 20 Floatation board 22 front upwardly curving end (nose) 24 top surface 26 bottom surface 28 rear end 30 Surfer figurine 40 Hydrofoil-generally V or boomerang shape (weighted) 42 left wing/vane 44 apex 46 right wing/vane 48 stabilizing tail/rudder 50 wing end stabilizers/weights (curved portions or disc shapes) 60 figurine mounting pegs 70 figurine mounting holes in floatation board 80 Keel/strut member 82 mount tenon (male member) 90 Keel mount mortise in bottom of surfboard 100 Shore surf 110 Small breaking shore wave 120 Person 130 Water line 140 Floatation zone of surfboard toy 150 Pivot point around which Surfer Dude assembly rotates when acted upon by a breaking wave
Second Embodiment
[0000]
200 Second embodiment surfboard toy
205 floatation board
210 top of board
212 front generally beveled tip edge
213 upwardly angling tip
214 generally flat surface
215 front cylindrical through-hole
216 rear square (or rectangular) through-hole
217 rounded beveled upper rear surface edge
218 flat rear end
219 rounded and beveled sides
220 bottom of board
222 flat upwardly angling front surface
223 rounded transition surface
224 generally flat lower surface
226 longitudinal indentation
227 angled tip indentation
228 flat rear indentation
229 slightly upwardly angled rear surface
230 figurine
231 rounded enlarged hair tip ends
232 downwardly extending front cylindrical male peg
233 parallel ribs on front face of front peg
234 flat surface under front foot
236 downwardly extending rear square (or rectangular) male peg
237 parallel ribs on front face of rear peg
238 flat surface under rear foot
239 curved hands
240 skeg
242 upwardly extending front cylindrical tube with socket Upper edge rests generally flush with (or slightly recessed from) upper board surface
243 parallel slits/slots in front face of front tube
244 flat upper ledge surface with narrow tip and flat rear to mateably fit into longitudinal indentation 226 in board bottom 220
246 upwardly extending rear square (or rectangular) tube with socket
Upper edge rests generally flush with upper (or slightly recessed from) board surface
247 parallel slits/slots in front face of rear tube
250 strut portion of skeg
252 front concave curved edge
256 rear convex curved edge
258 enlarged lower footer
260 male connector
262 front split step
264 longitudinal split fin portion
266 longitudinal side rib(s)
270 main wing
272 front convex edge
274 rear extending left wing/vane
275 enlarged rounded (weighted) end
276 rear right wing/vane
277 enlarged rounded (weighted) end
280 central rear extending tail
281 rounded tip end of tail
282 concave root ends of tail
284 sculpted surfaces about concave root ends 282
285 raised footer under front of main wing near apex to allow assembled toy surfboard to be balanced when placed on a flat surface for display purposes
286 through-hole mounting slot
287 front end indentation step in wing top
288 side indentation steps along slot 286 sides in wing bottom
First Embodiment
[0147] FIG. 1 is a top right perspective view of surfboard toy 10 having floatation board 20 with mounted figurine 30 and hydrofoil 40 . FIG. 2 is a top left perspective view of the surfboard toy 10 of FIG. 1 . FIG. 3 is a bottom left perspective view of the surfboard toy 10 of FIG. 1 . FIG. 4 is a bottom right perspective view of the surfboard toy 10 of FIG. 1 .
[0148] FIG. 5 is a side view of the surfboard toy 10 of FIG. 1 with dimensions of a preferred embodiment. FIG. 6 is a top view of the surfboard toy 10 of FIG. 1 . FIG. 7 is a bottom view of the surfboard toy 10 of FIG. 1 with dimensions of a preferred embodiment. FIG. 8 is a rear view of the surfboard toy 10 of FIG. 1 . FIG. 9 is a front view of the surfboard toy 10 of FIG. 1 . FIG. 10 is a top exploded perspective view of the surfboard toy 10 of FIG. 1 . FIG. 11 is a bottom exploded perspective view of the surfboard toy 10 of FIG. 1 .
Surfboard 20
[0149] Referring to FIGS. 1-11 , the novel surfboard toy 10 can include a floatation board 20 having a front upwardly curving end 22 with rounded tip and a rear end 28 with rounded edge with a top side 24 and bottom side 26 . The floatation board 20 can be formed from injection molded foam, or foam rubber cut into a selected shape, or other lightweight material impervious to water. Alternatively, the board 20 can be formed from in injection molded plastic hollow housing with rubber placed inside the plastic shell.
[0150] Referring to FIGS. 5-7 , the surfboard 20 can have dimensions of approximately 10.23 inches in length from the front end 22 to the rear end 28 , and have a width of approximately 3.01 inches that tapers down at both the front end 22 and the rear end 28 to rounded tips. The thickness of the surfboard 20 can have a thickness of approximately 1.28 inches with the rear end 28 curving downward to an outer edge. The surfboard 20 has a generally flat bottom surface 26 that curves upward near the front end 22 in order to aid in lift of the surfboard when riding incoming waves.
Figurine 30
[0151] Referring to FIGS. 1-11 and mounted to the top surface 24 of the surfboard 20 adjacent to the rear end 28 can be surfer figurine 30 mounted thereon. The figurine 30 can have downwardly extending male members 60 , such as pegs, that are insertable into figurine mounting holes (female receptacles) 70 on the top surface 24 of the surfboard 20 adjacent to the rear end 28 of the surfboard 20 as shown in FIGS. 10-11 . The pegs 60 can be locked into the mounting holes 70 with waterproof glue or cement and the like.
[0152] Referring to FIG. 5 , the figurine 30 can be formed from injection molded plastic and the like, and have a height from a foot portion mounted to the top surface 24 of the surfboard 20 to the top of the head portion to be approximately 4.62 inches and a width of approximately 3.72 inches between ends of the outstretched hands. Additionally, the figurine 30 can be formed from a lightweight foam so that it will stay upright easily while being pummeled by waves as the toy 10 is being used in the surf of incoming waves. The figurine can be narrow thin stick figure turned sideways so the plane of the planar shaped body is in the same plane as the keel/strut member 80 mounted underneath the board 20 . The figurine 30 can be mounted almost directly above the keel/strut member 80 .
Hydrofoil 40 and Keel/Strut Member 80
[0153] Referring to FIGS. 1-11 , and mounted underneath the surfboard 20 adjacent to the rear end 28 can be a hydrofoil 40 . A generally rectangular and narrow diameter keel type strut member 80 can be turned so that one side edge faces forward and the opposite side edge faces rearward. The keel/strut member can have a upper male member (tenon) that fits into a mateable slit 90 on the bottom surface 26 of the surfboard 20 adjacent to the rear end 28 of the surfboard 20 can be locked with waterproof glue or cement and the like.
[0154] Referring to FIG. 5 , the keel/strut member 80 can have a height of approximately 1.59 inches between the bottom surface 26 of the surfboard and the top of the generally flat left wing/vane (not shown) and right wing/vane 47 of the hydrofoil 40 .
[0155] Referring to FIGS. 1-11 , the hydrofoil 40 can have a generally V or boomerang shape with a generally flat thin left wing/vane 42 connected to a generally flat thin right wing/vane 46 by a rounded/curved tip apex portion 44 . The outer free ends of the left wing/vane 42 and right wing/vane 46 extend rearward from the apex portion and outward from the sides of the surfboard 20 , and end in additional stabilizer/weighted curved portions 50 . The wing end stabilizer/weighted portions 50 can be curve shaped and can include disc shapes and the like. The wing end stabilizer/weighted portions 50 can be slightly thicker with a slightly rounded top surface to add additional stabilizing weight to the hydrofoil 40 . Extending rearward from the apex portion 44 can be an optional generally flat stabilizing tail rudder 46 located between the left wing/vane 42 and the right wing/vane 46 .
[0156] Referring to FIGS. 5 and 7 , the hydrofoil 40 can have an overall length between outer ends of the of outer stabilizing weights to be approximately 6.03 inches, and a length from the apex portion outer edge 44 to the outer end of the tail/rudder member 48 to be approximately 3.25 inches. Each of the wings/vanes 42 , 46 can have a width of approximately 0.61 inches, with a width of the tail/rudder member 48 being approximately 0.93 inches. Each of the wing end stabilizers/weights 50 can have a radius of approximately R.74, and the distance between center points of each wing end stabilizers/weights 50 from one another can be approximately 4.55 inches.
[0157] The angle between the wings/vanes 42 , 46 of the generally V shape or generally boomerang shaped hydrofoil 40 can range between approximately 10 to approximately 120 degrees. A narrower range can be between approximately 22 to approximately 60 degrees, and a narrower range of a preferred embodiment can range between approximately 35 to approximately 5 degrees.
[0158] Both the keel/strut member 80 and the hydrofoil 40 can be formed from hardened plastic, that was injection molded, and can include metal layer imbedded within the plastic. The weight of the keel/strut 80 and hydrofoil 40 can be approximately 1.3 ounces, while the entire weight of the figurine 30 , surfboard 20 and keel/strut member 80 with hydrofoil 40 can be approximately 2.2 ounces. As such, the weight of keel/strut member 80 and the hydrofoil 40 can easily counter-balance the lighter weight of the figurine 30 in order to keep the surfboard toy 10 in an upright floating position.
[0159] The plane of the wings 42 , 46 of the hydrofoil to the generally flat bottom surface 26 of the surfboard can be slightly angled so that the bottom surface 26 of the surfboard 20 angles upward toward the front end 22 approximately 6 degrees.
[0160] The figurine 30 can be mounted to be approximately perpendicular to the top surface 24 of the surfboard 20 . The generally flat top surface 24 of the surfboard 20 can have an angle of approximately 95 degrees relative to the flat wings 42 , 46 of the hydrofoil 40 .
[0161] The dimensions referenced in a preferred embodiment shown and described in relation to FIGS. 5 and 7 are approximate. The term “approximately” can be +/−10% of the dimension numbers referenced for the preferred embodiment. The dimensions come from a preferred embodiment that has been tested in the ocean by the inventor to an effective working embodiment.
[0162] While FIGS. 5 and 7 show a preferred embodiment dimensions, the invention can use alternative dimensions when the toy is scaled up or scaled down to different sizes such as small as approximately 3 inches long as desired by the user.
[0000] Method of Playing with the Surfboard Toy
[0163] FIG. 12 shows a user 120 standing adjacent to a shoreline near the shore surf 100 and on the back-swing of throwing a surfboard toy 10 of FIG. 1 into the breaking surf 110 . FIG. 13 shows the user 120 in FIG. 12 throwing the toy surfboard 10 into the breaking surf 110 .
[0164] FIG. 14 shows the toy 10 of FIG. 13 just after landing upside-down in the breaking surf and resting on the water line 130 . FIG. 15 shows the beginning the self righting ability of the toy 10 in FIG. 14 . The weighted keel 80 and hydrofoil 40 will always insure that the surfboard toy 10 stays upright. FIG. 16 shows the toy 10 of FIG. 15 fully upright. Floatation zone is noted where a rear portion of the bottom surface 26 of the surfboard 20 can float on the water line 130 with the weighted hydrofoil 40 below the waterline 130 .
[0165] FIG. 17 shows the toy 10 of FIG. 16 floating in the breaking surf 100 with its side to the oncoming waves 110 .
[0166] FIG. 18 shows the toy 10 of FIG. 17 just being caught by a breaking wave 110 . The front three quarters of the board 20 float free of the water allowing the toy 10 to rotate about the floatation zone 140 as the wave exerts its influence. This naturally points the nose (front end) 22 of the floatation board 20 in the direction of wave travel and pivots at a pivot point 150 . FIG. 19 shows the toy 10 of FIG. 18 continuing to rotate influenced by the breaking wave 110 .
[0167] FIG. 20 shows the toy 10 of FIG. 19 has full oriented itself with its nose 22 in the direction of wave travel and is “surfing” on the breaking wave 110 .
[0168] FIG. 21 is an enlarged view of an alternative figurine 30 F that can be mounted on the surfboard toy 10 of FIG. 1 . The figurine 30 F can have similar dimensions to the previously described figurine 30 .
[0169] Additional games that can take place with the novel surfboard toys 10 can include two or more players tossing or throwing generally identical surfboard toys 10 into the surf and determining a winner when the first surfboard toy 10 reaches the shoreline.
Second Embodiment
[0170] FIG. 22 is an exploded view of another embodiment of the surfboard toy 200 with figurine 230 , board 205 , skeg 240 and main wing 270 . FIG. 23 is a side assembled view of the surfboard toy 200 with figurine 230 , board 205 , skeg 240 and main wing 270 of FIG. 22 . FIG. 24 is a front view of the assembled surfboard toy 200 of FIG. 23 . FIG. 25 is a rear view of the assembled surfboard toy 200 of FIG. 23 . Figurine 230 , board 205 , skeg 240 and main wing 270 can be formed from similar materials to similar components described in the previous embodiment. For example, figurine 230 can be formed from an injection molded hard plastic, and board 205 can be formed from EVA (ethylene vinyl acetate) foam.
[0171] FIG. 26 is a cross-sectional view of the assembled surfboard 200 of FIG. 23 along arrows 26 X. FIG. 27 is a side cross-sectional view of the assembled surfboard 200 of FIG. 24 along arrows 27 X.
[0172] FIG. 28 is an enlarged perspective view of the separated figurine 230 of the previous figures. FIG. 29 is a side view of the figurine 230 of FIG. 28 . FIG. 30 is a front view of the figurine 230 of FIG. 28 . FIG. 31 is a rear view of the figurine 230 of FIG. 28 .
[0173] Referring to FIGS. 28-31 , the figurine 230 be similar to the surfer figurine 30 of the previous embodiment, with some main differences. Figurine 230 can included rounded hair tip ends 231 , which are less sharp and safer than the hair ends in the previous embodiment, and curved hand portions with rounded ends 239 which are also less sharp and safer than those in the previous embodiment.
[0174] Figurine 230 can include a downwardly extending front cylindrical male peg 232 , with parallel ribs 233 on the front face, and a flat surface 234 under the front foot, and a downwardly extending rear square (or rectangular) male peg 236 with parallel ribs 237 on the front face and a flat surface 238 under rear foot.
[0175] FIG. 32 is an enlarged perspective view of the separated surfboard 205 of FIGS. 22-27 . FIG. 33 is a top view of the surfboard 205 of FIG. 33 . FIG. 34 is a bottom view of the surfboard 205 of FIG. 33 .
[0176] Referring to FIGS. 23 and 32 - 34 , board 205 can have a board top 210 with a front generally beveled tip edge 212 , and an upwardly angling tip 213 , and a generally flat top surface 214 . Tip edge 212 can have a slight beveling instead of being arced in the previous embodiment. Here, the tip edge is more perpendicular to the bottom with a small arc at the top of the tip edge 212 . Board 205 can also have a front cylindrical through-hole 215 and a rear square (or rectangular) through-hole 216 both adjacent to a rear end of the board 205 . Board 205 can also have a rounded upper rear surface edge 217 and a generally flat rear end 218 with rounded beveled upper side edges 219 on both sides of the board 205 .
[0177] The board bottom 220 can have a flat upwardly angling front surface 222 with a rounded transition surface 223 , and a generally flat lower surface 224 . Down the middle of the board bottom 220 adjacent to rear end of the board 205 can be a longitudinal indentation 226 with a angled front tip indentation 227 and a flat rear indentation 228 .
[0178] The lower rear surface 224 of the board 205 (also shown in FIG. 23 ) can have an approximately 9 degree angle that can beginning approximately 0.75 inches in from the end 218 of the board 205 sloping up to the end 218 of the board 205 .
[0179] FIG. 35 is an enlarged perspective view of the separated keel/strut member (skeg) 240 of FIGS. 22-27 . FIG. 35A is a bottom view of the skeg 240 of FIG. 35 along arrow 35 X. FIG. 36 is a side view of the skeg 240 from FIG. 35 assembled to the separate main wing 270 of FIGS. 22-27 .
[0180] Referring to FIGS. 22 , 23 , and 27 , main wing 270 can be at a downward 5 degree (+/−2 degrees) angle from board 205 on a perpendicular 90 degree upward angle through skeg 240 and a 35 degree (+/−5 degrees) to the front 212 of board 205 .
[0181] Referring to FIGS. 35-36 , skeg 240 can include an upwardly extending front cylindrical tube 242 with socket, having an upper edge which rests generally flush with (or slightly recessed from) upper (top) board surface 210 when assembled. The upper ends of the tubes 242 , 246 can be tapered (narrower) to allow for ease in inserting into the through-holes 215 , 216 in the board 205 . Front tube 242 can have parallel slits/slots 243 in the front face, and an upwardly extending rear square (or rectangular) tube 246 with socket having an upper edge which rests generally flush with (or slightly recessed from) upper (top) board surface 210 when assembled. Rear tube 246 can have parallel slits/slots 247 in the front face. The tubes 242 , 246 can raise upward from a flat upper ledge surface 244 that has a narrow tip end and a generally flat rear end which can mateably fit into the longitudinal indentation 226 in the board bottom 220 .
[0182] The strut portion 250 of the skeg 240 can have a front concave curved edge 252 and a rear convex curved edge 256 . Strut portion 250 can have an enlarged lower footer 258 with a male connector 260 extending downward therefrom. The male connector 260 can have a front split step 262 which protrudes from a longitudinal split fin portion 264 and longitudinal side rib(s) 266 can face sideways from the longitudinal split fin portion 264 .
[0183] FIG. 37 is a top view of the separate wing 270 of FIGS. 22-27 and 36 . FIG. 38 is a bottom view of the wing 270 of FIG. 37 . FIG. 39 is a side view of the wing 270 of FIG. 37 along arrow 39 X.
[0184] Referring to FIGS. 37-39 , main wing 270 can include a front convex edge 272 with a rear extending left wing/vane 274 and an enlarged rounded (weighted) end 275 , and a rear right wing/vane 276 with an enlarged rounded (weighted) end 277 . The weighted portions can be additional material such as metal, and/or weighted discs that can be imbedded therein, and/or more plastic type material for the added weight which provide ballast for helping maintain the surfboard toy in an upright position when be used in the ocean as described in the previous embodiment.
[0185] Wing 270 can also include a central rear extending tail 280 with a rounded tip end 281 . The root end of tail 280 can have concave edges 282 with sculpted indented surfaces 284 located about the concave root end edges 282
[0186] A through-hole mounting slot 286 can be located through a mid-portion of the wing between the left vane 274 and right vane 276 , with a front end indentation step 287 in the wing top, and side indentation steps 288 along the sides of the slot 286 in the wing bottom.
[0187] A raised footer 285 can have a pedestal type shape with flat bottom and be located under the front of main wing 270 near the apex portion. Footer 285 allows for the assembled toy surfboard 200 to be balanced when placed on a flat surface for display purposes.
[0188] Table 1 lists preferred dimensions of the board 205 , FIG. 230 , skeg 240 and main wing 270 used with the toy surfboard 200 .
[0000]
TABLE 1
Surfboard toy component
dimensions
Acceptable
Preferred
Component description
range
Narrowed range
dimension
in inches:
Surfboard, length
7.0000-12.0000
8.5000-11.5000
11.0236
Surfboard, width
2.1250-3.6429
2.5804-3.4911
3.3465
Surfboard, depth or thickness
0.6750-1.1572
0.8197-1.1089
1.0630
(measured at rear, before bevel,
or at midpoint of board)
Male figure, height (peg bottom to
3.7306-6.3954
4.5301-6.1289
5.8750
top of hair)
Male figure, width (front hand to
2.5400-4.3543
3.0843-4.1729
4.0000
back hand)
Male figure, thickness (rear foot
0.3572-0.6123
0.4337-0.5868
0.5625
puddle)
Male figure, thickness (torso)
0.0794-0.1361
0.0964-0.1304
0.1250
Skeg, height (front to back)
1.7463-2.9936
2.1205-2.8688
2.7500
Skeg, width (top to bottom)
1.8256-3.1296
2.2168-2.9992
2.8750
Skeg, depth (side to side)
0.3572-0.6123
0.4337-0.5868
0.5625
Wing, length (side to side)
3.8100-6.5314
4.6264-6.2593
6.0000
Wing, width (front to back)
1.9050-3.2657
2.3132-3.1296
3.0000
Wing, depth (weighted sides or
0.1588-0.2721
0.1928-0.2608
0.2500
vanes)
Wing, depth (including bottom
0.2381-0.4082
0.2892-0.3912
0.3750
souvenir bump)
in millimeters:
Surfboard, length
178-305
216-292
280
Surfboard, width
54-93
66-89
85
Surfboard, depth or thickness
17-29
21-28
27
(measured at rear, before bevel,
or at midpoint of board)
Male figure, height (peg bottom to
95-162
115-156
149
top of hair)
Male figure, width (front hand to
65-111
78-106
102
back hand)
Male figure, thickness (rear foot
9-16
11-15
14
puddle)
Male figure, thickness (torso)
2-3
2-3
3
Skeg, height (front to back)
44-76
54-73
70
Skeg, width (top to bottom)
46-79
56-76
73
Skeg, depth (side to side)
9-16
11-15
14
Wing, length (side to side)
97-166
118-159
152
Wing, width (front to back)
48-83
59-79
76
Wing, depth (weighted sides or
4-7
5-7
6
vanes)
Wing, depth (including bottom
6-10
7-10
10
souvenir bump)
[0189] Table 2 lists preferred weights of the board 205 , FIG. 230 , skeg 240 and main wing 270 used with the toy surfboard 200 .
[0000]
TABLE 2
Surfboard toy component
weights
Acceptable
Narrowed
Preferred
Component description
range
range
dimension
in ounces:
Surfboard only
0.7-1.3
0.8-1.2
1.1
Male figure
0.4-0.8
0.5-0.7
0.7
Skeg
0.3-0.5
0.3-0.5
0.4
Wing, including stability
1.2-2.2
1.5-2.1
1.9
weights
Wing, excluding stability
0.8-1.5
1.0-1.4
1.3
weights
Male figure
0.4-0.8
0.5-0.7
0.7
All toy components combined
2.6-4.8
3.1-4.5
4.1
in grams:
Surfboard only
19.2-36.3
23.4-34.8
30.3
Male figure
12.4-21.2
15.0-20.3
19.5
Skeg
7.9-14.3
9.6-13.7
12.5
Wing, including stability
33.7-60.6
40.9-58.1
53.0
weights
Wing, excluding stability
22.9-41.1
27.8-39.4
36.0
weights
All toy components combined
73.2-132.4
88.9-126.9
115.3
[0190] The assembly of the toy surfboard 200 will now be described with the figurine 230 mounted to the top 210 of the board 205 , and the skeg mounted to the bottom 220 of the board 205 , with the main wing 270 mounted to the bottom of the skeg 240 as shown by the arrows in FIG. 22 .
[0191] Referring to FIGS. 22-36 , the upwardly extending cylindrical tube 242 and square (or rectangular) tube 246 of skeg 240 can be pushed into the cylindrical through-hole 215 and square (or rectangular) through-hole 216 in the bottom 220 of the board 2015 until the flat ledge 244 rests against the flat bottom 224 recessed therein within indentation 226 . The locations of the square hole 216 and cylindrical hole 215 force the assembler to only use the correct holes 215 , 216 when assembling the skeg 240 to the board 205 .
[0192] Next, the assembler can mount the wing 270 to the bottom of the skeg 240 in reference to FIGS. 22-39 . The assembler can place the assembled board 205 and skeg 240 upside down on a surface. The top surface of wing 270 can be positioned such that the front end indentation step 287 is placed over front split step 262 and longitudinal split fin portion 264 is aligned into the rest of through-hole slot 286 . The outer facing edges of the longitudinal split fin portion 264 can be tapered to more easily fit into the slot 286 .
[0193] Next the assembler can push the wing 270 so that the slip fin portion 264 passes into the slot 286 which causes the split fin portion to be pinched together. The assembler can push until the longitudinal side facing ribs 266 of split fin portion 264 snap about side indentation steps 288 locking the wing 270 in place. Similarly, the split step can also pinch together and rest against step 287 .
[0194] Next the lower extending cylindrical peg 232 and square (or rectangular) peg 236 of the figurine 230 are passed into the top 210 of the board 205 , and their locations also force the assembler to use the proper through-holes 215 , 216 for assembly. The raised ribs 233 , 237 in the respective pegs 232 , 236 can snap into mateable slits/slots 243 , 247 in the respective tubes 242 , 246 , which locks the figurine 230 to the top 210 of the board 205 , and the skeg 240 to the bottom 220 of the board 205 .
[0195] The novel invention shown and described in the second embodiment allows for many additional benefits.
[0196] If the toy were stepped upon after it is assembled, the connection of skeg 240 and wing 270 would snap apart and not fracture, yet the figurine with board and skeg and wing is still strong enough to ensure that the wing (or hydrofoil) will not become unattached in normal play in surf and waves.
[0197] In addition, the novel surfboard toy can only be assembled in one orientation, ensuring that the consumer assembles the surfing toy in the correct orientation.
[0198] The redesign of the connecting mechanism results in the skeg having a rear square channel and a round front channel, which match a new rear square and front round peg in the figure. In addition, the surfboard can have two holes, one square at the rear, and one round toward the front, to match the design of both the skeg and the figurine.
[0199] This redesign ensures that the toy is assembled properly such that the figure and the skeg are logically inserted into the surfboard and their connection in only one orientation. In addition, the square peg of the figure cannot physically be inserted into the round hole of the receptor channel of the skeg.
[0200] The second embodiment can include a new downward pointing “split arrowhead” connector between the skeg and the wing or hydrofoil.
[0201] The first embodiment combined the “strut” (now called a skeg) and wing, or hydrofoil, into a single piece. This would have allowed the single piece construction, which consisted of two perpendicular planar surfaces, to potentially fracture if the toy were stepped on, which fractured piece could have resulted in a sharp edge.
[0202] The second embodiment splits these planar surfaces into two separate pieces and introduces a new “breakaway” split arrowhead (which is a split construction such that the space between the two sides of the “split arrowhead” condenses during insertion into the wing (or hydrofoil), then, once inserted, pops back open to secure the connection that is designed to “breakaway” if the toy were stepped upon, which connection is still strong enough to ensure that the wing (or hydrofoil) will not become unattached in normal play in surf and waves.
[0203] In addition, the second embodiment can only be assembled in one orientation, ensuring that the consumer assembles the surfing toy in the correct orientation.
[0204] The wing, or hydrofoil, was previously a flat, planar surface. The second embodiment smoothes the prior sharp angles and surfaces of the wing and thickens the wing/vanes of the first embodiment.
[0205] The revisions to shape and thickness, especially the “sculpting” of the wing in the second embodiment, promotes much better and more consistent surfing performance, catching random turbulence in the currents of waves which produces more “yawing” motion, which “yawing” motion is corrected by the new unitized design, causing more tricks to be performed during each surfing session, while more consistently keeping the surfboard toy in its natural upright surfing position on top of the surf and wave, perfecting the self-righting capability of the toy in surf.
[0206] The second embodiment can include weighted members, such as but not limited to two weighted disks that can be inserted into the wing, or hydrofoil, during its injection molding manufacturing process that precisely weight and balance, or stabilize, the wing and toy.
[0207] Additional tests during the further design and prototyping of the second embodiment toy surfboard revealed that precise weighting added to each wing vane, which weights were chrome-plated (to discourage rusting in water use) and inserted during the manufacturing (injection molding) process would result in much better and more consistent surfing performance, including more consistent righting of the surfboard toy on any inversion in the surf, helping to ensure the toy inverts to its natural upright position to resume its surfing session.
[0208] In addition, the rear weighting of the toy, combined with the increased upward angle of the nose of the surfboard and overall heavier weight of the toy, avoids the previous embodiment's tendency to “pearl” or submerge its nose as it acquired a wave.
[0209] In the second embodiment the weight of the wing was increased by over 75% from the previous embodiment 1.3 ounces (for the combined strut/keel and hydrofoil) to a combined weight for the skeg and wing (hydrofoil) of approximately 2.3 ounces.
[0210] The increased weight, and precise stabilization through the ballast weighting system, promotes the optimum combination of trick performance while surfing and ensuring the surfboard toy returns to its natural upright position whenever surf conditions invert the toy during a surfing session.
[0211] The second embodiment adds a bump to the front bottom of the wing such that the surfboard toy, when displayed after a surfing session in one's home or office, will sit upright.
[0212] The increased back weighting of the toy surfboard and increased angles promote better surfing performance and required the addition of a “souvenir bump” at the front edge of the wing to ensure the surfboard toy would sit upright when displayed on a dresser or credenza in a home bedroom or at an office after use on the beach.
[0213] Although the embodiment shows tubes with sockets extending upward from the skeg and male pegs extending downward from the figurine, the components can be reversed such that the tubes can extend downward from the figurine, and male pegs can extend upward from the skeg.
[0214] Although the embodiment shows a cylindrical hole in front and square (or rectangular) hole toward the rear, the locations of the respective geometrical shaped holes, can be reversed. Additionally, other shapes, such as but not limited to other geometrical shapes, such as but not limited to triangle shapes, hexagon, shapes, and the like can be used. Additionally less than or more than two side slits/slots, can be used, and different types of snaps can be used such as but not limited to raised protrusion locking into a small cylindrical hole, and the like.
[0215] 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. | Toy surfboards and methods of snapping together a figurine with a surfboard and a skeg and a wing to form a surfboard toy. The assembled toy can ride incoming waves back to a shore. The hydrofoil can have a V or boomerang shape with side wings having ends extending rearward and out from the surfboard. Wing ends can incorporate curved discs for stability. Optional stabilizing tail/fin/rudder can extend rearward from the hydrofoil. Games can include racing toys by tossing them simultaneously from the shore to see which one reaches the shore first. | 0 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to processor timing circuits. More specifically, this invention relates to a circuit and operating method for generating processor wait states.
2. Description of the Relevant Art
Functional testing of complex circuits, such as microprocessor circuits, involves the measurement of many various operating parameters. Many of these measurements are difficult to perform without special purpose test circuits and procedures.
In one example of such a functional test, the performance of a processor may be tested by measuring the execution time of a particular standard benchmark software routine. These measurements are useful for improving or optimizing processor performance under various operating conditions. One important operating condition of a processor relates to the processor's latency of operation. A wait state is a designation of the latency of a processor, the time interval between the instant at which a call for data is initiated and the instant the actual transfer of the data begins.
One valuable assessment of processor performance is measure of the time taken by a particular standard benchmark software routine to execute as a function of the latency, the number of wait states, of the processor. More specifically, a valuable measure of processor performance involves an analysis of the execution time of the processor as the processor executes a particular type of data access or input/output cycle, such as a read cycle, a write cycle, a read-write cycle or a burst access cycle, for example. Typically, the cycle types tested would encompass every type of data movement and every type of bus activity that is performed by a processor bus.
For some cycle types, variation in the number of wait states only has a marginal effect on the execution time of the processor. For other cycle types, varying the number of wait states greatly influences the execution time of software on the processor.
What is desired is a test apparatus and testing method that facilitate and provide for analysis of processor performance as a function of processor latency. More particularly, what is desired is a test apparatus and testing method that assist an analysis of processor performance when executing a particular type of data access or input/output cycle as a function of processor wait states.
SUMMARY OF THE INVENTION
In accordance with one aspect of the present invention, a conditional wait state generator is interposed into the timing circuitry of a processor. The conditional wait state generator provides for analysis of a selected cycle type and for selection of the latency or number of wait states that is imposed during processor execution for that selected cycle type.
In accordance with a second aspect of the present invention, a method of analyzing processor performance under specific operating conditions involves selection of a particular cycle type for testing and selection of a number of wait states that is imposed on processor operations for the selected cycle type and not for other cycle types. A conditional wait state generator is interposed into the timing circuitry of a processor and thereby imposes the selected conditions on the processor for analysis.
In accordance with one embodiment of the present invention, a timing circuit for generating a selectable number of wait states is provided. These wait state are imposed under a selectable system operating condition in a system which furnishes a timing signal on a timing signal line, a plurality of control signals indicative of a system operating condition on a corresponding plurality of system control signal lines and a clock signal on a clock signal line. The timing circuit includes a programmable selector of system operating condition setting a programmed operating condition and a wait state generation activation circuit connected to the plurality of system control signal lines and connected to the programmable selector of system operating condition. The wait state generation is activated when the system operating condition matches the programmed operating condition. The wait state generation is otherwise inactivated. A timing signal pass-through circuit is connected to the wait state generation activation circuit and connected to the timing signal line for passing through the timing circuit when the wait state generation is inactivated. A programmable selector of wait state delay number sets a programmed timing delay. A wait state counter is connected to the clock signal line and connected to the wait state generator activation circuit. The wait state counter counts a number of clock signals when the wait state generation is activated. The timing signal further includes a timing signal delay circuit connected to the wait state counter and connected to the programmable selector of wait state delay. The timing signal delay circuit delays the timing signal until the number of clock signals counted by the wait state counter reaches the programmed timing delay.
In accordance with another embodiment of the invention, a method of generating a selectable number of wait states is furnished. These selectable wait states are imposed under a selectable system operating condition in a system furnishing a timing signal on a timing signal line, a plurality of control signals indicative of a system operating condition on a corresponding plurality of system control signal lines and a clock signal on a clock signal line. The method includes steps of setting a programmed operating condition, comparing the programmed operating condition to the system operating condition and activating a wait state generation operation when the system operating condition matches the programmed operating condition. Otherwise, the wait state generation operation is inactivated. The method further includes the steps of passing through the timing circuit when the wait state generation is inactivated. When the wait state generation is activated, the method includes the steps of setting a programmed timing delay, counting a number of clock signals when the wait state generation is activated and delaying the timing signal until the number of clock signals counted by the wait state counter reaches the programmed timing delay.
Various advantages are achieved by the disclosed conditional wait state generator and operating method. One advantage is that the conditional wait state generator allows for isolation of a selected processor operating condition or group of operating conditions and for analysis of processor performance with respect to that operating condition alone. Another advantage is that this analysis of an isolated selected processor operating condition is reflected in overall system throughput. It is further advantageous that numerous different isolated processor operating conditions or group of operating conditions are selectable for analysis.
It is further advantageous that the conditional wait state generator facilitates the analysis of processor performance for a particular selected cycle type or set of types. For example, the conditional wait state generator may be used to determine whether optimization of a particular processor functionality is worthwhile. If processor performance remains nearly the same while the number of wait states is widely varied, optimization of processor functionality is not warranted. However, substantial degradation in processor performance which results from changes in processor wait state latency indicates that processor optimization is advantageous.
Still additional advantages are achieved due to the large number of wait states, corresponding to a long latency, that may be imposed under operating conditions such as conditions that occur during a large number of cache memory accesses.
The disclosed conditional wait state generator and operating method are also advantageous for greatly improving the efficiency of benchmark testing. Real time testing of software operating on a processor does not typically allow isolation of particular operating conditions on the basis of cycle type and latency. Such testing would typically take many hours of simulation to test using conventional simulation techniques.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention may be better understood, and its numerous objects, features, and advantages made apparent to those skilled in the art by referencing the accompanying drawings.
FIG. 1 is a schematic block diagram showing an exemplary computer system into which a conditional wait state generator is implemented.
FIG. 2 is a schematic circuit diagram which illustrates an embodiment of a conditional wait state generator in accordance with the present invention.
FIG. 3 is a flowchart which depicts steps of a processor analysis procedure.
DETAILED DESCRIPTION OF THE INVENTION
The following sets forth a detailed description of the best contemplated mode for carrying out the invention. The description is intended to be illustrative of the invention and should not be taken to be limiting.
Referring to FIG. 1, an exemplary embodiment of a computer system circuit 100 is shown which incorporates a conditional wait state generator 150. In this example, the conditional wait state generator 150 receives processor control signals 152, an address strobe signal (ADS#) 154 and a clock signal 156 from a processor 110. The conditional wait state generator 150 inserts wait states which modify the address strobe signal so that a modified address strobe signal (ADS 13 OV#) is transferred to a system bus 160. In this example, the processor 110 is connected to a set-associative cache which includes a cache-tag directory 120, a cache controller 122 and a cache data memory 124. Address buffers 130 and data buffers 132 are interposed between the processor 110 and the system bus 160 and main memory (not shown) which is typically connected to the system bus 160. Although the conditional wait state generator 150 may be utilized in many processor system structures, including structures which do not include a cache, a processor system which includes a cache memory is depicted in this example because performance of a processor system which includes a cache is advantageously tested using the conditional wait state generator 150.
Referring to FIG. 2, a schematic circuit diagram shows an embodiment of a conditional wait state generator 150, which is used to generate wait states for a microprocessor. The number of wait states generated is determined by the type of memory access in progress. In this embodiment, an address strobe signal (ADS#) starts a bus cycle, for example for the purpose of initiating a memory or input/output access, and is applied to the conditional wait state generator 150. The conditional wait state generator 150 delays the ADS# signal for a cycle or set of cycles under test, but does not delay the ADS# signal for other cycle types. Examples of cycles under test include data access cycles such as memory read cycles, memory write cycles, I/O read cycles, I/O write cycles, read-write cycles and burst access cycles. All signals are shown active high to improve clarity of operation of the circuit.
The conditional wait state generator 150 receives input signals including processor control signals on processor control signal lines, an address strobe (ADS#) signal and a clock signal on a CLK line. The address strobe (ADS#) signal is used by external bus circuitry to indicate that the processor has started a bus cycle. An external system may sample the bus cycle definition pins on the next rising edge of the clock after ADS# is driven active. The ADS# signal is driven active in the first clock of a bus cycle and is driven inactive in the second and subsequent clocks of the cycle. The ADS# signal is driven inactive when the bus is idle. The clock signal on the CLK line furnishes the fundamental timing for a processor and typically corresponds to the operating frequency of the processor. The clock signal serves as a reference timing signal for sampling other signals. Processor control signals are various control signals for controlling the operation of a processor. Examples of a processor control signal is a write/read (W/R#) signal. The write/read (W/R#) signal is a fundamental bus cycle definition signal, which distinguishes between processor read and write cycles. The W/R# signal is driven valid in the same clock as the ADS# signal is asserted.
The conditional wait state generator also includes a cycle type register 210 and a wait state register 212. The cycle type register 210 holds a digital value indicative of the cycle type to be tested. Testing of multiple cycles is achieved by setting multiple control bits of the cycle type register 210. The multiple control bits are logically combined to test multiple cycles. The wait state register 212 is programmed to a wait state count that sets the count for the cycle type to be tested that is set in the cycle type register 210. In the illustrative embodiment, the wait state register 212 has a bit width of five bits. This number of bits is useful for extending the latency a relatively large amount for testing various conditions such as processor performance during a large number of cache memory accesses. The cycle type register 210 and wait state register 212 are programmable and influence the operation of the conditional wait state generator 150 on the basis of that programming.
A cycle type comparator 214 has a first multiple-bit input terminal that is connected to the processor control signal lines and a second multiple-bit input terminal that is connected to the cycle type register. The cycle type comparator 214 compares the processor control signals to the digital value set in the cycle type register 212 on a bitwise basis so that a cycle match output signal of the cycle type comparator 214 becomes active when a match occurs. When a match occurs and the cycle type comparator 214 is active, the count enable flip-flop 220 is set, enabling a wait state counter 224. When enabled, the wait state counter 224 counts until the count is equal to the value programmed in the wait state register 212, as determined by a wait state comparator 226, at which time the delayed ADS#signal is output by the conditional wait state generator 150. Each delay increment programmed in the wait state counter 224 is one clock cycle in duration. The output signal of the wait state comparator 226 is applied to reset the count enable flip-flop 220.
When no match occurs, the ADS# signal is passed unchanged through the conditional wait state generator 150.
The cycle match signal is applied to an inverter 216 and an AND gate 218. AND gate 218 is a two-input AND gate having a first input terminal connected to the cycle match signal line and a second input terminal connected to receive the address strobe (ADS#) signal. When both the ADS# signal and the cycle match signal are active, AND gate 218 becomes active so that a count enable flip-flop 220 is set. The count enable flip-flop 220 has a set input terminal that is connected to the output of the AND gate 218 and an input reset terminal that is connected to the output terminal of a wait count comparator 222. The count enable flip-flop 220 has a Q output terminal that is connected to a count enable input terminal of a wait state counter 224. The count enable flip-flop 220 controls the counter of the wait state counter 224. A count enable flip-flop 220 Q output signal of "1" enables the wait state counter 224 while a Q output signal of "0" disables the wait state counter 224. The count enable flip-flop 220 is set when an address strobe (ADS#) signal is active and the cycle match signal is asserted. The count enable flip-flop 220 is reset when the wait state count is attained and a count match signal is generated. The count match signal is generated by a wait state comparator 226. The wait state comparator 226 has a first digital input terminal which is connected to the wait state register 212 and a second digital input terminal connected to an output terminal of the wait state counter 224. The wait state comparator 226 compares the value of the current wait state count in the wait state counter 224 with the programmed value in the wait state register 212 and generates the count match signal which becomes active when the wait state count value is equal to the programmed wait state register 212 value. The count match signal is active and valid for exactly one clock signal.
The wait state counter 224 has a clear input terminal connected through an OR gate 228. The OR gate 228 has a first input terminal connected to the address strobe (ADS#) line and a second input terminal connected to the count match signal. The OR gate 228 is thus a two-input OR gate that is used to clear the wait state counter 224. The wait state counter 224 is a multiple-bit counter for counting wait states. In the illustrative embodiment of the conditional wait state generator 150, the wait state counter 224 is a five-bit counter. The wait state counter 224 is clear when an address strobe is asserted at the start of a cycle and is also asserted when a count match signal is asserted when the current count is complete. The clock of the wait state counter 224 is the same as the processor clock so that the value in the wait state counter 224 is a count in time units that are equal to processor clock time units. The wait state counter 224 only counts when the output of the count enable flip-flop 220 is asserted to a "1" value.
An address strobe (ADS#) select OR gate 230 is a two input OR gate that selects an address strobe signal from either the input ADS# line or the delayed address strobe signal from the output terminal of the wait state comparator 226. The ADS# select OR gate 230 has a first input terminal that is connected to the output terminal of the wait state comparator 226 and a second input terminal that is connected to the output terminal of a pass-through AND gate 232. The pass-through AND gate 232 is a two-input AND gate having a first input terminal connected to the address strobe (ADS#) line and a second input terminal connected to an inverted cycle match signal that is output by the cycle type comparator 214 and inverted by inverter 216. Accordingly, the pass-through AND gate 232 generates a signal that is the AND of the address strobe (ADS#) signal and the inversion of the cycle match signal. The output signal from the pass-through AND gate 232 is active when the address strobe signal is active and the current cycle type is not the program-requested cycle type. In this manner the conditional wait state generator 150 passes through the address strobe (ADS#), unchanged, unless the processor control signals correspond to the cycle type that is written in the cycle type register 210.
Referring to FIG. 3, a flowchart of a processor analysis procedure is shown. In operating cycle selection step 310, a particular test operating condition is selected by programming the cycle type register 210. The latency is initialized in wait state initialize step 312, typically with the number of wait states set to a small value, such as zero. Execute benchmark program step 314 begins the running of the benchmark program for analyzing processor function. In measure system throughput step 316, execution time is measured for completion of a benchmark test routine. Record information step 318 updates a test record including recordation of the number of wait states and the corresponding execution time. Modify wait state step 320 modifies the number of wait states for a next test condition. Typically, the number of wait states is incremented, often by a single count. If the processor is to be tested for further wait state counts, more tests step 322 loops to execute benchmark program step 314. Otherwise, compare data step 324 is invoked to compare the execution time for different wait states. One technique for comparing processor performance over a number of wait state latencies is to graph the information.
Other Embodiments
While the invention has been described with reference to various embodiments, it will be understood that these embodiments are illustrative and that the scope of the invention is not limited to them. Many variations, modifications, additions, and improvements of the embodiments described are possible.
For example, the illustrative circuit may be replaced by other equivalent circuits which perform the same cycle type selection, wait state selection and wait state generation operations. Although the illustrative circuit utilizes active high logic, other logic conventions may be implemented while remaining within the scope of the invention.
Furthermore, the conditional wait state generator may be implemented in various other processor systems, including many systems which implement a variety of different cache structures or systems which do not include a cache.
These and other variations, modifications, additions, and improvements may fall within the scope of the invention as defined in the claims which follow. | A conditional wait state generator is interposed into the timing circuitry of a processor. The conditional wait state generator provides for analysis of a selected cycle type and for selection of the latency or number of wait states that is imposed during processor execution for that selected cycle type. In accordance with another aspect of the conditional wait state generator, a method of analyzing processor performance under specific operating conditions involves selection of a particular cycle type for testing and selection of a number of wait states that is imposed on processor operations for the selected cycle type and not for other cycle types. A conditional wait state generator is interposed into the timing circuitry of a processor and thereby imposes the selected conditions on the processor for analysis. | 6 |
This application claims the benefit of U.S. Provisional Application No. 60/659,696, filed on Mar. 8, 2005.
BACKGROUND OF THE INVENTION
1. Technical Field
The invention relates to an improved process for the preparation of macrocyclic compounds useful as agents for the treatment of hepatitis C viral (HCV) infections.
2. Background Information
The macrocyclic compounds of the following formula (I) and methods for their preparation are known from: Tsantrizos et al., U.S. Pat. No. 6,608,027 B1; Llinas Brunet et al, U.S. Application Publication No. 2003/0224977 A1; Llinas Brunet et al, U.S. Application Publication No. 2005/0075279 A1; Llinas Brunet et al, U.S. Application Publication No. 2005/0080005 A1; Brandenburg et al., U.S. Application Publication No. 2005/0049187 A1; and Samstag et al., U.S. Application Publication No. 2004/0248779 A1:
wherein W is CH or N,
L 0 is H, halo, C 1-6 alkyl, C 3-6 cycloalkyl, Cl 1-6 haloalkyl, C 1-6 alkoxy, C 3-6 cycloalkoxy, hydroxy, or N(R 23 ) 2 , wherein each R 23 is independently H, C 1-6 alkyl or C 3-6 cycloalkyl; L 1 , L 2 are each independently H, halogen, C 1-4 alkyl, —O—C 1-4 alkyl, or —S—C 1-4 alkyl (the sulfur being in any oxidized state); or L 0 and L 1 or L 0 and L 2 may be covalently bonded to form together with the two C-atoms to which they are linked a 4-, 5- or 6-membered carbocyclic ring wherein one or two (in the case of a 5- or 6-membered ring) —CH 2 — groups not being directly bonded to each other, may be replaced each independently by —O— or NR a wherein R a is H or C 1-4 alkyl, and wherein said ring is optionally mono- or di-substituted with C 1-4 alkyl;
R 2 is H, halo, C 1-6 alkyl, C 3-6 cycloalkyl, C 1-6 haloalkyl, C 1-6 thioalkyl, C 1-6 alkoxy, C 3-6 cycloalkoxy, C 2-7 alkoxy-C 1-6 alkyl, C 6 or C 10 aryl or Het, wherein Het is a five-, six-, or seven-membered saturated or unsaturated heterocycle containing from one to four heteroatoms selected from nitrogen, oxygen and sulfur;
said cycloalkyl, aryl or Het being substituted with R 6 , wherein R 6 is H, halo, C 1-6 alkyl, C 3-6 cycloalkyl, C 1-6 alkoxy, C 3-6 cycloalkoxy, NO 2 , N(R 7 ) 2 , NH—C(O)—R 7 ; or NH—C(O)—NH—R 7 wherein each R 7 is independently: H, C 1-6 alkyl or C 3-6 cycloalkyl; or R 6 is NH—C(O)—OR 8 wherein R 8 is C 1-6 alkyl or C 3-6 cycloalkyl; R 3 is hydroxy, NH 2 , or a group of formula —NH—R 9 , wherein R 9 is C 6 or C 10 aryl, heteroaryl, —C(O)—R 10 , —C(O)—NHR 10 or —C(O)—OR 10 ,
wherein R 10 is C 1-6 alkyl or C 3-6 cycloalkyl;
D is a 5 to 10-atom unsaturated alkylene chain; R 4 is H, or from one to three substituents at any carbon atom of said chain D, said substituent independently selected from: C 1-6 alkyl, C 1-6 haloalkyl, C 1-6 alkoxy, hydroxy, halo, amino, oxo, thio, and C 1-6 thioalkyl; and A is an amide of formula —C(O)—NH—R 11 , wherein R 11 is selected from: C 1-8 alkyl, C 3-6 cycloalkyl, C 6 or C 10 aryl; C 7-16 aralkyl and SO 2 R 11A wherein R 11A is C 1-8 alkyl, C 3-7 cycloalkyl or C 1-6 alkyl-C 3-7 cycloalkyl; or A is a carboxylic acid or a pharmaceutically acceptable salt or ester thereof;
The compounds of formula (I) are disclosed in the above-mentioned patent documents as being active agents for the treatment of hepatitis C virus (HCV) infections. The methods disclosed for the preparation of these compounds include many synthetic steps. The problem addressed by the present invention is to provide a practical and economical process which allows for the efficient manufacture of these compounds with a minimum number of steps and with sufficient overall yield.
BRIEF SUMMARY OF THE INVENTION
It has been discovered that the compounds of formula (I) described above can be prepared more efficiently if the synthesis is carried out using the following key synthetic substitution step wherein a macrocyclic compound of formula (3) is reacted with a sulfonyl-substituted compound of formula QUIN:
and when A is a protected carboxylic acid group, optionally subjecting the compound of formula (I) to de-protection conditions to obtain a compound of formula (I) wherein A is a carboxylic acid group;
and when A is a carboxylic acid group in the resulting compound of formula (I), optionally coupling this compound with a sulfonamide of formula R 11A SO 2 NH 2 in the presence of a suitable coupling agent, such as carbodiimide reagents, TBTU or HATU, to obtain a compound of formula (I) wherein A is —C(O)—NH— SO 2 R 11A .
In this process there is also no inversion of configuration at the hydroxyl group of the proline moiety which further renders the approach more direct and minimizes problems of stereocontrol, and the quinoline building block is incorporated in the molecule toward the end of the process thus minimizing losses of a costly intermediate.
The present invention is therefore directed to a synthetic process for preparing compounds of formula (I) using the synthetic sequences as described herein; particular individual steps of this process; and particular individual intermediates used in this process.
DETAILED DESCRIPTION OF THE INVENTION
Definition of Terms and Conventions Used
Terms not specifically defined herein should be given the meanings that would be given to them by one of skill in the art in light of the disclosure and the context. As used in the specification, however, unless specified to the contrary, the following terms have the meaning indicated and the following conventions are adhered to.
In the groups, radicals, or moieties defined below, the number of carbon atoms is often specified preceding the group, for example, C 1-6 alkyl means an alkyl group or radical having 1 to 6 carbon atoms. In general, for groups comprising two or more subgroups, the last named group is the radical attachment point, for example, “thioalkyl” means a monovalent radical of the formula HS-Alk-. Unless otherwise specified below, conventional definitions of terms control and conventional stable atom valences are presumed and achieved in all formulas and groups.
The term “C 1-6 alkyl” as used herein, either alone or in combination with another substituent, means acyclic, straight or branched chain alkyl substituents containing from 1 to six carbon atoms and includes, for example, methyl, ethyl, propyl, butyl, hexyl, 1-methylethyl, 1-methylpropyl, 2-methylpropyl, and 1,1-dimethylethyl.
The term “C 3-6 cycloalkyl” as used herein, either alone or in combination with another substituent, means a cycloalkyl substituent containing from three to six carbon atoms and includes cyclopropyl, cyclobutyl, cyclopentyl, and cyclohexyl.
The term “unsaturated alkylene chain” as used herein means a divalent alkenyl substituent derived by the removal of one hydrogen atom from each end of a mono- or poly-unsaturated straight or branched chain aliphatic hydrocarbon and includes, for example:
—CH 2 —CH 2 —CH 2 —CH 2 —CH 2 —CH═CH— and —CH 2 —CH 2 —CH 2 —CH 2 —CH═CH—CH 2 —.
The term “C 1-6 alkoxy” as used herein, either alone or in combination with another substituent, means the substituent C 1-6 alkyl-O— wherein alkyl is as defined above containing up to six carbon atoms. Alkoxy includes methoxy, ethoxy, propoxy, 1-methylethoxy, butoxy and 1,1-dimethylethoxy. The latter substituent is known commonly as tert-butoxy.
The term “C 3-6 cycloalkoxy” as used herein, either alone or in combination with another substituent, means the substituent C 3-6 cycloalkyl-O— containing from 3 to 6 carbon atoms.
The term “C 2-7 alkoxy-C 1-6 alkyl” as used herein, means the substituent C 2-7 alkyl-O—C 1-6 alkyl wherein alkyl is as defined above containing up to six carbon atoms.
The term “haloalkyl” as used herein means as used herein, either alone or in combination with another substituent, means acyclic, straight or branched chain alkyl substituents having one or more hydrogens substituted for a halogen selected from bromo, chloro, fluoro or iodo.
The term “thioalkyl” as used herein means as used herein, either alone or in combination with another substituent, means acyclic, straight or branched chain alkyl substituents containing a thiol (HS) group as a substituent. An example of a thioalkyl group is a thiopropyl, e.g., HS—CH 2 CH 2 CH 2 — is one example of a thiopropyl group.
The term “C 6 or C 10 aryl” as used herein, either alone or in combination with another substituent, means either an aromatic monocyclic system containing 6 carbon atoms or an aromatic bicyclic system containing 10 carbon atoms. For example, aryl includes a phenyl or a naphthyl ring system.
The term “C 7-16 aralkyl” as used herein, either alone or in combination with another substituent, means an aryl as defined above linked through an alkyl group, wherein alkyl is as defined above containing from 1 to 6 carbon atoms. Aralkyl includes for example benzyl, and butylphenyl.
The term “Het” as used herein, either alone or in combination with another substituent, means a monovalent substituent derived by removal of a hydrogen from a five-, six-, or seven-membered saturated or unsaturated (including aromatic) heterocycle containing carbon atoms and from one to four ring heteroatoms selected from nitrogen, oxygen and sulfur. Examples of suitable heterocycles include: tetrahydrofuran, thiophene, diazepine, isoxazole, piperidine, dioxane, morpholine, pyrimidine or
The term “Het” also includes a heterocycle as defined above fused to one or more other cycle be it a heterocycle or a carbocycle, each of which may be saturated or unsaturated. One such example includes thiazolo[4,5-b]-pyridine. Although generally covered under the term “Het”, the term “heteroaryl” as used herein precisely defines an unsaturated heterocycle for which the double bonds form an aromatic system. Suitable example of heteroaromatic system include: quinoline, indole, pyridine,
The term “oxo” means the double-bonded group (═O) attached as a substituent.
The term “thio” means the double-bonded group (═S) attached as a substituent.
In general, all tautomeric forms and isomeric forms and mixtures, whether individual geometric isomers or optical isomers or racemic or non-racemic mixtures of isomers, of a chemical structure or compound are intended, unless the specific stereochemistry or isomeric form is specifically indicated in the compound name or structure.
The term “pharmaceutically acceptable ester” as used herein, either alone or in combination with another substituent, means esters of the compound of formula I in which any of the carboxyl functions of the molecule, but preferably the carboxy terminus, is replaced by an alkoxycarbonyl function:
in which the R moiety of the ester is selected from alkyl (e.g. methyl, ethyl, n-propyl, t-butyl, n-butyl); alkoxyalkyl (e.g. methoxymethyl); alkoxyacyl (e.g. acetoxymethyl); aralkyl (e.g. benzyl); aryloxyalkyl (e.g. phenoxymethyl); aryl (e.g. phenyl), optionally substituted with halogen, C 1-4 alkyl or C 1-4 alkoxy. Other suitable prodrug esters are found in Design of Prodrugs , Bundgaard, H. Ed. Elsevier (1985) incorporated herewith by reference. Such pharmaceutically acceptable esters are usually hydrolyzed in vivo when injected in a mammal and transformed into the acid form of the compound of formula I.
With regard to the esters described above, unless otherwise specified, any alkyl moiety present advantageously contains 1 to 16 carbon atoms, particularly 1 to 6 carbon atoms. Any aryl moiety present in such esters advantageously comprises a phenyl group. In particular the esters may be a C 1-16 alkyl ester, an unsubstituted benzyl ester or a benzyl ester substituted with at least one halogen, C 1-6 alkyl, C 1-6 alkoxy, nitro or trifluoromethyl.
The term “pharmaceutically acceptable salt” as used herein includes those derived from pharmaceutically acceptable bases. Examples of suitable bases include choline, ethanolamine and ethylenediamine. Na + , K + , and Ca ++ salts are also contemplated to be within the scope of the invention (also see Pharmaceutical Salts , Birge, S. M. et al., J. Pharm. Sci., (1977), 66, 1-19, incorporated herein by reference).
The following chemicals may be referred to by these abbreviations:
Abbreviation
Chemical Name
ACN
Acetonitrile
Boc
Tert-butoxylcarbonyl
DABCO
1,4-diazabicyclo[2.2.2]octane
DBU
1,8-Diazabicyclo[5.4.0]undec-7-ene
DCC
1,3-Dicyclohexylcarbodiimide
DCHA
Dicyclohexylamine
DCM
Dichloromethane
DIPEA
Diisopropylethylamine or Hünigs-Base
DMAP
Dimethylaminopyridine
DMF
N,N-Dimethylformamide
DMSO
Dimethylsulfoxide
DMTMM
4-(4,6-Dimethoxy-1,3,5-triazin-2-yl)-4-
methylmorpholinium Chloride
EDC
1-(3-dimethylaminopropyl)-3-ethylcarbodiinide
hydrocholide
HATU
O-(7-azabenzotriazol-1-yl)-N,N,′,N′-tetramethyluronium
hexafluorophosphate
HBTU
O-Benzotriazol-1-yl-N,N,′,N′-tetramethyluronium
hexafluorophosphate
HOAT
1-Hydroxy-7-azabenzotriazole
HOBT
1-Hydroxybenzotriazole
IPA
Isopropyl alcohol
KDMO
Potassium 3,7-dimethyl-3-octanoxide
MCH
Methylcyclohexane
MIBK
4-Methyl-2-pentanone
NMP
1-Methyl-2-pyrrolidinone
SEH
Sodium 2-ethylhexanoate
TBTU
O-(Benzotriazol-1-yl)-N,N,N′,N′-tetramethyluronium
tetrafluoroborate
THF
Tetrahydofuran
THP
Trishydroxymethylphosphine
TKC
Tetrakis hydroxymethyl phosphonium chloride
EMBODIMENTS OF THE INVENTION
In the synthetic schemes below, unless specified otherwise, all the substituent groups in the chemical formulas shall have the same meanings as in the Formula (I). The reactants used in the synthetic schemes described below may be obtained either as described herein, or if not described herein, are themselves either commercially available or may be prepared from commercially available materials by methods known in the art. Certain starting materials, for example, may be obtained by methods described in the International Patent Applications WO 00/59929, WO 00/09543 and WO 00/09558, U.S. Pat. No. 6,323,180 B1 and U.S. Pat. No. 6,608,027 B1.
Optimum reaction conditions and reaction times may vary depending on the particular reactants used. Unless otherwise specified, solvents, temperatures, pressures, and other reaction conditions may be readily selected by one of ordinary skill in the art to obtain optimum results for a particular reaction. Typically, reaction progress may be monitored by High Pressure Liquid Chromatography (HPLC), if desired, and intermediates and products may be purified by chromatography on silica gel and/or by recrystallization.
I. General Multi-Step Synthetic Method
In one embodiment, the present invention is directed to a general multi-step synthetic method for preparing the compounds of formula (I). Specifically, this embodiment is directed to a process for preparing a compound of the following formula (I):
wherein W is CH or N,
L 0 is H, halo, C 1-6 alkyl, C 3-6 cycloalkyl, C 1-6 haloalkyl, C 1-6 alkoxy, C 3-6 cycloalkoxy, hydroxy, or N(R 23 ) 2 ,
wherein each R 23 is independently H, C 1-6 alkyl or C 3-6 cycloalkyl;
L 1 , L 2 are each independently H, halogen, C 1-4 alkyl, —O—C 1-4 alkyl, or —S—C 1-4 alkyl (the sulfur being in any oxidized state); or
L 0 and L 1 or
L 0 and L 2 may be covalently bonded to form together with the two C-atoms to which they are linked a 4-, 5- or 6-membered carbocyclic ring wherein one or two (in the case of a 5-or 6-membered ring) —CH 2 — groups not being directly bonded to each other, may be replaced each independently by —O— or NR a wherein R a is H or C 1-4 alkyl, and wherein said ring is optionally mono- or di-substituted with C 1-4 alkyl;
R 2 is H, halo, C 1-6 alkyl, C 3-6 cycloalkyl, C 1-6 haloalkyl, C 1-6 thioalkyl, C 1-6 alkoxy, C 3-6 cycloalkoxy, C 2-7 alkoxy-C 1-6 alkyl, C 6 or C 10 aryl or Het, wherein Het is a five-, six-, or seven-membered saturated or unsaturated heterocycle containing from one to four heteroatoms selected from nitrogen, oxygen and sulfur;
said cycloalkyl, aryl or Het being substituted with R 6 ,
wherein R 6 is H, halo, C 1-6 alkyl, C 3-6 cycloalkyl, C 1-6 alkoxy, C 3-6 cycloalkoxy, NO 2 , N(R 7 ) 2 , NH—C(O)—R 7 ; or NH—C(O)—NH—R 7 , wherein each R 7 is independently: H, C 1-6 alkyl or C 3-6 cycloalkyl;
or R 6 is NH—C(O)—OR 8 wherein R 8 is C 1-6 alkyl or C 3-6 cycloalkyl;
R 3 is hydroxy, NH 2 , or a group of formula —NH—R 9 , wherein R 9 is C 6 or C 10 aryl, heteroaryl, —C(O)—R 10 , —C(O)—NHR 10 or —C(O)—OR 10 ,
wherein R 10 is C 1-6 alkyl or C 3-6 cycloalkyl;
D is a 5 to 10-atom unsaturated alkylene chain;
R 4 is H, or from one to three substituents at any carbon atom of said chain D, said substituent independently selected from: C 1-6 alkyl,
C 1-6 haloalkyl, C 1-6 alkoxy, hydroxy, halo, amino, oxo, thio, and C 1-6 thioalkyl; and
A is an amide of formula —C(O)—NH—R 11 , wherein R 11 is selected from: C 1-8 alkyl, C 3-6 cycloalkyl, C 6 or C 10 aryl; C 7-16 aralkyl and SO 2 R 11A wherein R 11A is C 1-8 alkyl, C 3-7 cycloalkyl or C 1-6 alkyl-C 3-7 cycloalkyl;
or A is a carboxylic acid or a pharmaceutically acceptable salt or ester thereof; said process comprising the following steps: (i) when R═PG and PG is a protecting group, cyclizing a diene compound of formula (1) in the presence of a suitable catalyst to obtain a compound of formula (2) and subsequently subjecting the compound of formula (2) to de-protection conditions to obtain a compound of formula (3); or when R═H, cyclizing a diene compound of formula (1) in the presence of a suitable catalyst to obtain a compound of formula (3):
wherein A, D, R 3 and R 4 are as defined for formula (I) above, R is hydrogen or PG wherein PG is a protecting group, n is an integer from 0 to 2, and D 1 =D−(n+2);
(ii) when A is a protected carboxylic acid group in formula (3), optionally subjecting the compound of formula (3) to de-protection conditions to obtain a compound of formula (3) wherein A is a carboxylic acid group; and
(iii) reacting a compound of formula (3) with a compound of formula QUIN, wherein R 3 , R 4 , D, A, L 0 , L 1 , L 2 , W and R 2 are as defined for formula (I) above, and R is C 1-6 alkyl, C 6 or C 10 aryl or heteroaryl, to obtain a compound of formula (I):
and when A is a protected carboxylic acid group in formula (I), optionally subjecting the compound of formula (I) to de-protection conditions to obtain a compound of formula (I) wherein A is a carboxylic acid group;
and when A is a carboxylic acid group in the resulting compound of formula (I), optionally coupling this compound with a sulfonamide of formula R 11A SO 2 NH 2 in the presence of a suitable coupling agent, such as carbodiimide reagents, TBTU or HATU, to obtain a compound of formula (I) wherein A is —C(O)—NH— SO 2 R 11A .
II. The Individual Steps of the Synthetic Method
Additional embodiments of the invention are directed to the individual steps of the multistep general synthetic method described above and the individual intermediates used in these steps. These individual steps and intermediates of the present invention are described in detail below. All substituent groups in the steps described below are as defined in the general multi-step method above.
Step (i)
This step is directed to cyclizing a diene compound of formula (1) in the presence of a suitable catalyst to obtain a compound of formula (2) when R=a protecting group and subsequently subjecting the compound of formula (2) to de-protection conditions to obtain a compound of formula (3); or when R═H, cyclizing a diene compound of formula (1) in the presence of a suitable catalyst to directly obtain a compound of formula (3):
Suitable ring-closing catalysts for this cyclization step include ruthenium based catalysts, as well as the commonly used molybdenum-based (Schrock and modified Schrock catalysts) and tungsten-based catalysts. For example, any of the well-known ruthenium based catalysts used in olefin metathesis reactions, such as Grubb's catalyst (first and second generation), Hoveyda's catalyst (first and second generation) and Nolan's catalyst, may be used with appropriate adjustment of reaction conditions as may be necessary to allow ring-closing to proceed, depending upon the particular catalyst that is selected.
Suitable ruthenium catalysts for the cyclization step include, for example, the compounds of formula A, B, C, D or E:
wherein
X 1 and X 2 each independently represent an anionic ligand,
L 1 represents a neutral electron donor ligand which is bonded to the ruthenium atom and is optionally bonded to the phenyl group, and
L 2 represents a neutral electron donor ligand which is bonded to the ruthenium atom;
and R 5 is selected from one or more substituents on the benzene ring, each substituent independently selected from hydrogen, C 1-6 alkyl, haloC 1-6 alkyl, HS—C 1-6 alkyl, HO—C 1-6 alkyl, perfluoroC 1-6 alkyl, C 3-6 cycloalkyl, C 1-6 alkoxy, hydroxyl, halogen, nitro, imino, oxo, thio or aryl; and
wherein X 2 and L 2 may optionally together form a chelating bidentate ligand.
In a more specific embodiment, the ruthenium catalyst is a compound of formula (A-1) or (A-2):
wherein:
L 1 is a trisubstituted phosphine group of the formula PR 3 , wherein R is selected from C 1-6 alkyl and C 3-8 -cycloalkyl,
L 2 is a trisubstituted phosphine group of the formula PR 3 , wherein R is selected from C 1-6 alkyl and C 3-8 -cycloalkyl,
or L 2 is a group of the formula A or B:
wherein
R 7 and R 8 each independently represent a hydrogen atom or a C 1-6 alkyl, C 2-6 alkenyl, C 6-12 aryl or C 6-12 aryl-C 1-6 alkyl group; and
R 9 and R 10 each independently represent a hydrogen atom or a C 1-6 alkyl, C 2-6 alkenyl, C 6-12 aryl or C 6-12 aryl-C 1-6 alkyl group, each optionally substituted by one, two or three groups selected from hydrogen, C 1-6 alkyl, haloC 1-6 alkyl, HS—C 1-6 alkyl, HO—C 1-6 alkyl, perfluoroC 1-6 alkyl, C 3-6 cycloalkyl, C 1-6 alkoxy, hydroxyl, halogen, nitro, imino, oxo, thio or aryl;
X 1 and X 2 each independently represent a halogen atom;
R 5 represent hydrogen or nitro; and
R 6 represents a C 1-6 alkyl group.
In another more specific embodiment, the ruthenium catalyst is selected from:
where Ph is phenyl and Mes is 2,4,6-trimethylphenyl.
Ruthenium-based catalysts useful for the metathesis cyclization step, such as those set forth above, are all known catalysts that may be obtained by known synthetic techniques. For example, see the following references for examples of suitable ruthenium-based catalysts:
Organometallics 2002, 21, 671; 1999, 18, 5416; and 1998, 17, 2758; J. Am. Chem. Soc. 2001, 123, 6543; 1999, 121, 791; 1999, 121, 2674; 2002, 124, 4954; 1998, 120, 2484; 1997, 119, 3887; 1996, 118, 100; and 1996, 118, 9606 J. Org. Chem. 1998, 63, 9904; and 1999, 64, 7202; Angew. Chem. Int. Ed. Engl. 1998, 37, 2685; 1995, 34, 2038; 2000, 39, 3012 and 2002, 41, 4038; U.S. Pat. Nos. 5,811,515; 6,306,987 B1; and 6,608,027 B1
In another specific embodiment of the present invention the ring-closing reaction is carried out in a solvent at a temperature in the range of from about 20° to about 120° C., Any solvent that is suitable for the ring closing metathesis reaction may be used. Examples of suitable solvents include alkanes, such as n-pentane, n-hexane or n-heptane, aromatic hydrocarbons, such as benzene, toluene or xylene, chlorinated hydrocarbons such as dichloromethane, trichloromethane, tetrachloromethane or dichloroethane, tetrahydrofuran, 2-methyl-tetrahydrofuran, 3-methyl-tetrahydrofuran, cyclopentyl methyl ether, methyl tert-butyl ether, dimethyl ether, methyl alcohol, dioxane, ethyl acetate and tert-butyl acetate.
In another specific embodiment of the present invention the ring-closing reaction is carried out wherein the molar ratio of the diene compound (1) to the catalyst ranges from 1000:1 to 100:1, preferably from 500:1 to 110:1, in particular from 250:1 to 150:1.
In another specific embodiment of the present invention the ring-closing reaction is carried out at a ratio of the diene compound (1) to solvent in the range from 1:400 by weight to 1:25 by weight, preferably from 1:200 by weight to 1:50 by weight, in particular from 1:150 by weight to 1:75 by weight.
In another specific embodiment of the present invention the ring-closing reaction is carried out by portionwise addition of the catalyst in the range from 2 to 6 portions, preferably from 3-5 portions.
One skilled in the art can readily optimize the cyclization step by selecting and adjusting appropriate conditions suitable for the particular ring-closing catalyst selected. For example, depending upon the catalyst selected it may be preferable to run the cyclization step at high temperature, e.g., higher than 90° C., although lower temperatures may also be possible with the addition of an activator such as copper halide (CuX, where X is halogen) to the reaction mixture.
In a particular embodiment of this step, the compound of formula (1) is dissolved in a degassed organic solvent (such as toluene or dichloromethane) to a concentration below about 0.02M, then treated with a ruthenium-based catalyst such as Hoveyda's catalyst, at a temperature from about 40° C. to about 110° C. until completion of the reaction. Some or all of the ruthenium metal may be removed from the reaction mixture by treatment with a suitable heavy metal scavenger, such as THP or other agents known to scavenge heavy metals. The reaction mixture is then washed with water and the organic layer separated and washed. The resulting organic solution may be decolorized, such as by the addition of activated charcoal with subsequent filtration.
In one embodiment, the proline ring oxygen atom in formula (1) has been protected with a protecting group (where R═PG) at any time prior to the cyclization step using conventional techniques. Any suitable oxygen protecting group may be used including, for example, acetate, benzoate, para-nitro benzoate, naphthoates, halogenoacetate, methoxyacetate, phenyl acetate, phenoxy acetate, pivaloate, crotonate, methyl carbonate, methoxymethyl carbonate, ethyl carbonate, halogeno carbonate, para-nitro phenyl carbonate, triisopropyl silyl, triethyl silyl, dimethylisopropyl, diethylisopropyl, dimethylthexylsilyl, t-butyldimethylsilyl, t-butyldiphenylsilyl, tribenzylsilyl, triphenylsilyl, diphenylmethylsilyl, di-t-butylmethylsilyl, tris(trimethylsilyl)silyl, t-butoxymethoxyphenylsilyl, t-butoxydiphenylsilyl, etc. Following the cyclization step, the protecting group PG in compound (2) is removed using conventional de-protection conditions suitable for the particular protecting group, as would be readily understood by one skilled in the art, to obtain compound (3).
In another embodiment, it may be desirable to purify the solution of diene compound of formula (1) prior to the methathesis cyclication step to remove any impurities from the reaction mixture that might inhibit the cyclization reaction. Conventional purification procedures well known to those skilled in this art may be employed. In one preferred embodiment, the solution of diene compound is purified by treatment with alumina, for example, activated alumina, prior to its use in the cyclization step.
Step (ii)
When A is a protected carboxylic acid group in formula (3), e.g. a carboxylic acid ester group, the compound of formula (3) can optionally be subjected to de-protection (hydrolysis) conditions to obtain the corresponding free carboxylic acid compound prior to the next step. Hydrolysis can be carried out using conventional hydrolysis conditions known in the art. In a particular embodiment, for example, an esterified compound of formula (3) is dissolved in an organic solvent such as THF, and a suitable hydrolyzing agent such as lithium hydroxide monohydrate (LiOH.H 2 O) or sodium hydroxide (NaOH) is added followed by the addition of water. The resultant solution is stirred at a temperature from about 35° C. to about 50° C. At the end of the reaction, the solution is cooled, and the organic layer collected. A suitable solvent such as ethanol is added to the organic layer and the pH is adjusted to from about pH 5 to about pH 6. The mixture is then warmed to a temperature from about 40° C. to about 50° C. at which point water is added and solution is stirred whereupon the compound of formula (3) begins to precipitate. Upon completion of the precipitation, the solution is cooled to ambient temperature and the compound of formula (3) is collected by filtration, washed and dried.
Step (iii)
This step is directed to a process for preparing a compound of formula (I), comprising reacting a compound of formula (3) with a compound of formula QUIN to obtain a compound of formula (I):
and when A is a protected carboxylic acid group, optionally subjecting the compound of formula (I) to de-protection conditions to obtain a compound of formula (I) wherein A is a carboxylic acid group;
and when A is a carboxylic acid group in the resulting compound of formula (I), optionally coupling this compound with a sulfonamide of formula R 11A SO 2 NH 2 in the presence of a suitable coupling agent, such as carbodiimide reagents, TBTU or HATU, to obtain a compound of formula (I) wherein A is —C(O)—NH— SO 2 R 11A .
R groups on the sulfonyl group in QUIN include, for example, C 1-6 alkyl, C 6 or C 10 aryl or heteroaryl. A preferred R group is phenyl.
The coupling reaction between the compounds of formulas (3) and QUIN is typically preformed in the presence of a base in a suitable solvent or solvent mixture. Examples of suitable bases for this reaction include t-BuOK, t-BuONa, t-BuOCs, sodium bis(trimethylsilyl)amide, and KDMO, with t-BuOK and KDMO being preferred bases. Examples of suitable solvents for this reaction include polar aprotic solvents, for example, DMSO, DMF, NMP or other common polar aprotic solvents, as well as THF and other moderately polar ethers, or suitable mixtures of these solvents. A preferred solvent is DMSO.
The preferred temperature would be between 0° C. and 50° C. (depending upon solvent freezing points), and most preferably between 10° C. and 25° C.
In yet another preferred embodiment of this step, the following set of reaction conditions may be employed: A flask is charged with the macrocycle (3) and the quinoline QUIN, purged with nitrogen (3 times), then DMSO is added via syringe. The mixture is again purged with nitrogen (3 times), and the temperature adjusted to 20° C. To the slurry is then added 50% KDMO/heptane via syringe pump over 1 hour. The resulting mixture is stirred under nitrogen at ˜20° C. for 2 h. The mixture is then quenched by the dropwise addition of glacial HOAc, and the mixture is stirred. The reaction mixture is then slowly added to water, to cause product precipitation. The slurry is then stirred, filtered, and the cake washed with water, then hexanes, and the solid dried.
When A is a protected carboxylic acid group in formula (I), e.g. a carboxylic acid ester group, the compound of formula (I) can optionally be subjected to de-protection (hydrolysis) conditions to obtain the corresponding free carboxylic acid compound. Hydrolysis can be carried out using conventional hydrolysis conditions known in the art. Suitable conditions are the same as discussed previously for step (ii). In addition, when A is a carboxylic acid group in the resulting compound of formula (I), this compound may be coupled with a sulfonamide of formula R 11A SO 2 NH 2 in the presence of a suitable coupling agent, such as carbodiimide reagents, TBTU or HATU, to obtain a compound of formula (I) wherein A is —C(O)—NH— SO 2 R 11A .
III. Preparation of Peptidic Diene Starting Material
The peptidic diene starting material (1) employed in the above schemes may be synthesized from known materials using the procedures as outlined in the Schemes I to III below.
The peptide coupling to give P2-P1-PG, wherein PG is an amino-protecting group, in Scheme I could be performed using any of the conventional peptide coupling reagents and protocols known in the art, and the amino-protecting group PG can be any suitable amino-protecting group that is well known in the art. See, for example, the intermediates and coupling techniques disclosed in WO 00/09543, WO 00/09558 and U.S. Pat. No. 6,608,027 B1. Peptide coupling between compounds of formula P2-PG and P1 could be achieved, for example, under a variety of conditions known in the art using conventional peptide coupling reagents such as DCC, EDC, TBTU, HBTU, HATU, DMTMM, Cyanuric chloride (CC), tosyl chloride (TsCl), mesyl chloride (MsCl), isobutyl chloroformate (IBC), HOBT, or HOAT in aprotic solvents such as dichloromethane, chloroform, THF, DMF, NMP, DMSO.
The next step of cleaving the nitrogen protecting group in the compound of formula P2-P1-PG can also be accomplished by well known techniques, e.g., as described in 00/09543, WO 00/09558 and U.S. Pat. No. 6,608,027 B1. In particular embodiments, this process involves the acid hydrolysis of the compound of formula P2-P1-PG with an organic or inorganic acid, such as HCl, H 2 SO 4 , TFA, AcOH, MeSO 3 H, in a variety of protic or polar nonprotic solvents such as alcohols, ethers, ACN or DCM.
The compounds of formula P2-PG used as starting material are either commercially available, e.g., Boc-4(R)-hydroxyproline, or can be prepared from known materials using conventional techniques. In one example, the compounds of formula P2-PG where R is hydrogen and PG is an amino-protecting group may be prepared by amino-protection of 4-hydroxyproline:
In the first step, an appropriate amino-protecting group is introduced onto the ring nitrogen atom of the 4-hydroxyproline compound using conventional procedures. For example, the compound may be dissolved in a suitable solvent and reacted with an appropriate amino-protecting group introducing reagent. For example, and not intending to be limited in its scope, when Boc (tert-butyloxycarbonyl) is the desired protecting group, the compound is reacted with the anhydride Boc 2 O (or Boc-ON) in a solvent mixture such as Acetone/Water, MIBK/Water or THF/Water to which a base such as NaOH, KOH, LiOH, triethylamine, diisopropylethylamine, or N-methyl-pyrrolidine is added, the reaction being carried out at a temperature between 20-60° C.
The compounds of formula P1 are known from WO 00/09543, WO 00/09558 and U.S. Pat. No. 6,608,027 B1, and may be prepared by techniques as described therein.
The peptide coupling to give P3-P2-Me in Scheme II could be performed using any of the conventional peptide coupling reagents and protocols known in the art. Examples of suitable reagents and conditions are outlined above with respect to peptide coupling step of Scheme I.
The subsequent hydrolysis to give P3-P2 in Scheme II would be performed with an aqueous basic solution, optionally containing a co-solvent that is miscible with H 2 O such as THF, dioxane, alcohols, or DME or combinations of these co-solvents. The preferred solvent mixture would be aqueous base containing THF as a co-solvent. Any water soluble base could be used such as LiOH, NaOH, KOH, Na 2 CO 3 , K 2 CO 3 , and the like. The preferred base would be LiOH. The amount of base could vary from 1 to 100 equivalents with 1-10 equivalents being preferred. The concentration of base could range from 0.25 M to 12 M, with 1-4 M being preferred. The reaction temperature could vary from −40° C. to 100° C., with −20° C. to 50° C. being preferred.
A one-pot sequence for the peptide coupling of P3 with P2-Me can be carried out using CC or an alkyl- or aryl-sulfonyl chloride (e.g., TsCl, MsCl) under coupling conditions, to form P3-P2-Me followed by hydrolysis of the product by the addition of an aqueous basic solution to provide the compound P3-P2 of Scheme II which may then be crystallized. In this one-pot sequence, the P3 compound can also be used in the form of its salt with a sterically hindered secondary amine, such as its DCHA salt.
The substituted acid compound of formula P3 used as a starting material are known from U.S. Pat. No. 6,608,027 B1 and may be obtained from commercially available materials using the techniques as described therein.
The peptide couplings to give compound (1) in Scheme III could be performed using any of the conventional peptide coupling reagents and protocols known in the art. Examples of suitable reagents and conditions are outlined above with respect to peptide coupling step of Scheme I. IBC is a preferred peptide coupling reagent for Scheme III.
IV. Preparation of Sulfonated Quinoline Starting Material
The sulfonated quinoline starting material QUIN can be prepared from known materials according to the procedure outlined in Scheme IV below:
These hydroxyl-substituted quinolines II can be converted to sulfonequinolines QUIN by first converting them to a halo-quinoline compound III (where X is halogen) by following well known halogenation procedures using various halogenating reagents such as the commonly used POX 3 and PX 5 , where X═F, Cl, Br or I, wherein these reagents can be used in some cases as solvents or in combination with polar aprotic solvents, such as DMF or Acetonitrile; and then converting halogenated compound III to the target sulfonequinoline QUIN by reaction with a sulfinate salt RSO 2 M wherein M is an alkali metal, such as PhSO 2 Na.
Alternatively, II can be converted to the sulfonequinoline in a one-pot procedure by first generating an intermediate sulfonate by reaction with an arene sulfonylchloride compound R A SO 2 Cl wherein R A is a neutral or electron rich arene group, such as benzenesulfonyl chloride or tosyl chloride, in the presence of a suitable base in a sutiable solvent. Suitable bases for this step include tertiary amine bases such as N-methylpyrrolidine and diisopropylethylamine, and suitable solvents include aprotic solvents such as acetonitrile, THF, toluene and DMF, preferably acetonitrile. The resulting species is then reacted in situ, under acidic conditions (for example in the presence of acetic, trifluoroacetic, hydrochloric acid or the like, preferably acetic acid), with a sulfinate salt RSO 2 M wherein M is an alkali metal, such as PhSO 2 Na, PhSO 2 K or PhSO 2 Cs, at a suitable reaction temperature, for example in the range of 0 to 100° C., preferably 25 to 50° C. The sulfonequinoline product can be isolated from the reaction mixture using conventional techniques well know to those skilled in the art. In one embodiment, the sulfonequinoline can be crystallized out by cooling the solution to room temperature and adding water. The crystallized product can then be filtered, rinsed and washed using conventional techniques.
The hydroxyl-susbtituted quinoline compounds of formula (II) can be synthesized from commercially available materials using the techniques described in, e.g. from WO 00/59929, WO 00/09543 and WO 00/09558, U.S. Pat. No. 6,323,180 B1, U.S. Pat. No. 6,608,027 B1 and U.S. Application Publication No. 2005/0020503 A1.
An alternative procedure for preparing certain hydroxyl-susbtituted quinoline compounds of formula (II) and their halogenation to a comound of formula (III) is set forth in Scheme V below (in which compound 7 is an example of a compound (II) and compound 8 is an example of a compound (III):
wherein each Alk is independently a C 1 -C 6 alkyl group, X is a halogen atom, Z is tert-butyl or t-butyl-oxy, and R 6 and Het are as defined for Formula I.
In the first step, a compound of formula 1 is treated with a base and a brominating agent to obtain compound 2. The general requirements for this step are the use of a base of strength sufficient to form the desired dianion. This could be any alkyllithium, a metalloamide such as Lithium diisopropylamide (LDA), Lithium tetramethylpiperidide, a metallohexamethyldisilazide such as KHMDS, an organozincate, a metal alkoxide in a cation-solvating solvent such as DMSO, and the like. The preferred bases would be n-Butyllithium and LDA. Any organic solvent that does not interfere with the dianion formation could be used, such as THF, alkyl-THF's, dioxane, alkanes, cycloalkanes, dialkylethers such as MTBE, cyclopentylmethylether, dibutylether, and the like. The preferred solvents would be THF, alkyl-THF's and alkanes. The temperature for the dianion formation could be between −100° C. and 25° C., with the preferred range between −30° C. and 25° C. The brominating reagent could be any compound which contains a labile bromine atom such as Br 2 , NBS, bromohydantoins, N-bromophthalimides, bromohaloalkanes such as 1,2-dibromotetrachloroethane and perfluoroalkylbromides, and the like. The preferred brominating reagents would be the bromohaloalkanes. Once the dianion has been generated in a suitable solvent, the brominating reagent could be added neat or in solution, or alternatively the dianion could be added to the brominating reagent either neat or in solution. The preferred mode would be to add the dianion slowly to the brominating reagent in solution. The temperature for the bromination could be between −100° C. and 25° C., with the preferred range between −30° C. and 25° C.
In the next step, compound 2 is hydrolyzed by treatment with an aqueous acid mixture to obtain 3. Any aqueous acid mixture could be used such as water with [trifluoroacetic acid, a chloroacetic acid such as trichloroacetic acid, a sulfonic acid such as methanesulfonic acid, hydrochloric acid, sulfuric acid, nitric acid, phosphoric acid, a strong acid resin such as DOWEX 50], and the like. The preferred acids would be hydrochloric acid and sulfuric acid in 2-12 M concentration, preferably at least 6M. Cosolvents that are miscible with water could also be used, such as alcohols like ethanol, isopropanol, or ethers such as DME, diglyme, and the like. The hydrolysis could be carried out between 0° C. and 200° C., with the preferred temperature between 0° C. and 100° C.
In the next step, compound 3 is treated with an alkylated nitrile (Alk—CN) and a Lewis acid to obtain compound 4. For the conversion of 3 to 4, Lewis acids by themselves or in combination, could be used, such as AlCl 3 , BCl 3 , GaCl 3 , FeCl 3 and mixtures thereof, and the like. The preferred method would be to use BCl 3 with AlCl 3 . Any solvent which will not be easily acylated could be used such as halocarbons, halobenzenes, alkylbenzenes such as toluene, and alkylnitriles such as acetonitrile, with the preferred solvents being 1,2-dichloroethane, chlorobenzene and toluene. The reaction temperature could be between 0° C. and 150° C., preferably between 25° C. and 75° C.
In the next step, compound 4 is acylated with compound 5 to obtain compound 6. For the conversion of 4 to 6, acylation could be achieved by either first converting carboxylic acid 5 to an activated form such as an acid chloride or by using standard peptide coupling protocols. The preferred method would be to create the acid chloride of compound 5 using oxalyl chloride or thionyl chloride. This activated species would then be coupled with aniline 4 in any organic solvent or in water, with or without an added base. The preferred solvents would be NMP and THF and the preferred base (if used) is triethylamine. The reaction temperature could be between −30° C. and 150° C., preferably between −20° C. and 50° C.
In the next step, compound 6 is cyclized in the presence of a base to obtain compound 7. Compound 6 can be isolated and purified, or alternatively, crude 6 in an organic solvent such as NMP can simply be subjected to the cyclization conditions to furnish quinolone 7 directly, preforming two steps in a one-pot process. For the conversion of 6 to 7 in Scheme I, any base capable of forming the enolate could be used, such as t-BuOK, KDMO, LDA, and the like, with t-BuOK and KDMO being preferred. Any organic solvent which does not react with the enolate could be used, such as THF's, dioxane, DMSO, NMP, DME, and the like, with NMP, DME and DMSO being preferred. The cyclization could be performed at any temperature between 25° C. and 150° C., with 50° C. to 100° C. being preferred.
In the final step, hydroxoquinoline compound 7 is treated with a halogenating agent to obtain the compound 8. For the conversion of 7 to 8 in Scheme I, many halogenating reagents could be used, such as methanesulfonyl chloride, SOCl 2 , POCl 3 , PCl 3 , PCl 5 , POBr 3 , HF, and the like, with POCl 3 and SOCl 2 being preferred. The halogenation could be performed neat in the halogenating reagent, or in any organic solvent which does not react with the halogenating reagent, such as DME, diglyme, THF's, halocarbons and the like, with DME and THF's being preferred. The reaction temperature could be between −20° C. and 150° C. with 25° C. to 100° C. being preferred.
V. Preferred Embodiments of The Compound of Formula (I)
Preferred embodiments of the compounds of formula (I) that might be prepared by the process of the present invention include the embodiments set forth below.
Preferred embodiments include compounds of formula (I) as described above, wherein the cyclopropyl moiety on the right-hand side is selected from the 2 different diastereoisomers where the 1-carbon center of the cyclopropyl has the R configuration as represented by exemplary structures (i) and (ii):
In one specific embodiment of the compounds of formula (I), the D linker is in the configuration syn to the A group as represented by structure (ii) above;
W is N; L 0 is selected from H, —OH, —OCH 3 , —OC 2 H 5 , —OC 3 H 7 , —OCH(CH 3 ) 2 , —NHCH 3 , —NHC 2 H 5 , —NHC 3 H 7 , —NHCH(CH 3 ) 2 , —N(CH 3 ) 2 , —N(CH 3 )C 2 H 5 , —N(CH 3 )C 3 H 7 and —N(CH 3 )CH(CH 3 ) 2 . L 1 and L 2 are each independently selected from hydrogen, fluorine, chlorine, bromine, —CH 3 , —C 2 H 5 , —C 3 H 7 , —CH(CH 3 ) 2 , —OCH 3 , —OC 2 H 5 , —OC 3 H 7 and —OCH(CH 3 ) 2 , R 2 is H, C 1-6 thioalkyl, C 1-6 alkoxy, phenyl or Het selected from the following:
wherein R 6 is H, C 1-6 alkyl, NH—R 7 , NH—C(O)—R 7 , NH—C(O)—NH—R 7 , wherein each R 7 is independently: H, C 1-6 alkyl, or C 3-6 cycloalkyl;
or R 6 is NH—C(O)—OR 8 , wherein R 8 is C 1-6 alkyl;
R 3 is NH—C(O)—R 10 , NH—C(O)—OR 10 or NH—C(O)—NR 10 , wherein in each case R 0 is C 1-6 alkyl, or C 3-6 cycloalkyl; and
D is a 6 to 8-atom unsaturated alkylene chain;
R 4 is H or C 1-6 alkyl;
and A is a carboxylic acid or a pharmaceutically acceptable salt or ester thereof.
In another specific embodiment of the compounds of formula (I), the D linker is in the configuration syn to the A group as represented by structure (ii) above;
W is N; L 0 is selected from H, —OH, —OCH 3 and —N(CH 3 ) 2 ; one of L 1 and L 2 is —CH 3 , —F, —Cl or —Br and the other of L 1 and L 2 is H, or both L 1 and L 2 are H; R 2 is
wherein R 6 is NH—R or NH—C(O)—R 7 , wherein R 7 is independently: C 1-6 alkyl, or C 3-6 cycloalkyl;
R 3 is NH—C(O)—OR 10 , wherein R 10 is C 1-6 alkyl, or C 3-6 cycloalkyl; R 4 is H or C 1-6 alkyl; D is a 7-atom unsaturated alkylene chain having one double bond; and A is a carboxylic acid or a pharmaceutically acceptable salt or ester thereof.
In another specific embodiment, the compounds of formula (I) have the formula (I′) below:
L 0 is —OCH 3 ;
L 1 is —CH 3 , —F, —Cl or —Br and and L 2 is H, or both L 1 and L 2 are H;
R 6 is NH—R 7 or NH—C(O)—R 7 , wherein R 7 is independently: C 1-6 alkyl or C 3-6 cycloalkyl;
R 10 is butyl, cyclobutyl or cyclopentyl;
A is a carboxylic acid or a pharmaceutically acceptable salt or ester thereof.
The following table lists compounds representative of the compounds of formula (I). A compound of the formula below:
wherein L 0 , L 1 , L 2 and R 2 are as defined below:
Cpd #
L 2
L 0
L 1
R 2
101
H
—OMe
Me
102
H
—OMe
Me
103
H
—OMe
Me
104
H
—OMe
Me
105
H
—OMe
Br
106
H
—OMe
Br
107
H
—OMe
Cl
108
H
—OMe
Cl
109
Me
—OMe
Me
110
Me
—OMe
Me
111
H
—OMe
F
112
H
—OMe
F
113
H
—OMe
Cl
114
H
—OMe
Br
115
H
—OMe
Br
116
H
—OMe
Br
The following table list additional compounds representative of the compounds of formula (I). A compound of the formula below:
wherein the bond from position 14 to the cyclopropyl group is syn to the COOH, said 13,14 double bond is cis, R 13 , R 4 and R 2 are defined as follows:
Cpd #
R 13 :
R 4 :
R 2 :
201
H
202
H
203
H
204
H
OEt;
205
H
OEt;
206
H
207
H
208
H
209
H
210
H
211
H
212
H
213
H
214
H
215
H
216
H
217
H
218
H
219
H
220
10- (R) Me
OEt;
221
H
222
H
223
H
and 224
H
Additional specific compounds that are representative of the compounds of formula (I) may be found in U.S. Pat. No. 6,608,027 B1.
VI. Preferred Embodiments of The Compound of Formula QUIN
Preferred embodiments of the compounds of formula QUIN that might be used in the process of the present invention include the embodiments set forth below, i.e., those corresponding to the preferred embodiments of formula (I) compounds described above.
In one embodiment of the compounds of formula QUIN:
W is N; L 0 is selected from H, —OH, —OCH 3 , —OC 2 H 5 , —OC 3 H 7 , —OCH(CH 3 ) 2 , —NHCH 3 , —NHC 2 H 5 , —NHC 3 H 7 , —NHCH(CH 3 ) 2 , —N(CH 3 ) 2 , —N(CH 3 )C 2 H 5 , —N(CH 3 )C 3 H 7 and —N(CH 3 )CH(CH 3 ) 2 . L 1 and L 2 are each independently selected from hydrogen, fluorine, chlorine, bromine, —CH 3 , —C 2 H 5 , —C 3 H 7 , —CH(CH 3 ) 2 , —OCH 3 , —OC 2 H 5 , —OC 3 H 7 and —OCH(CH 3 ) 2 , R 2 is C 1-6 thioalkyl, C 1-6 alkoxy, or Het selected from the following:
wherein R 6 is H, C 1-6 alkyl, NH—R 7 , NH—C(O)—R 7 , NH—C(O)—NH—R 7 , wherein each R 7 is independently: H, C 1-6 alkyl, or C 3-6 cycloalkyl;
or R 6 is NH—C(O)—OR 8 , wherein R 8 is C 1-6 alkyl;
and R is an C 6 or C 10 aryl group.
In another specific embodiment of the compounds of formula QUIN:
W is N; L 0 is selected from H, —OH, —OCH 3 and —N(CH 3 ) 2 ; one of L 1 and L 2 is —CH 3 , —F, —Cl or —Br and the other of L 1 and L 2 is H, or both L 1 and L 2 are H; R 2 is
wherein R 6 is NH—R 7 or NH—C(O)—R 7 , wherein R 7 is independently: C 1-6 alkyl, or C 3-6 cycloalkyl;
and R is a C 6 or C 10 aryl group.
In another specific embodiment, the compounds of formula QUIN have the formula below:
L 0 is —OCH 3 ;
L 1 is —CH 3 , —F, —Cl or —Br and L 2 is H, or both L 1 and L 2 are H;
R 6 is NH—R 7 or NH—C(O)—R 7 wherein R 7 is independently: C 1-6 alkyl or C 3-6 cycloalkyl;
and R is a C 6 or C 10 aryl group.
The following table lists compounds representative of the compounds of formula QUIN. A compound of the formula below:
wherein Ph is phenyl and L 0 , L 1 , L 2 and R 2 are as defined below:
Cpd #
L 2
L 0
L 1
R 2
301
H
—OMe
Me
302
H
—OMe
Me
303
H
—OMe
Me
304
H
—OMe
Me
305
H
—OMe
Br
306
H
—OMe
Br
307
H
—OMe
Cl
308
H
—OMe
Cl
309
Me
—OMe
Me
310
Me
—OMe
Me
311
H
—OMe
F
312
H
—OMe
F
313
H
—OMe
Cl
314
H
—OMe
Br
315
H
—OMe
Br
316
H
—OMe
Br
The following table list additional compounds representative of the compounds of formula QUIN. A compound of the formula below:
wherein Ph is phenyl and R 2 is as defined as follows:
Cpd #
R 2
401
402
403
404
OEt;
405
OEt;
406
407
408
409
410
411
412
413
414
415
416
417
418
419
420
OEt;
421
422
423
and 424 | Intermediates of the formula QUIN:
and methods for their preparation are described. The intermediate compounds are useful for preparing active agents for the treatment of hepatitis C virus (HCV) infection. | 2 |
BACKGROUND OF THE INVENTION
The invention relates to an air intake device for internal combustion engines
An air intake device is disclosed in DE 40 03 492. It provides for a collector which is rotatable about its axis. A part that is continuously variable in length branches out to each cylinder of the internal combustion engine. This part is an intake duct made of a synthetic resin tube of flexible length and is reinforced by spiral springs.
A disadvantage of this air intake device is that the tube disposed outside of the collector becomes dirty, and moreover there is a danger that the tube may break or become leaky due to mechanical influences.
Another disadvantage is that atmospheric pressure bears against an externally situated tube. With increasing engine speed and consequently increasing vacuum in the air intake, the tube thus is increasingly exposed to mechanical stress. Unless reinforced by a spiral spring the tube walls must be so stiff that, in an intake tube of continuously variable length, the possible variation in length is too greatly limited, and with it the maximum possible range of adjustment.
Precisely in the case of air intake systems for internal combustion engines it is necessary to make the possible change of length as great as possible in order to optimally adapt the air intake line to the corresponding engine speed. In the state of the art the adaptation can only be made by a rotation of approximately 270°. EP 0 747 584 furthermore discloses an air intake system for an internal combustion engine in which a pivotable intake tube portion is provided. By pivoting this intake tube portion, two predefined intake tube lengths can be established. A variable adaptation of the intake tube length is not possible.
DE 38 25 000 describes an air intake duct of internal combustion engines with a continuously variable effective length, wherein an intake channel is provided in which a slide is mounted. A channel is opened or closed and the channel length adjusted depending on the position of the slide. A disadvantage of this system is that the structure involves large friction losses and the arrangement of the slide in the air intake duct of an internal combustion engine can be achieved industrially only at a disproportionately great cost.
SUMMARY OF THE INVENTION
It is therefore the object of the invention to provide an air intake device which avoids the described disadvantages, can be manufactured economically and operates reliably. This object is achieved by the invention as described and claimed hereinafter.
The substantial advantages of the invention lie in the fact that a flexible tube is also used for the intake ducts, but it is arranged to be protected within the collector.
According to one embodiment of the invention, the length and the diameter of the flexible tube can be adapted in a simple manner to the particular internal combustion engine. For example, in the case of an internal combustion engine of lower displacement volume, smaller tube diameters are needed, and in an internal combustion engine with a larger displacement volume, larger intake diameters and possibly also greater tube lengths are necessary. The air intake device can therefore be optimally adapted to the motor in question.
According to an additional embodiment of the invention the length of the flexible tube can also be varied as steplessly as desired. For this purpose the mouth of the flexible tube lies, for example, on a supporting body that is mounted for rotation. The tube also can be in contact with this supporting body. Of course, it is also possible to lengthen or shorten the flexible tube rectilinearly. In this case the supporting body would perform a longitudinal movement. The flexible tube is variable in lenght both rectilinearly and arcuately or circularly.
These and additional features of preferred embodiments of the invention will be found not only in the claims but also in the description and the drawings, and the individual features can be realized each by itself or together in the form of subcombinations in the embodiment of the invention and in other fields, and can constitute advantageous as well as independently patentable embodiments, for which protection is hereby claimed.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be explained in detail below with reference to a working embodiment.
FIG. 1 shows an air intake device in a schematic sectional view,
FIG. 2 shows a variant of an air intake device,
FIG. 3 a shows a plan view of a variant of the air intake device,
FIG. 3 b shows a plan view of the device according to FIG. 2, and
FIG. 4 shows a detail view.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The air intake device of FIG. 1 comprises a housing 10 . On this there is disposed an air filter 11 with a filter element 12 , a raw air inlet 13 and a clean air outlet 14 . The clean air passes, starting out from the clean air outlet 14 , via an interposed throttle valve, not shown, to clean air inlet 15 of the air intake device and flows through a flexible tube 16 to the connecting flange 17 and from there into the internal combustion engine, not shown. The flexible tube 16 lies on a supporting body 18 and is connected at the tube mouth 19 with the supporting body 18 . The supporting body is mounted so as to be rotatable or movable in a spindle-like manner. A rotary movement of the supporting body 18 according to arrow 20 leads to a change of length, so that the length of the intake tube can be adapted to the operating conditions of the motor. The flexible tube can comprise a corrugated, thin-walled, synthetic resin tube without reinforcement, so that the flexible tube can be compressed or stretched approximately equal amounts from it's initial length.
The air intake device advantageously comprises of a synthetic resin housing. The housing can, of course, also be made as a metal housing. Since the supporting body does not need to provide any sealing functions, only a slight friction needs to be overcome when adjusting the position of the supporting body 18 . The flexible tube 16 lies loosely on the supporting body 18 . Contact of the tube 16 with the wall of the housing 10 does not occur, so that no additional friction forces need to be taken into account.
FIG. 2 shows a variant. Corresponding parts are provided with the same reference numbers. The flexible tube 16 is arranged on a supporting drum 21 enclosed on all sides and is likewise attached thereto at the tube mouth 19 . The hollow space in the supporting drum can be used for any desired additional peripheral components of the engine. The flexible tube is guided closely on all sides between the connecting flange 17 and its contact with the supporting drum, so that when it is turned back it will not kink and cannot jam in the guide.
As already mentioned in FIG. 1, the air intake device is coupled via a connecting flange to an internal combustion engine, not shown. The air intake device carries the injection nozzles for the fuel in the vicinity of the connecting flange. Furthermore, additional elements, such as air flow meters, fuel distributors and the like can be disposed on or integrated with the air intake device.
The flexible tube 16 is fastened to the connecting flange 17 , for example, by an adhesive bond. Of course, the flexible tube can also be shrunk onto the connecting flange or be welded to it.
FIG. 3 a shows the guidance of a flexible tube on a supporting drum 21 which is to be seen in FIG. 4 . The spiral arrangement has the advantage that the supporting drum can execute two or more rotations and thus very large changes in length are possible. A flexible tube with two turns 29 and 30 is disposed on the supporting drum. The upper winding 29 leads to the connecting flange of the internal combustion engine. It is apparent that with this arrangement it is possible to carry out a change in the length of the intake duct through 2 turns of the flexible tube. Since the flexible tube is fixed in its position by guides 24 and 25 there is no need to fear deformation of the tube by vacuum.
FIG. 3 b shows the guidance of the flexible tube 16 on a supporting drum, in which guides 24 to 27 are provided. In this arrangement a maximum of one rotation of the supporting drum 21 is possible. The entire arrangement can be constructed modularly, i.e., the air intake device is composed of two or more modules, wherein one module forms the filter system with the filter element 12 , and the further module is the intake system of variable length. The modular construction has the advantage that it is possible without great difficulty to vary the individual elements to adjust to the engine.
FIG. 4 shows the positioning of the flexible tube 16 and the adjacent tube 22 on the supporting drum 21 . Depending on the number of cylinders of the internal combustion engine, a corresponding number of variable flexible tubes are found on the supporting body. | An air intake device for an internal combustion engine, in which the device includes at least one collecting vessel ( 10 ) as well as a plurality of intake ducts which extend separately toward different cylinders in the engine. The intake ducts extend into the collecting vessel and are formed from a flexible tube ( 16 ), such as a synthetic resin tube. | 5 |
This application claims the benefit of provisional application No. 60/141,988 filed Jul. 1, 1999 and No. 60/161,957 filed Oct. 28, 1999.
BACKGROUND OF THE INVENTION
The present invention relates to processes for the preparation of (R)-1-(3,5-bis(trifluoromethyl)phenyl)ethan-1-ol which is useful as an intermediate in the preparation of certain therapeutic agents. In particular, the present invention provides a process for the preparation of (R)-1-(3,5-bis(trifluoromethyl)phenyl)ethan-1-ol which is an intermediate in the synthesis of pharmaceutical compounds which are substance P (neurokinin-1) receptor antagonists.
The (R)-1-(3,5-bis(trifluoromethyl)phenyl)ethan-1-ol prepared by the present invention may be utilized in the synthesis of (2R, 2-alpha-R, 3a)-2-[ 1-[3,5 -bis(trifluoromethyl)phenyl]ethoxy-3-(4-fluorophenyl)-1,4-oxazine of the formula:
which is a known intermediate in the synthesis of pharmaceutical compounds which are substance P (neurokinin-1) receptor antagonists.
The general processes disclosed in the art for the preparation of (R)-1-(3,5-bis(trifluoromethyl)phenyl)ethan-1-ol result in relatively low and inconsistent yields of the desired product. In contrast to the previously known processes, the present invention provides effective methodology for the preparation of (R)-1-(3,5-bis(trifluoromethyl)phenyl)ethan-1-ol in relatively high yield and enantiomeric purity.
It will be appreciated that (R)-1-(3,5-bis(trifluoromethyl)phenyl)ethan-1-ol is an important intermediate for a particularly useful class of therapeutic agents. As such, there is a need for the development of a process for the preparation of (R)-1-(3,5-bis(trifluoromethyl)phenyl)ethan-1-ol which is readily amenable to scale-up, uses cost-effective and readily available reagents and which is therefore capable of practical application to large scale manufacture.
Accordingly, the subject invention provides a process for the preparation of (R)-1-(3,5-bis(trifluoromethyl)phenyl)ethan-1-ol via a very simple, short and highly efficient synthesis.
SUMMARY OF THE INVENTION
The novel process of this invention involves the synthesis of (R)-1-(3,5-bis(trifluoromethyl)phenyl)ethan-1-ol. In particular, the present invention is concerned with novel processes for the preparation of a compound of the formula:
This compound is an intermediate in the synthesis of compounds which possess pharmacological activity. In particular, such compounds are substance P (neurokinin-1) receptor antagonists which are useful e.g., in the treatment of inflammatory diseases, psychiatric disorders, and emesis.
DETAILED DESCRIPTION OF THE INVENTION
The present invention is directed to processes for the preparation of (R)-1-(3,5-bis(trifluoromethyl)phenyl)ethan-1-ol of the formula:
An embodiment of the general process for the preparation of (R)-1-(3,5-bis(trifluoromethyl)phenyl)ethan-1-ol is as follows:
In accordance with this embodiment of the present invention, the treatment of 1-(3,5-bis(trifluoromethyl)-phenyl)ethan-1-one with a rhodium or a ruthenium catalyst and a ligand in the presence of an alcohol provides (R)-1-(3,5-bis(trifluoromethyl)-phenyl)ethan-1-ol in higher yields, in greater entantiomeric purity and in a more efficient route than the processes disclosed in the art.
In another embodiment, the present invention is directed to a process for the preparation of (R)-1-(3,5-bis(trifluoromethyl)phenyl)ethan-1-ol which comprises the treatment of 1-(3,5-bis(trifluoromethyl)-phenyl)ethan-1-one with a rhodium a ruthenium catalyst and a ligand in the presence of an alcohol to give (R)-1-(3,5-bis(trifluoromethyl)phenyl)ethan-1-ol.
A specific embodiment of the present invention concerns a process for the preparation of (R)-1-(3,5-bis(trifluoromethyl)phenyl)ethan-1-ol of the formula:
which comprises:
treating 1-(3,5-bis(trifluoromethyl)phenyl)ethan-1-one of the formula:
with a rhodium or a ruthenium catalyst and a ligand in the presence of an alcohol;
to give (R)-1-(3,5-bis(trifluoromethyl)phenyl)ethan-1-ol of the formula:
In the present invention, it is preferred that the rhodium catalyst is selected from bis((pentamethylcyclopentadienyl)rhodium chloride) (i.e. ((pentamethylcyclopentadienyl)RhCl 2 ) 2 ) and bis((cyclopentadienyl)rhodium chloride) (i.e. ((cyclopentadienyl)RhCl 2 ) 2 ). The preferred rhodium catalyst is bis((pentamethylcyclopentadienyl)rhodium chloride). The rhodium catalyst is preferably present at a concentration of about 0.1-1 mol % and more preferably about 0.5 mol %.
In the present invention, it is preferred that the ruthenium catalyst is selected from bis((4-isopropyl-toluenyl)ruthenium chloride) and bis((cyclopentadienyl)ruthenium chloride). The preferred ruthenium catalyst is bis((4-isopropyltoluenyl)ruthenium chloride) [i.e. bis((para-cymenyl)ruthenium chloride))]. The ruthenium catalyst is preferably present at a concentration of about 0.1-1 mol % and more preferably about 0.3 mol %.
To minimize expense, the use of a ruthenium catalyst is preferred.
In the present invention, it is preferred that the ligand is selected from (R,R)-cyclohexane diamine (R,R)CHXD, pseudoephedrine, nor-pseudoephedrine, ephedrine, nor-ephedrine and (S,R)-cis-1-amino-2-hydroxy-indane. In the present invention, it is more preferred that the ligand is (S,R)-cis-1-amino-2-hydroxy-indane. The ligand is preferably present at a concentration of about 0.1-1 mol % and more preferably about 0.5 mol %.
For convenience, the rhodium or ruthenium catalyst and the ligand may be contacted together in situ. In the present invention the rhodium or ruthenium catalyst and the ligand optionally may be contacted together to form a catalyst-ligand complex prior to reaction with (R)-1-(3,5-bis(trifluoromethyl)phenyl)ethan-1-ol.
In an alternate embodiment, the present invention is directed to a compound which is:
wherein Cp* is pentamethylcyclopentadienyl.
In an alternate embodiment, the present invention is directed to a compound which is:
wherein Cym* is p-cymene (4-isopropyl-toluene).
In the present invention, it is preferred that the alcohol is selected from methanol, ethanol, isopropanol, isobutanol or n-butanol. The most preferred alcohol is isopropanol. Although other solvents may also be present, for convenience it is preferred that the alcohol is employed as a solvent for the conducting the reaction.
In the present invention a base is optionally present with the alcohol. The base may be an inorganic base such as a base selected from potassium or sodium hydroxide, potassium or sodium carbonate, potassium or sodium bicarbonate potassium or sodium alkoxides, and the like. The alkoxides can be derived from lower (C 1 -C 5 ) or higher (>C 6 ) primary, secondary or tertiary alcohols. A preferred base is sodium hydroxide.
The (R)-1-(3,5-bis(trifluoromethyl)phenyl)ethan-1-ol obtained in accordance with the present invention may be used as starting material in further reactions directly or following purification.
In an alternate embodiment, the present invention is directed to a process for purification or enhancing the enantiomeric purity of (R)-1-(3,5-bis(trifluoromethyl)-phenyl)ethan-1-ol which comprises:
contacting (R)-1-(3,5-bis(trifluoromethyl)phenyl)ethan-1-ol with 1,4-diazabicyclo[2.2.2]octane in an organic solvent to form bis-((R)-1-(3,5-bis(trifluoromethyl)phenyl)ethan-1-ol)1,4-diazabicyclo[2.2.2]octane;
recovering the bis-((R)-1-(3,5-bis(trifluoromethyl)phenyl)ethan-1-ol)1,4-diazabicyclo[2.2.2]octane;
and optionally dissociating the 1,4-diazabicyclo[2.2.2]octane from the bis-((R)-1-(3,5-bis(trifluoromethyl)phenyl)ethan-1-ol)1,4-diazabicyclo[2.2.2]octane to give (R)-1-(3,5-bis(trifluoromethyl)phenyl)ethan-1-ol.
In this process, it is preferred that the organic solvent is an alkane, it is more preferred that the organic solvent is selected from: hexane and heptane and it is even more preferred that the organic solvent is heptane.
The diazabicyclo[2.2.2]octane is preferably present at a ratio of 0.5 equivalents of diazabicyclo[2.2.2]octane to 1.0 equivalents of (R)-1-(3,5-bis(trifluoromethyl)phenyl)ethan-1-ol.
The diazabicyclo[2.2.2]octane is preferably present at a concentration of about 0.05-1 mol % and more preferably about 0.5 mol %.
Optionally, the mixture is seeded with bis-((R)-1-(3,5-bis(trifluoromethyl)phenyl)ethan-1-ol)1,4-diazabicyclo[2.2.2]octane after contacting (R)-1-(3,5-bis(trifluoromethyl)phenyl)ethan-1-ol with 1,4-diazabicyclo[2.2.2]octane in the organic solvent. The temperature in the formation of bis-((R)-1-(3,5-bis(trifluoromethyl)phenyl)ethan-1-ol)1,4-diazabicyclo[2.2.2]octane is preferably about 50° C. to about −40° C., more preferably about 40° C. to about −20° C., and even more preferably about 0° C. to about −20° C.
It will be appreciated by those skilled in the art that this alternate embodiment may be repeated in an itterative manner to further enhance the enantiomeric purity of (R)-1-(3,5-bis(trifluoromethyl)-phenyl)ethan-1-ol with each subsequent cycle.
In an aspect of this alternate embodiment, the present invention is directed to a compound which is:
Another aspect of this alternate embodiment is directed to (R)-1-(3,5-bis(trifluoromethyl)phenyl)ethan-1-ol which is present in an enantiomeric purity (enantiomeric excess) of greater than 90%, preferably greater than 95%, more preferably greater than 98%, particularly greater than 99% and especially greater than 99.5% (enantiomeric excess).
The starting materials and reagents for the subject processes are either commercially available or are known in the literature or may be prepared following literature methods described for analogous compounds. The skills required in carrying out the reaction and purification of the resulting reaction products are known to those in the art. Purification procedures include crystallization, distillation, normal phase or reverse phase chromatography.
The following examples are provided for the purpose of further illustration only and are not intended to be limitations on the disclosed invention.
EXAMPLE 1
3,5-Bis(trifluoromethyl)bromobenzene
Materials
MW
Density
Amount
Mmol
Equiv.
1,3-Bis(trifluoro-
214.1
1.38
107
g
500
1.0
methyl)benzene
96% H 2 SO 4
142
mL
Glacial HOAc
22
mL
1,3-Dibromo-5,5-
285.93
77.25
g
270
1.08 (Br + )
dimethylhydantoin
5N Aq NaOH
75
mL
To glacial acetic acid (22.0 mL), cooled to 15° C. in a 1 L 3-neck round bottom flask (equipped with mechanical stirrer, thermocouple, and addition funnel), was added concentrated (96%) sulfuric acid (142 mL) in one portion. An exothermic heat of solution raised the temperature to 35° C. After cooling to 25° C., 1,3-bis(trifluoro-methyl)benzene (107 g, 500 mmol) was added. With the acid mixture rapidly stirring, 1,3-dibromo-5,5-dimethylhydantoin (77.25 g; 270 mmol) was added over 2 min to give a multiple phase mixture (solid and two liquid). An exothermic reaction occured that raised the internal temperature to ˜40° C. (jacket cooling at 15° C. After the reaction temperature began to drop (after 5 min) the reaction mixture was maintained at 45° C. for 4.5 hr.
The rate and selectivity of the bromination is highly dependent on the agitation of the two phase reaction. Slower stirring increases the amount of bis-bromination and slows the overall rate of reaction. The reaction mixture remains heterogeneous throughout the reaction and the organic phase separates when agitation is interrupted. At the end of the reaction, the phases separate slowly (bromide density=1.699). The rate of bromination is also dependent on the ratio of acetic to sulfuric acid.
Progress of the reaction is monitored by GC analysis, as follows.
Sample: ˜50 μl of mixed phase, dilute with cyclohexane (1.5 mL), wash with water (1 mL), then 2N NaOH (1 mL), separate and inject.
Resteck RTX-1701 [60 meter×0.320 mm]: 100° C.; ramp: 5° C./min to 200° C.; 200° C. for 10 min; Flow 1.15 mL/min
R t :1,3-bis(trifluoromethyl)benzene: 7.0 min
3,5-bis(trifluoromethyl)bromobenzene: 9.4 min
Biaryl: 19.2 min
The mixture was cooled to 2° C. and poured slowly into cold water (250 mL). The mixture was stirred vigorously for 10 min, allowed to settle, and the lower organic layer was separated and washed with 5N NaOH (75 mL) to give 145.1 g of a clear, colorless organic layer.
The assay yield of 1,3-bis(trifluoromethyl)bromobenzene was 93.7% (137.3 g, 469 mmol), which contained 0.6% 1,3-bis(trifluoromethyl)benzene, 1.0% 1,2-dibromo-3,5-bis(trifluoromethyl)benzene, and 0.3% 1,4-dibromo-3,5-bis(trifluoromethyl)benzene. Total isomer byproducts measured by GC were 2.0 mol %.
EXAMPLE 2
1-(3,5-Bis(trifluoromethyl)phenyl)ethan-1-one
Materials
MW
Density
Amount
Mmol
Equiv.
3,5-Bis(trifluoro-
293.03
1.699 g/L
29.3
g
98.0
1.0
methyl)-bromoben-
zene
Magnesium
24.3
5.10
g
2.1
granules, 20 mesh
Acetic Anhydride
102.1
1.08 g/L
40
mL
423
4.5
THF
260
mL
(KF = 60 μg/mL)
MTBE
650
mL
Water
300
mL
50% NaOH
40
mL
Product
3′,5′-Bis(trifluoro-
256.14
20.3
g
79.0
82%
methyl)aceto-
Yield
phenone
To a 500 mL 3-neck round bottom flask equipped with an addition funnel, N 2 inlet, and a Teflon coated thermocouple was added magnesium granules (5.10 g, 210 mmol) and THF (200 mL). The mixture was heated to reflux. 3,5-Bis(trifluoromethyl)bromobenzene (29.3 g, 98 mmol) was dissolved in 30 mL of THF. Some bromide solution (5 mL) was added to the gently refluxing magnesium slurry over 2 minutes to initiate the Grignard reaction. Alternatively, the Grignard initiation may be conducted at 0-20° C. to minimize the loss of solvent. After Grignard initiation, the remaining bromide was added over 1 hour.
An initial induction period of 5 minutes is generally permitted. If the reaction does not initiate, another 5% charge of bromide solution is added. If the reaction still does not initiate after a bromide charge of 10%, 100 mg of iodine is added. The reaction exotherm was controlled by slowing or stopping the bromide addition if the reaction appeared too violent.
After complete bromide addition (˜60 minutes), the dark brown solution was heated at gentle reflux for an additional 30 minutes.
The reaction was monitored by HPLC (sample preparation: 100 μL sample quenched into 3.5 mL of 1:1 THF:2N HCl, then diluted to 100 mL in 65:35 acetonitrile:pH 6 buffer). Grignard formation was considered complete when the bromide level is less that 1 mol %.
After cooling to ambient temperature in a water bath, the mixture was transferred via cannula to a 1L addition funnel. THF (10 mL) was used as rinse. This solution was then added to a solution of acetic anhydride (40 mL) in THF (40 mL) maintained at −15° C. over 1 hr. The dark brown mixture was warmed to 10° C. in a water bath, and water (300 mL) was added over 3 minutes. The biphasic mixture was vigorously stirred while 50% NaOH was added dropwise over 1 hr, until a pH of 8.0 was maintained for 5 minutes. MTBE (300 mL) was added, the layers were separated and the aqueous layer was further extraced with MTBE (3×150 mL). The organic layers were combined and assayed (22.4 g ketone), then concentrated in vacuo at bath temperature of 32° C. (50-80 torr). The concentrate was then distilled at atmospheric pressure and 20.7 g (82% yield based on LC purity) of colorless oil was collected at 150-189° C., with the bulk collected at 187-189° C.
HPLC Assay: 97.7 LCAP
Method: Luna C18, Acetonitrile:0.1% aq H 3 PO 4 , 75:25 to 95:5 over 20 min;
maintain 5 min.
R t (min):
HPLC Assay:
97.7 LCAP
Method:
Luna C18, Acetonitrile:0.1% aq H 3 PO 4 ,
75:25 to 95:5 over 20 min; maintain 5 min.
R t (min):
Phenol
5.2
Ketone
6.3
Aromatic
7.3
Bromide
9.7
Dimer
13.3
GC Assay:
95.5 GCAP
Method:
Resteck RTX-1701 [60 meter × 0.320 mm]
100° C. to 200° C. @ 5° C./min; 200° C. for
10 min; Flow 35 cm/sec constant flow.
R t (min):
1,3-bis(trifluoromethyl)-
4.4
benzene
Acetic anhydride
5.6
Methyl Ketone
10.6
3,5-bis(trifluoromethyl)-
6.2
bromobenzene
Bis adduct
19.6
EXAMPLE 3
(R)-1-(3,5-Bis(trifluoromethyl)phenyl)ethan-1-ol
1-(3,5-Bis(trifluoromethyl)-
256.15
3.9
1
Kg
phenyl)ethan-1-one
(Cp*RhCl 2 ) 2
618.08
0.01
6
g
(Cp* = Pentamethylcyclopentadienyl)
(S,R)-cis-Aminoindanol
149.20
0.02
3.0
g
NaOH
5N (H 2 O)
0.05
9
mL
IPA
7
L
HCl
1N (H 2 O)
7
L
Heptane
7
L
1,4-diazabicyclo[2.2.2]octane
112.18
2.2
240
g
(DABCO)
Rhodium salt and ligand were added to IPA at RT and aged 0.5 h. The solution generally turned bright orange over the age period. Ketone followed by base were then added and the reaction was aged until complete by HPLC (˜3 h). The reaction was then quenched with 1 N HCl and extracted with heptane (2×3.5 L) and washed with 5 L brine. DABCO was added and the solution was concentrated to a volume of ˜4 mL/g of alcohol. At this point the KF was less than 200 and less than 5% EPA remains. The reaction can be flushed with additional heptane if these criteria are not met. Optionally, the reaction was seeded with the DABCO complex at 40° C. and the reaction was allowed to slowly cool to RT. Crystallization began to occur immediately. The reaction was then cooled to 0° C. and filtered. The cake was washed with cold heptane. The DABCO complex was isolated in ˜70% yield with an enatiomeric excess of ˜99%.
EXAMPLE 4
(R)-1-(3,5-Bis(trifluoromethyl)phenyl)ethan-1-ol
1-(3,5-Bis(trifluoromethyl)-
256.15
3.9
1
Kg
phenyl)ethan-1-one
(Cp*RhCl 2 ) 2
618.08
0.01
6
g
(Cp* = Pentamethylcyclopentadienyl)
(R,R)-Toluenesulfonyl
268.38
0.02
5.2
g
cyclohexanediamine
NaOH
5N (H 2 O)
0.05
9
mL
IPA
7
L
HCl
1N (H 2 O)
7
L
Heptane
7
L
1,4-diazabicyclo[2.2.2]octane
112.18
2.2
240
g
(DABCO)
Rhodium salt and ligand were added to IPA at RT and aged 0.5 h. The solution generally turned bright orange over the age period. Ketone followed by base were then added and the reaction was aged until complete by HPLC (˜3 h). The reaction was then quenched with 1 N HCl and extracted with heptane (2×3.5 L) and washed with 5 L brine. DABCO was added and the solution was concentrated to a volume of ˜4 mL/g of alcohol. At this point the KF was less than 200 and less than 5% EPA remains. The reaction can be flushed with additional heptane if these criteria are not met. Optionally, the reaction was seeded with the DABCO complex at 40° C. and the reaction was allowed to slowly cool to RT. Crystallization began to occur immediately. The reaction was then cooled to 0° C. and filtered. The cake was washed with cold heptane. The DABCO complex was isolated in ˜75% yield with an enatiomeric excess of ˜99.5%. The (R,R)-toluenesulfonyl cyclohexanediamine was prepared by reacting tosyl chloride with (R,R)-diaminocylcohexane. The product was isolated in 40-50% yield.
EXAMPLE 5
(R)-1-(3,5-Bis(trifluoromethyl)phenyl)ethan-1-ol
Materials
MW
Mol
Amt
1-(3,5-Bis(trifluoromethyl)-
256.15
11.7
3
Kg
phenyl)ethan-1-one
[RuCl 2 (p-cymene)] 2
612.40
0.03
18.4
g
(Cym = p-cymene (4-isopropyltoluene))
(S,R)-cis-Aminoindanol
149.20
0.06
9.0
g
NaOH
5N (H 2 O)
0.14
28
mL
IPA
21
L
HCl
1N (H 2 O)
21
L
Heptane
21
L
1,4-Diazabicyclo[2.2.2]octane
112.18
˜6.6
˜740
g
(DABCO)
The ruthenium salt [RuCl 2 (p-cymene)] 2 and (S,R)-cis-aminoindanol were added to IPA at RT and aged 0.5 h. The solution generally turned bright yellow-orange over the age period. 1-(3,5-Bis(trifluoromethyl)phenyl)ethan-1-one was added and the reaction was degassed under vacuum. Base was then added and the reaction was aged until >98% complete by HPLC (4-6h). The reaction was then quenched by pouring it into 1 N HCl and extracted with heptane (2×10.5 L) and washed with 15 L brine. 1,4-Diazabicyclo[2.2.2]octane (DABCO) was added and the solution was concentrated to a volume of ˜4 mL/g of alcohol. At this point the KF was less than 200 and less than 5% IPA remains. The reaction can be flushed with additional heptane if these criteria are not met. Optionally, the reaction was seeded with the DABCO complex at 40° C. and the reaction was allowed to slowly cool to RT. Crystallization began to occur immediately. The reaction was then cooled to 0° C. and filtered. The cake was washed with cold heptane. The DABCO complex was isolated in 75-80% yield with an enantiomeric excess of >99%.
While the invention has been described and illustrated with reference to certain particular embodiments thereof, those skilled in the art will appreciate that various adaptations, changes, modifications, substitutions, deletions, or additions of procedures and protocols may be made without departing from the spirit and scope of the invention. For example, reaction conditions other than the particular conditions as set forth herein above may be applicable as a consequence of variations in the reagents or methodology to prepare the compounds from the processes of the invention indicated above. Likewise, the specific reactivity of starting materials may vary according to and depending upon the particular substituents present or the conditions of manufacture, and such expected variations or differences in the results are contemplated in accordance with the objects and practices of the present invention. It is intended, therefore, that the invention be defined by the scope of the claims which follow and that such claims be interpreted as broadly as is reasonable. | The present invention is concerned with novel processes for the preparation of (R)-1-(3,5-bis(trifluoromethyl)phenyl)ethan-1-ol. This compound is useful as an intermediate in the synthesis of compounds which possess pharmacological activity. | 2 |
FIELD OF THE INVENTION
The invention relates to compositions for generating oxygen and more particularly to the well-known chlorate candle type.
BACKGROUND OF THE INVENTION
Conventional chlorate candles burn to release oxygen when ignited and comprise a primary oxygen source of chlorates or perchlorates and a metallic powder or fiber, usually iron, to provide a source of heat for the thermal decomposition of the chlorate or perchlorate. The candles conventionally contain BaO 2 that acts both as a catalyst for maintaining an even burning rate and as a scavenger for chlorine that is produced during burning. The candle compositions contain a fiber binder, e.g. glass fiber, ceramic fiber or steel wool. Effective proportions of BaO 2 range from about 2 to 6%, with 4% most often being used. See, for example, U.S. Pat. Nos. 3,089,855 and 3,207,695.
Under Environmental Protection Agency regulations the presence of barium in excess of established amounts in leachate tests has a characteristic of EP toxicity. Accordingly, it is desirable to eliminate or reduce the barium content of chlorate candles to avoid the need for special disposal requirements for expended candles.
BRIEF SUMMARY OF THE INVENTION
In accordance with this invention, the BaO 2 in chlorate candles is replaced by an alkaline earth metal or transition metal ferrate. The ferrate anion catalyzes burning, and the alkaline earth or transition metal cation acts as a chlorine scavenger.
Ferrates are compounds with iron and oxygen in the anion. Ferrate anions may contain various proportions of iron and oxygen and may be mixture of anions, solid solutions or complex crystal structures. Ferrates suitable for use in this invention have sufficient oxygen to give an apparent iron valence of more than +3. The associated metal cation may be any group 2A metal having an atomic number between 12 and 56 (i.e. magnesium, calcium, strontium or barium), manganese, cobalt, nickel or zinc. Magnesium is preferred.
The oxygen candles preferably comprise between about 7 to 10% iron powder, 6 to 8% fiber binder, 2 to 6% metal ferrate, with the remainder being an alkali metal chlorate, preferably sodium chlorate NaClO 3 . It should be recognized that the ferrates are effective in modified candle compositions with other additives such as perchlorates, or when iron is provided in whole or in part by iron fiber, with or without another fiber binder.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Magnesium ferrate was prepared according to the method of Bashkirov, L. A.; Palkin, A. P. and Sirota, N. N., "Formation of Ferrites During Decomposition of Salts" Ferrity, Fiz. i Fiz.-Khim. Svoistva, Doklady 3-go A'Sesoyuz. Soveschaniya (1960), 111-116 c.f. C.A.55:8141e. Equimolar proportions of Mg(NO 3 ) 2 and Fe(NO 3 ) 3 are dissolved in distilled water and precipitated with an excess of (NH 4 ) 2 CO 3 . The precipitate is filtered, washed twice with distilled water and removed for drying at 100° C. The mixture is fired at 300-320° C. to form MgFeO 4 , which is ground to <200 mesh.
A mixture of 80% (by weight) NaClO 3 , 8% iron powder, 7% fiberglass and 4% MgFeO 4 is blended and pressed in a mold to form a coherent candle body. When ignited, the candle combustion was self-propagating and burned at an even rate. Burning rate, oxygen evolution and chlorine release were substantially the same as from a candle containing 4% BaO 2 , instead of MgFeO 4 . Similar results are obtained with MnFeO 4 ; when (Mg-Co)FeO 4 is used the candles show some bubbling and expansion when burned.
Other methods of preparing alkaline earth and transition metal ferrates are described in Scholder, R.; Bunsen, H. V. and Zeiss, W., "Orthoferrates" Zeit. Anorg. and Allgem. Chem. 283, 330-7 (1956) c.f. C.A.50: 11151b and Scholder, R.; Kindervater, F. and Zeiss, W., "Metaferrates" Zeit. Anorg. and Allgem. Chem. 283, 338-45 (1956) c.f. C.A.50: 11151d.
It is to be understood that this invention may be practiced otherwise than as specifically described within the scope of the appended claims. | Alkaline earth metal and transition metal ferrates are used as burning catalysts and chlorine scavengers in chlorate candle oxygen generating compositions. | 2 |
This application claims benefit of priority of U.S. provisional application Ser. No. 60/231,391 titled “Novel Data Transmission Architecture” filed Sep. 8, 2000, whose inventors were Trenton B. Henry, Henry Wurzburg, Richard C. Counts, and Christopher D. Sawran.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to computer systems, and more particularly, to data transmission between various units of a computer system.
2. Description of the Related Art
Computer systems typically include a several chips for the purpose of data transmission to and from peripheral devices. FIG. 1 is a block diagram of one embodiment of a peripheral controller chip. A typical peripheral controller chip includes various functional units. Such functional units may include a microcontroller/CPU, a serial interface engine (SIE), one or more peripheral interfaces, a memory management unit (MMU) and a direct memory access controller (DMAC) associated with each interface. The microcontroller/CPU may be a simple (and sometimes low-speed) processor which manages the data flow within the chip from one interface to another. The SIE may include logic that translates a data format between a serial data stream of a serial bus to a parallel data stream internal to the chip. Similarly, any peripheral interface may perform data translations between a format suitable for the peripheral bus and the format of data internal to the chip. The MMU may include a FIFO (first-in first out) memory, as in the embodiment shown, or a dual-ported static random access memory (SRAM) in other embodiments. The FIFO or the SRAM of the MMU may provide temporary storage for data being transmitted between two interfaces to allow rate adaptation and/or flow control between the interfaces. A DMAC associated with each interface may control data transfers between the MMU and the various external interfaces. The chip may also include an internal address and data bus to accommodate the data transfers internal to the chip.
Such devices as the one described above may experience significant delays and latencies during their operation. Each functional unit transmitting data internal to the chip must first acquire control of the internal data and address buses. Thus, other functional units needing to transmit and/or receive data may be delayed until the buses are released. The process of acquiring and releasing the bus by each of the functional units may slow down the movement of data through the chip. This may also result in more demanding processing requirements for the microcontroller/CPU. As a result, many such chips may not be suitable for use in systems that require high-speed data movement. Furthermore, since the bandwidth of the FIFO or SRAM (i.e. the ability to read from or write to) is much greater than the required bandwidth for data transmissions between one functional unit and another, MMU utilization may be very inefficient.
Another performance issue may deal with the type of data being transmitted. In some cases, the data being transferred between two function units may include commands, which may need to be intercepted and interpreted by the MCU/CPU.
In addition to the performance drawbacks, such chips may be expensive to implement. In particular, the need for DMACs may significantly increase the cost of a given device. Such devices may also require a bus arbiter in order to arbitrate access to the internal buses. Adding a bus arbiter may further add to both the complexity and expense of such a device, as well as increasing the complexity of other logic that must interface with the bus arbiter. A FIFO memory that may be employed in some embodiments may consume a significant amount of chip area.
In general, many such devices with greater logic complexity may be more costly to implement and yet still may not meet the requirements for high-speed data transmission.
SUMMARY OF THE INVENTION
An interface chip is disclosed. In one embodiment, the chip is a peripheral controller in a computer system. The peripheral controller includes a microcontroller/processor (MCU/CPU) coupled to an internal data bus and an internal address bus. One or more interfaces, including either one serial interface or one parallel interface are also coupled to the processor via the internal address bus and the internal data bus. The interface chip also includes data movement circuitry, wherein the data movement circuitry is configured for transmitting data between a first of the plurality of interfaces and a second of the plurality of interfaces using time division multiplexing. The use of time division multiplexing for the interfaces and the MCU/CPU may guarantee a certain amount of bandwidth to each of these units.
In one embodiment, the data movement circuitry of the interface chip may include N latches coupled to the data bus, wherein N is an integer value corresponding to the number of interfaces in the interface chip. The latches may be data latches, and may provide access to the data bus for each of the N interfaces. A static random access memory (SRAM) may be coupled to each of the latches. The data movement circuitry may also include N address generators. The address generators may generate addresses in the SRAM, and may be under control of one or more of the interfaces or the processor. One of each of the address generators may correspond to one of the latches. The data movement circuitry also includes a phase clock generator, wherein the phase clock generator is configured to generate a clock signal with N phases. Each of the N phases of the clock signal corresponds to one of the interfaces in the interface chip. Data may be transmitted between the interfaces across the data bus in frames, wherein each of the frames includes N time divisions.
Various types of interfaces may be incorporated into different embodiments of the interface chip. The interfaces may include both serial and parallel interfaces. In one embodiment, a Universal Serial Bus Interface (USB) may be present. Other types of interfaces include peripheral component interconnect (PCI), general purpose I/O (GPIO), industry standard architecture (ISA), advanced graphics port (AGP), general purpose interface bus (GPIB), integrated drive electronics (IDE) and virtually any other type of interface architecture.
By employing data movement circuitry which moves data between interface units using time division multiplexing, it may be possible to implement the interface chip without using a memory management unit. This may result in a significant reduction of both the complexity and the cost for the interface chip. In addition, it may be possible to eliminate DMAC (direct memory access controller) circuitry from some embodiments.
The design may also be scalable. Expanding the capacity of the interface chip may include adding additional SRAM, latches, address generators, and interfaces. The clock signal may also be divided into additional phases to match the number of interfaces. In general, there is no theoretical limit to the number of interfaces that may be present in the interface chip.
BRIEF DESCRIPTION OF THE DRAWINGS
Other aspects of the invention will become apparent upon reading the following detailed description and upon reference to the accompanying drawings in which:
FIG. 1 (Prior Art) is a block diagram of one embodiment of an interface chip;
FIG. 2 is a block diagram of one embodiment of a computer system implementing an interface chip as a peripheral controller;
FIG. 3 is a block diagram of one embodiment of an interface chip configured for data transmissions using time-division multiplexing; and
FIG. 4 is a diagram illustrating the operation of one embodiment of the interface chip using time division multiplexing.
While the invention is susceptible to various modifications and alternative forms, specific embodiments thereof are shown by way of example in the drawings and will herein be described in detail. It should be understood, however, that the drawings and description thereto are not intended to limit the invention to the particular form disclosed, but, on the contrary, the invention is to cover all modifications, equivalents, and alternatives falling with the spirit and scope of the present invention as defined by the appended claims.
DETAILED DESCRIPTION OF THE INVENTION
Moving now to FIG. 2 , a block diagram of one embodiment of a computer system implementing an interface chip as a peripheral controller. Computer system 100 includes a central processing unit (CPU) 102 . Embodiments having multiple instances of CPU 102 are possible and contemplated. CPU 102 is coupled to memory 104 by chipset logic 110 . Chipset logic 110 may provide a wide variety of I/O functions for computer system 100 . Chipset logic 110 may be coupled to a peripheral component interconnect (PCI) bus 111 . PCI bus 111 may allow for the coupling of a plurality of peripheral devices (such as peripheral devices 112 A, 112 B, and 112 C shown here). Chipset logic 110 may also be coupled to disk drive 114 and universal serial bus (USB) interface 116 . USB interface 116 may be a USB port, and may be coupled to USB peripheral/controller 117 . Chipset logic 110 may be implemented using one or more interface chips, such as the one which will now be described in reference to FIG. 3 .
Turning now to FIG. 3 , a block diagram of one embodiment of an interface chip configured for data transmissions using time-division multiplexing is shown. Other embodiments are possible and contemplated. Interface chip 200 may be a peripheral controller, such as USB peripheral/controller 117 of FIG. 2 . Interface chip 200 includes by a microcontroller or CPU, shown here as MCU/CPU 201 , in order to provide various control functions. MCU/CPU 201 is coupled to both serial interface 205 and ATA interface 210 by control lines 208 and 209 , respectively, and may provide certain control functions to these interfaces. The interface chip includes a data bus 203 . Data bus 203 is coupled to a static random access memory (SRAM) 220 . In the embodiment shown, SRAM 220 is a single-ported SRAM, and may provide buffering of data transferred within the chip. Data bus 203 is also coupled to a plurality of latches, designated here as latch phase 0 , latch phase 1 , etc. In various embodiments, there may be up to N latches, where N is an integer value. For the embodiment shown, N=4.
Latch phases 0 , 1 , and 2 are each coupled to an interface of the interface chip. Latch phase 0 is coupled to serial interface 205 by data bus 203 . Serial interface 205 may provide an interface to a serial bus, such as a universal serial bus (USB). Latch phase 2 in this embodiment is coupled to a parallel interface, ATA (Advanced Technology Attachment) interface 210 . ATA interface 201 may provide an interface to an ATA device, such as a disk drive or a CD-ROM drive. Latch phase 1 is coupled to MCU/CPU 201 via data bus 203 . In the example shown, latch phase 3 is shown as unused for the sake of simplicity. Latch phase 3 may also be coupled to an interface via data bus 203 in some embodiments, or may be reserved for future use in others.
Data bus 203 may be shared by each of the interfaces to which it is coupled, as well as MCU/CPU 201 . The sharing of data bus 203 may be accomplished using time division multiplexing. Clock divider 230 may used to divide an input clock signal into N different phases. This may allow each of the interfaces to have access to the data bus at a frequency that is 1/N of the input clock frequency. For example, if the input clock in the embodiment shown is 60 MHz, each of the interfaces may access data bus 203 at a rate of 15 MHz. Access to the data bus for each of the interfaces is proved by the latches. For example, serial interface 205 may be granted access to the data bus by latch phase 0 . Latch phase 0 is configured to receive phase 0 of the divided input clock signal in this embodiment. Similarly, ATA interface 210 may be given access to data bus 203 by latch phase 2 , which is configured to receive phase 2 of the divided input clock signal.
In the embodiment shown, interface chip 200 also includes address multiplexer 225 and a plurality of address generators (AAG 0 through 3 in this embodiment). Address multiplexer 225 may be configured to select an address from one of those generated by one of the auto address generators. Data may be written to or read from SRAM 200 at the address received from address multiplexer 225 . The auto address generators may be implemented using simple binary counters, which generate a new address each time they are incremented.
An example of the operation of interface chip 200 will now be presented. For the purposes of this discussion, it is assumed that data is to be transferred from serial interface 205 to ATA interface 210 . It is further assumed that serial interface 205 is a USB interface.
Serial interface 205 may receive a USB packet in a serial fashion. Logic in serial interface 205 may read the USB packet endpoint (i.e. the logical destination of data in USB terminology). This may enable the appropriate address generator, which is AAG 0 in this particular example. Enabling the address generator may comprise setting a certain number of bits to a start address. The address generator, implemented as binary counter in the embodiment shown, may then be incremented by 1 for each double word that is received. The address from the address generator may be passed through address multiplexer 225 to address lines of SRAM 220 . An extra bit from the address generator may also be passed through address multiplexer 225 . The extra bit may be a logic 1 or logic 0, depending on the final destination of the data. For example, if the endpoint of the data is another interface (i.e. data is being transferred from serial interface 205 to another interface), a logic 1 may be passed, while a logic 0 may be passed if serial interface 205 is to receive data.
As the data is streamed from serial interface 205 , it may be written directly into SRAM 220 . During the writing of data to SRAM 220 , there is no intervention by MCU/CPU 201 . When serial interface 205 has completed the transfer of the USB packet to SRAM 220 , it may then send an interrupt to MCU/CPU 201 . In response to the interrupt, MCU/CPU 201 may verify that the packet was properly received and that data written into SRAM 220 is valid. In the embodiment shown, MCU/CPU 201 may accomplish this task by checking control registers present in serial interface 205 .
After validating the data written into SRAM 220 , MCU/CPU may initiate data movement to the receiving interface, ATA interface 210 in this example. MCU/CPU may initiate data movement by setting AAG 2 to the starting address of the packet that was written into SRAM 220 . The transfer of data to ATA interface 210 may then begin with no further intervention by MCU/CPU 201 . Data may be read from SRAM 220 at the starting address of the packet and transferred to ATA interface 210 . AAG 2 may increment for each address to which packet data was written into SRAM 220 until the entire packet has been transferred to ATA interface 210 .
During the reading out of data from SRAM 220 to ATA interface 210 (when latch phase 2 is active), serial interface 205 may continue receiving data from the universal serial bus. This data may then be transferred to SRAM 220 in a different buffer location when latch phase 0 is active, while ATA interface 210 may forward data to an attached ATA device. When latch phase 2 becomes active again, ATA interface 210 may receive data that serial interface 205 has previously written to and buffered in SRAM 220 . In this manner, both serial interface 205 and ATA interface 210 may be continuously sending and/or receiving data. Thus, data may flow through interface chip in a continuous fashion.
Data transfers between two interfaces may be interleaved with data transfers between other interfaces within interface chip 200 using time division multiplexing. In the example above, it may be possible for another data transfer between two interfaces to be interleaved with the data transfer from serial interface 205 . Each interface may be granted access to the data bus at a frequency that is 1/N of the input clock frequency. Transfers of data typically involve reading from or writing to SRAM 220 . Thus, it is possible for each device to perform a read or write with respect to SRAM 220 during the time division in which it is granted access to the data bus.
Moving now to FIG. 4 , a diagram illustrating the operation of one embodiment of the interface chip using time division multiplexing is shown. During the operation of interface chip 200 of FIG. 3 , the various devices are granted access to the data bus in a “round robin” fashion using time-division multiplexing. Latch 0 may be activated, thereby granting access to the data bus for serial interface 205 at a clock rate that is, in this particular embodiment, ¼ of the clock rate at which SRAM 220 of FIG. 3 may be accessed. Latch 1 may be activated upon the deactivation of Latch 0 , and may grant data bus access to MCU/CPU 201 . Latch 2 may be activated when Latch 1 is deactivated, granting data bus access to ATA interface 210 . The data bus may be in an idle state when Latch 3 is activated, as the embodiment shown does not utilize this latch to couple an interface to the bus. Other embodiments are possible and contemplated wherein Latch 3 is used to couple an interface to the data bus. Following the deactivation of Latch 3 , Latch 0 is again activated, and this cycle may continue throughout the operation of interface chip 200 . In addition, embodiments with a greater or lesser number of latches (and hence, time divisions) are possible and contemplated.
While the present invention has been described with reference to particular embodiments, it will be understood that the embodiments are illustrative and that the invention scope is not so limited. Any variations, modifications, additions, and improvements to the embodiments described are possible. These variations, modifications, additions, and improvements may fall within the scope of the inventions as detailed within the following claims. | An interface chip is disclosed. In one embodiment, an interface chip includes a processor coupled to an internal data bus and an internal address bus. A plurality of interfaces, including at least on serial interface and at least one parallel interface are also coupled to the processor via the internal address bus and the internal data bus. The interface chip also includes data movement circuitry, wherein the data movement circuitry is configured for transmitting data between a first of the plurality of interfaces and a second of the plurality of interfaces using time division multiplexing. | 6 |
REFERENCE TO GOVERNMENT CONTRACTS
Not applicable.
CROSS REFERENCES TO RELATED APPLICATIONS
Not applicable.
BACKGROUND OF THE INVENTION
1 . The Field of the Invention
This invention relates to elongated cable bolts useful for installation, with cooperating resin systems, in boreholes in underground mines, to achieve ground control and, when installed in mine roofs, are useful, in combination with trussing systems, support plates and the like, for delimiting dilation of mine roofs, thereby contributing to safety of workmen and machinery and deterring mine roof collapse. In particular, the invention pertains to designing cable bolt proximal ends and torque-applying devices therefor, for permitting the application of both axial thrust and also torque to cable bolts, to thrust these into boreholes and simultaneously axially spin the cable bolts so as to mix to desired degree, and without over-mixing, the pre-implanted resin systems within the boreholes, whereby to allow the latter to cure in optimal fashion and secure properly the respective cable bolts within their respective boreholes at the bolts' distal ends.
2. Statement of Related Art
There is a great deal of prior art in the general field of cable bolts and their design, as well as torquing equipment for cable bolts. As to the present invention, the following art is noted: the article in “Wire Rope New & Sling Technology,” p. 56 (citing U.S. Pat. No. 5,741,092), October 1998; also, U.S. Pat. Nos. 906,040; 1,590,200; 3,161,090; 3,940,941; 5,531,545 (the inventor herein being patentee); U.S. Pat. Nos. 5,511,909; 5,230,589; 5,259,703 and 5,951,064. Many additional patents and other literature are cited in these references as background, all of which are fully incorporated herein by way of reference.
The art of introducing resin system capsules in a mine borehole and then advancing these to the blind end of a borehole by a cable bolt backing the capsules is well known. The spinning of the cable bolt ruptures the capsules and mixes the resin system supplied. The mixing should continue until the resin has a particular viscosity, but should not be overmixed. Otherwise, the holding power of the resin, now disposed between the cable bolt shank and the wall of the borehole, will become lessened. Failure can occur, either when the cable bolt plus resin, pulls out of the hole when the bolt is placed in tension, or when the bolt simply pulls through the resin sleeve, or when simply the resin does not make a secure anchor with the surrounding strata of the borehole. Manufacturers specify optimal mixing time needed to achieve the viscosity desired and, hence, the point of maximum holding power. The present invention precludes the optimal mixing from being exceeded, by supplying a relief feature whereby the cable bolt is not spun further once a particular torque resistance level is reached. None of the above art and references, taken either singly or in combination, is believed to anticipate this invention as described below.
BRIEF SUMMARY OF THE INVENTION
The invention resides in the combination, and also in the individual constituents therein, of a cable bolt and a torquing tool, the latter to be secured in and revolved by conventional, installation power equipment, or simply rotated manually, whereby the cable bolt can be axially spun and thrust home, by such tool and, e.g., its power equipment, within a borehole. This is achieved by a new design of the proximal end of the cable bolt and the design of the tool by which such proximal end is engaged. Since cable bolts, owing to high-volume use, must be manufactured at low cost, reliance is made herein upon the wedge barrel of the cable bolt having an outer peripheral surface of revolution, free of radial projections, and reliance being made of either (1) designing the wedge barrel so that its outer surface is conically tapered inwardly toward said proximal end, for effecting a mutual conical frictional engagement as between the wedge barrel and the tool designed to drive the same, and/or (2) where the wedge barrel and tool have releasably inter-engaging undulations or protuberances, to effect a releasable keying of the tool to the collar, for accomplishing the spinning function, or both.
The method inherent in the invention in setting a cable bolt in a mine borehole, provided with resin, comprises the steps of: (1) providing a cable bolt having an elongated shank and a wedge barrel, provided a peripheral surface of revolution, fixed to said shank and constructed for operational, releasable engagement by a spin-and-axial-thrust providing tool; (2) providing a tool constructed and dimensioned for releasably engaging said wedge barrel in a manner whereby to axially spin said wedge barrel and thus said cable bolt through a predetermined permissible torque range and automatically to interrupt such axial spin function once said predetermined torque range is exceeded, and (3) operatively releasably engaging said tool with said wedge barrel. The over-all object of the invention is to provide, in a cable bolt structure and method of installing the same in a resin-provided borehole, both the means and the method of both spinning and thrusting home a cable bolt in its intended borehole and, in doing so, mixing the resin without chancing over-mixing the same, whereby to optimize the holding power of the resin anchor for the cable bolt.
The invention, both as to its objects and advantages, may best be understood by reference to the following description, taken in conjunction with the following drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a cable bolt of the present invention, showing its installation in a borehole in an underground mine.
FIG. 2 is an exploded perspective of the cable bolt and torque producing tool, with the wedge elements which are supplied the wedge barrel of the cable bolt.
FIGS. 3A, 3 B and 3 C are longitudinal sections, taken along the line 3 — 3 in FIG. 1, illustrating equivalent, greater, and lesser conical interior taper of the tool of the torque producing device relative to the corresponding taper of the wedge barrel outer peripheral surface.
FIG. 4 is similar to FIG. 2 but illustrated a further embodiment wherein the proximal edge of the wedge barrel, as well as, e.g., the base interior of the tool, have mutually cooperative undulating surfaces which selectively engage for spinning the cable bolt about its central axis.
FIG. 5 illustrates the tool in engaged position relative to the undulating end surface of the wedge barrel.
FIG. 6A is similar to FIG. 3A, but illustrates the engagement referred to in FIG. 5 .
FIG. 6B is similar to FIG. 6A, but now showing the structure when the wedge barrel has a cylindrical exterior peripheral surface.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
In FIG. 1 mine roof strata 10 is provided the borehole 11 , having resin R, which receives the cable length 12 of cable bolt 13 . Cable bolt 13 includes a wedge barrel 14 having a rounded end distal end 15 . The proximal end 16 is received by the end of tool 17 that is driven by the shank 18 of standard installation mechanism 19 . The cable length 12 proceeds through aperture 20 of support plate 21 . Mesh 22 may be provided and be secured in place by support plate 21 .
In FIG. 2 the cable bolt is seen to include a pair of wedge elements 23 each having a cylindrically formed inner surface 24 that is serrated at 25 . In their combination, the wedge elements have a combined outer frusto-conical surface made up of peripheral surface segments 26 and 27 . These aligned elements are preferably retained in place by an elastomeric O-ring 28 , see FIG. 3A, when positioned in grooves 29 and 30 . The wedge elements are received in the frusto-conical interior of the wedge barrel 14 as will hereafter be pointed out. Tool 17 may now take the form as shown at 17 A.
FIG. 3A illustrates that the distal end 15 of wedge barrel 14 is rounded so as to adjustably seat at aperture 20 of support plate 21 . The position of proximal end 16 of the wedge barrel is likewise shown. In this figure the frusto-conically tapered interior wall 32 , of tool 17 , essentially exactly matches the frusto-conical peripheral surface of revolution 31 of the wedge barrel. Thus, a full friction contact is achieved as between the inter-cooperating and matching frusto-conical friction surfaces of the tool 17 and the wedge barrel 14 . FIG. 3B illustrates the case where the interior wall at 32 , now seen as 32 A, has a more pronounced taper than that of surface 31 of the wedge barrel. This condition still enables the tool 17 to frictionally engage and rotate the wedge barrel about its axis, howbeit at a reduced inter-cooperating surface area. FIG. 3C illustrates the reverse case, wherein the taper at 32 B, if any, of the interior cavity wall, of cavity C, of the tool 17 is less than the frusto-conical taper of peripheral surface 31 of wedge barrel 14 . Here again, there will be some frictional engagement contact between a restricted wall area of tool 17 and the peripheral surface of wedge barrel 14 . The frictional drive relative to FIGS. 3B and 3C will be somewhat less than the full surface friction drive of FIG. 3 A. Nonetheless, all three embodiments will function satisfactorily in accordance with specific conditions present.
FIG. 4 is similar to FIG. 2 but this time illustrates that the wedge barrel 14 may include a proximal end surface 16 having an undulating surface 16 A comprised of a series of peaks, waves or protuberances 16 B mutually spaced apart by valleys or troughs 16 C. Correspondingly, the tool 17 A may include a base 17 B provided with an upstanding undulating surface 17 C comprised of interspaced peaks 17 D separated by troughs or valleys 17 E. Accordingly, the tool may be brought into engagement with wedge barrel 14 both at the inter-cooperating frusto-conical frictional surfaces of the two and, in addition, the undulating surfaces of both parts will be brought together in a releasable, temporary, positive drive. When the viscosity of the resin R increases to an optimal point, for maximum holding power of the cable within the borehole, then the structure may be so designed such that the tool and its undulating surface will simply ride over the undulating surface of proximal end 16 A so that no further rotation of the cable bolt takes place. FIG. 5 illustrates the condition just described prior to the torque threshold being achieved, at which point the tool backs off incrementally so as not to apply excess torque and additional spin to the cable bolt. FIGS. 6A and 6D are similar to FIGS. 3B and 3C, respectively, and this time illustrate the inter-cooperation of the corresponding undulating surfaces of the tool and wedge barrel.
In summary, the friction drive contact of the tool with wedge barrel 14 may be frusto-conical in nature, whereby to provide the necessary frictional drive to spin the cable bolt and advance the same along its central axis A. The tool, wedge barrel, and their inter-cooperating frusto-conical surfaces will be designed for specific, anticipated mine conditions such that, at and above a given torque threshold, the tool will spin over and not further rotate the cable bolt when optional resin viscosity, and the resultant holding power, is reached. In some instances it may be desirable to additionally include the undulating surfaces, inter-cooperating as between the wedge barrel and the torque-supplying tool so as to provide a positive spin to the cable bolt throughout a predetermined torque threshold. However, when that threshold is exceeded, then the tool will simply back off slightly and the undulations thereof will simply click over the corresponding undulations of the wedge barrel such that no further revolvement of the of the wedge bold barrel occurs. In this invention the method, inherent in the system, is to install a cable bolt in a mine borehole provided with resin, which comprises the steps of: (1) providing a cable bolt having an elongated shank and an enlarged head, e.g., wedge barrel, provided a peripheral surface of a revolution, fixed to said shank and constructed for operational, releasable engagement by a spin-and-axial-thrust providing tool; (2) providing a tool constructed and dimensioned for releasably engaging said enlarged head in a manner whereby to axially spin said head and thus said mine bolt through a predetermined permissible torque range and automatically to interrupt such axial spin function once said predetermined torque range is exceeded; and (3) operatively releasably engaging said tool with said enlarged head.
In brief summation: Standing alone, the concept of a wedge barrel having an interior conical taper of nominally 7 degrees, with corresponding wedges therein for gripping a cable bolt length passing through the wedge barrel or collar, is well known in the art and is widely practiced in the industry. The problem, heretofore, has been forming the proximal end of the barrel or collar, or the wedge elements themselves, with a positive drive head in the form of a hex-head, square head, or other non-circular head. This results in an undesirable, continuous positive drive wherein the torque imposed to spin the cable bolt is unrelieved even though the optimal point of resin mix and torque resistance is passed, resulting in a lessening of the holding power of the resin surrounding the cable length in the borehole. The present invention overcomes this difficulty by having the wedge barrel provided with an exterior peripheral surface of revolution, e.g., cylindrical or conical, which thereby does not serve as a non-circular positive drive. Where such surface is cylindrical, as in the present invention, then the end, and not the sidewall, is relied upon to produce the beginning operational engagement with the torque-supplying tool, by means of inter-engaging undulating end surfaces as between the wedge barrel and the tool. Consider the more or less pronounced degree of undulation lying between 0 to 1.0 being a smooth surface-contact and 1 being a normal or 90 degree relationship, i.e., square slots and cooperating square-formed protuberances; both of these extremes (0 and 1) the present invention avoids. Rather, the design of the undulations is between these two extremes such that slippage can and does occur automatically when a particular torque resistance threshold is reached. For some mines, both the feature above described and also the inter-engagement of frusto-conical frictional surfaces of the tool and wedge barrel may be advantageously employed. In such event, a frusto-conical taper, relative to the surface of revolution of the wedge barrel and the cooperative interior of the torque-applying tool may be desirable, as fully described above, for rotating the cable bolt by friction-drive below a torque threshold, and then permit any additional spinning the tool to occur over the non-rotating cable bolt when torque resistance, owing to the setting and viscosity of the borehole resin, exceeds a predetermined level. In all instances, the further mixing of the resin beyond its optimal threshold is discontinued.
While particular embodiments have been shown and described, it will be understood that various changes and modifications may be made without departing from the invention in its essential aspects and, therefore, the aim in the appended claims is to cover all such changes and modifications as fall within the true spirit and scope of the invention. | Cable bolt wedge barrel, installation apparatus and method, for cable bolt installation in a mine borehole provided an interior resin system, wherein the wedge barrel of the cable bolt employed, and the tool used to revolve and supply thrust to the same, are mutually designed for (1) mutual, operative, wall-friction and/or end-detent drive engagement within a given torque range for the resin system employed, as applied by said tool, and (2) operative slippage when said range is exceeded, thereby precluding the emergence of the undesirable condition of over-mixing the resin system present in said borehole and consequent diminution of the resin system's holding power relative to the cable bolt within the borehole. | 4 |
BACKGROUND OF THE INVENTION
This invention relates to continuous molding of synthetic resin to produce features that are integral with a base sheet, and has particular application to the production of fastener elements for touch fasteners and the like.
Hook elements for hook-and-loop touch fasteners and other products are effectively produced by the machine and method of Fischer U.S. Pat. No. 4,794,028. In commercial production, a mold roll is formed by a large number of thin, disk-shaped mold rings and spacer rings which are stacked concentrically about a central barrel. At the periphery of the mold rings are cavities for molding the hook elements. In current production machines each cavity of a mold ring has been formed, one at a time, by wire electro-discharge machining (EDM).
In practice of the Fischer method, molten resin is forced into the mold cavities, tending to raise the temperature of the mold rings. A fluid coolant is circulated through cooling passages within the barrel on which the rings are mounted to remove the heat from the rings. In this way an appropriate temperature of the mold cavities is maintained so that the product becomes sufficiently solid that it can be withdrawn on a continuous basis, typically without opening the mold cavities.
The Fischer technique has proven successful commercially and has represented an important advance over prior proposals in this field such as Menzin et al. U.S. Pat. No. 3,752,619.
SUMMARY OF INVENTION
Given the large capital costs of the equipment and the need to form improved products, it is desirable to find improvements for implementing the Fischer machine and method and similar processes.
According to one aspect of the invention it has been realized that because the cooling device has been a separate member from the mold rings, the speed with which heat can be removed is detrimentally affected by resistance to heat transfer at the interface between rings and cooling device. We realize that even in areas in which direct contact between the rings and the cooling device may occur, the resistance to heat transfer caused, e.g. by microscopic surface imperfections, can adversely limit operation of the process. Furthermore, we realize that manufacturing tolerances of the rings and cooling device, and the manner in which they are assembled, result in small nonuniform air gaps between various portions of the ring and cooling device surfaces. These act as detrimental thermal insulators that produce non-uniformities.
We have realized that nonuniform cooling, non-uniformities in the product produced, limitations on the speed of operation, and other drawbacks can be overcome by eliminating interfaces between the cooling medium and the rings of the mold roll.
According to an aspect of the invention, fluid cooling passages are defined in the mold rings themselves and means are provided to prevent leakage of the cooling fluid between the individual rings.
The invention enables the temperature of the mold cavities to be maintained more uniformly around and along the mold roll even at high speed operation, thereby achieving advantages in product quality and throughput.
According to a further aspect of the invention, the means to prevent leakage at the mating rings comprises an array of axially extending tie rods that apply significant compressive force between the rings of the stack. Besides creating a sealing effect between the faces of mating rings at the aligned coolant passages, this axial compression is found to be important in improving the bending resistance of the assembled roll. This enables uniform and tightly controlled thickness of the base layer of the product to be achieved. In turn, this enables production of thinner base layers. This can lower product cost and achieve highly flexible products that are useful, for example, on curved or flexing surfaces. The improved stiffness of the mold roll further enables thee use of longer mold rolls and improved machine geometries for producing wider products.
According to one aspect of the invention, a molding apparatus useful for continuously forming features of synthetic resin integral with a base has a shaft and a mold roll having an axis and comprising a multiplicity of thin, sheet-form rings of heat-conducting material. The rings each have an inner diameter, an outer diameter, and a substantially circular array of coolant holes. The rings are mounted to form a stack about the axis of the mold roll. At least many of the rings are mold rings, each mold ring having a series of mold cavities disposed at its periphery.
The mold roll features means for axially compressing the stack and an array of fluid passages for liquid coolant. The passages are formed by the aligned coolant holes of each ring, and extend through the roll for cooling the mold cavities via heat transfer from the material of the disks substantially directly to liquid coolant in contact with the edges of the disk material about the holes.
The apparatus also includes means for introducing heated resin to the surface of the mold roll under pressure conditions, filling the mold cavities and forming a base layer integral with features molded in the cavities. Also included in the apparatus is a means for removing the resultant product from the mold roll after the product has cooled to a desired temperature below the temperature of introduction of the resin.
In a preferred embodiment, the apparatus further includes an inlet manifold mounted at a first end of the mold roll for directing cooling liquid into the coolant passages through the rings.
In another embodiment, a return passage communicates with the coolant passages through the rings and extends axially through the roll. Preferably, the return passage is in a shaft upon which the rings are mounted. In a current configuration, a large number of the coolant passages are arranged in a circle adjacent the periphery of the mold roll, preferably about 50 cooling passages disposed within about one-half inch of the periphery of a mold roll with a diameter between about 8 to 12 inches.
In preferred embodiments, the cavities are shaped to form fastener elements for touch fasteners. Preferably, the mold cavities are hook-shaped to form fastener hooks.
In one embodiment the cavities and the holes are of photochemical etched form. In another embodiment, the cavities and the holes are of laser machined form.
In some embodiments, the means for compressing the stack comprises a circumferential array of tie-rods extending through the rings parallel to the shaft and exerting axial compressive force on the-aligned rings. In a presently preferred configuration, there are at least 6 tie rods disposed within about 2 inches of the periphery of a mold roll with a diameter of the order of 8 to 12 inches.
Some embodiments include means to maintain subatmospheric pressure on cooling fluid in the passages.
In some embodiments a sealant material is employed in the vicinity of the fluid holes to promote sealing. In some cases the rings are coated on their sides adjacent the fluid holes with sealant material. In some cases the sealant material is fluid-deposited in interstices between the rings. The sealant material is preferably hydrophobic.
In some embodiments the cavities do not extend through the thickness of the ring.
In some configurations the cavities are on a first side of a mold ring. In other configurations the cavities are on both sides of a mold ring.
In some situations the cavities advantageously each have an enclosing face which is substantially concave.
In some embodiments the fluid holes, the inner diameter and the outer diameter of the mold ring are of photochemical etched form extending through the thickness of the ring.
In the presently preferred embodiment the apparatus also has a pressure roll positioned in proximity to the mold roll to form at least a broad surface of the base. The pressure roll has a circular array of passages for liquid coolant, with the passages extending through the roll for cooling the periphery of the pressure roll via heat transfer from the material of the roll substantially directly to liquid coolant in contact with the inner surface of the passages.
In some embodiments the pressure roll also has mold cavities disposed at its periphery.
According to another aspect of the invention, a method of forming a mold roll for forming fastener elements for touch fasteners is provided. The mold roll comprises a stack of thin, sheet-form mold rings of heat-conducting material having an inner diameter and an outer diameter, each ring having a circular array of holes near its periphery. At least some rings are mold rings, each having a series of mold cavities disposed at its periphery. The method includes forming the cavities and holes, and stacking the rings in alignment such that the aligned holes form coolant passages through the mold roll. The passages extend through the roll for cooling the mold cavities via heat transfer from the material of the disks substantially directly to liquid coolant in contact with the edges of the disk material about the holes.
In some embodiments, forming the cavities and holes is performed by a photochemical etching process. In some other embodiments, forming the cavities and holes is performed by a laser machining process.
According to another aspect of the invention, a method of molding an article comprised of synthetic resin includes providing the apparatus described above, filling the mold cavities with heated resin under pressure conditions while passing cooling liquid through the cooling passages, and removing the resultant product from the mold roll after the product has cooled to a desired temperature below the temperature of introduction of the resin.
According to another aspect of the invention, a method of aligning a multiplicity of thin, disk-shaped mold rings, each having an array of aligning holes and an outer circumferential surface, to form a mold roll, is provided. The method includes
1. providing an alignment shell defining a circular aligning surface, and at least one aligning bar;
2. stacking the rings together to form a stack, each ring being supported on its outer circumferential surface by the aligning surface, with the aligning bar extending through a the aligning hole in each ring;
3. axially compressing the stack of rings to maintain the radial alignment provided by the circular aligning surface; and
4. removing the aligned stack of rings from the alignment shell.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic representation of a molding system employing a mold roll;
FIG. 2 is a fragmentary view of a mold roll, according to the invention;
FIG. 3 is an enlarged cross-sectional view, taken along line 3--3 in FIG. 2;
FIG. 4 is an enlarged view of area 4 in FIG. 3;
FIG. 5 is an enlarged cross-sectional view, taken along line 5--5 in FIG. 4;
FIGS. 5A through 5C are enlarged views of a preferred embodiment of a hook feature formed by a cavity of the mold roll;
FIG. 6 is an enlarged cross-sectional view, taken along line 6--6 in FIG. 2;
FIGS. 7A through 7C are enlarged views of preferred embodiments of area 7 in FIG. 2;
FIG. 8 is a schematic view illustrating a process for forming the structure of FIG. 7C;
FIG. 9 is a schematic illustration of a cooling system;
FIGS. 10A and 10B illustrate preferred methods of ring manufacture;
FIG. 11 illustrates a method for aligning and assembling the mold roll;
FIGS. 12 and 13 illustrate machines and methods for making various fastener products utilizing the mold roll; and
FIG. 14 is an enlarged view of area 14 in FIG. 13.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The figures illustrate equipment useful for the continuous molding of synthetic resin to produce features that are integral with a base sheet, having particular application to the production of fastener elements for touch fasteners and the like.
FIG. 1 shows a molding system using the molding roll for the production of hook elements for touch fastener products. The process and basic machine shown are in accordance with the Fischer techniques as described in U.S. Pat. Nos. 4,775,310, 4,794,028 and 4,872,243, which are hereby incorporated by reference as if they were fully set forth.
The mold roll 1 has miniature hook form mold cavities around its periphery for forming hook projections on an extruded strip-form touch fastener product 4. Mold roll 1 comprises many annular, thin mold rings, for instance of 0.006 to 0.020 inch thickness, held together as a stack. Heat-softened synthetic resin 5 is forced into the cavities under pressure. In a continuous process, the hook-form projections at least partially solidify in the mold cavities, and are then pulled out of the cavities in area 8 after the product has cooled to a temperature at which the projections have solidified sufficiently to be pulled intact out of their mold cavities, remaining integral with the base sheet of the product. The projections are pulled out of mold roll 1 by passing the product around an idler roll 44, and from there to the takeup assembly 50.
FIG. 2 illustrates improvements made by the present invention as they relate to mold roll 1 of FIG. 1. We have realized that substantial axial compression of mold roll 1 near its periphery, as produced by the structure shown in FIG. 2, will so reduce bending deflection of mold roll 1 during the molding process that advantages are obtained. The transverse load applied to the mold roll by the pressure roll 6 (FIG. 1), or by other means for applying resin under pressure, tends to cause mold roll 1 to bend, which can result in uneven product thickness. Stiffening mold roll 1 in the manner shown in FIG. 2 facilitates the production of product 4 with a desirably thinner base, and also enables the use of longer mold rolls 1, producing desirably wider products 4.
In the present invention, the individual mold rings 9 of mold roll 1 are aligned and stacked axially around a common shaft 15. Rings 9 are held together under axial compression by an array of tie rods 16 extending through aligned holes in the stack of rings, running parallel to shaft 15 and tensioned by threaded nuts 17 at each end.
According to this invention, an array of many coolant passages 22 pass through mold roll 1 near the periphery of mold rings 9 for improved cooling of the mold cavities at the periphery of the mold roll. In the presently preferred configuration, cooling fluid is pumped into the mold roll through an annular inlet 60 in shaft 15, and passes through shaft holes 62 and passages 64 of an inlet manifold 26. From the inlet manifold, the coolant passes through the mold roll along cooling passages 22 to an outlet manifold 25 at the other end of the mold roll, which also has passages 64 to direct the coolant through shaft holes 65 and a return passage 66 in shaft 15, to outlet 68.
FIG. 3 is a cross-sectional view of the mold roll 1 of Radius R, showing the arrangement of tie rods 16 around shaft 15. In one embodiment, a circular array of eight one-inch diameter tie rods within about 2 to 3 inches of the periphery of a roll of radius R of 5.0 inch, on a bolt circle of radius R 2 of 3.8 inch, each tightened to establish substantial preload tension, enable axial compression of the mold roll such as to provide advantageous bending resistance. An array of many, relatively small coolant holes 21 are also seen near the periphery of the mold ring at radius R 1 . The coolant holes 21 in each ring are aligned to form the cooling passages 22 extending through the assembled mold roll 1 (FIG. 2). For a mold roll radius R of about 5.0 inches, an array of about 60 one-quarter inch diameter coolant holes, arrayed on a radius R, of about 4.75 inches, provide improved temperature consistency around the mold roll. The axial compression of the mold roll by the tensioned tie rods 16 establishes a degree of thermal contact between the faces of the rings and serves to keep liquid coolant within coolant holes 21 from leaking between mold rings 9. A key 41 is employed to transfer driving torque from shaft 15 to the stacked mold rings.
Referring to FIG. 4, the mold cavities 2 near the periphery of mold roll 1 are shaped to form fastener elements integral to a base sheet. These mold cavities 2 form features of about 0.005 to 0.100 inch in height, and on the order of 0.005 to 0.100 inch wide. For improved cooling, coolant holes 21 are in close proximity to mold cavities 2, within a distance d of, for instance, 0.2 inch. Also visible in this view is a gap 70 between tie rod 16 and the wall of an associated hole 71 through the mold roll. This gap enables improved mold ring alignment, as will be discussed later.
As seen in FIG. 5, in certain circumstances mold cavities 2 are formed such that they do not extend through the entire thickness of a mold ring 9. With the mold cavities thus formed, mold rings 9 are stacked directly against one another, with the open surface 18 of one ring, for instance ring 9a, against the closed surface 19 of the next ring, for instance ring 9b, which forms a side of the mold cavities in ring 9a.
An advantage of forming mold cavities 2 such that they do not extend through the thickness of mold ring 9 is that they may be used to form features with at least one curved side, formed by a concave surface 20. The resulting tapered and convex nature of the hooks, as shown in FIGS. 5A through 5C, can contribute to the penetrability of the hooks into shallow loops, such as presented by non woven fabrics. In the case of extremely small hooks in close rows, the portion 72 of the mold ring that functions as a spacer between rows of hooks adds thickness to the ring and makes it easier to handle during fabrication and assembly.
In other embodiments (not shown), the mold cavities extend through the thickness of the mold rings. In these configurations, spacer rings void of mold cavities are stacked between mold rings to enclose the mold cavities that are otherwise defined in the mold rings. In yet another embodiment, mold cavities are formed on both sides of some mold rings, the array of mold cavities on the two sides of the ring being circumferentially offset to avoid interference between mold cavities on mating rings. In another preferred embodiment a mold cavity for a given feature is formed by accurately aligned cavity portions in two or more mold rings to form a single mold cavity.
Referring to FIG. 6, the ring-facing side of exhaust manifold 25 has an inner and an outer recess, 74 and 76, respectively, connected by several radial grooves 78. Recesses 74 and 76, and grooves 78, form a hydraulic passage (e.g. 64 in FIG. 2) to hydraulically connect the coolant passages in the mold rings with shaft 15. Holes 80 in shaft 15, similar to shaft holes 62 near the inlet manifold 26 (FIG. 2), enable coolant to flow from inner manifold recess 74 to return passage 66.
Referring to FIGS. 7A and 7B, sealant material 30 is employed To contribute to sealing cooling passages 22 within mold rings 9 in a preferred embodiment. Sealing is augmented by axial compression of the mold roll by the tie rods. In a presently preferred embodiment, sealant 30 is placed along the surfaces of mold rings 9 before assembly, as shown in FIG. 7, and is compressed by the axial compression of the mold roll. In another embodiment (FIG. 7B), the sealant is fluid-deposited, e.g. as carried by automobile radiator repair fluid, by the leakage of coolant into any interstitial space between mold rings 9 near coolant passages 22. Sealant material 30 is also placed at each end of the stacked roll of mold rings 9, near the location of tie rods 16 and shaft 15, to seal against leakage from manifolds 25 and 26 (FIG. 2). Use of a hydrophobic material as sealant 30 helps to restrict the migration of water-based coolant between the mold rings.
Referring to FIG. 7C, in another embodiment of the invention a thermally conductive material 39 is deposited on the surface of the cooling passages 22, and acts as a sealant to keep the coolant from leaking between mold rings 9. This conductive material may be deposited in an electroplating process as shown in FIG. 8 after the mold rings 9 are stacked together and compressed. In the electroplating process, the compressed stack 38 of rings serves as one electrode as electroplating fluid 40 is circulated through the cooling passages 22. In this manner a layer of plating material (e.g. thermally conductive material 39) is deposited along the surface of cooling passages 22. Sufficient axial compression of stack 38 during this process, along with an appropriate viscosity of fluid 40, keeps the fluid 40 from migrating between the mold rings, although a small amount of migration of fluid 40 between rings 9 is not adverse to the function of the assembled mold roll.
Although not shown, other seals are also employed as required to maintain the integrity of the cooling system, such as static seals at the interfaces of manifolds 25 and 26 to shaft 15 and to the stack of mold rings, and dynamic seals between the ends of shaft 15 and the stationary plumbing.
Referring to FIG. 9, coolant is circulated through the cooling system by a pump 23, and flows into mold roll 1, through inlet manifold 26 in communication with all of the cooling passages 22, along cooling passages 22, through outlet manifold 25, into shaft 15 and back to a cooling reservoir 27. To reduce the effect of any leaks between the mold rings, in certain preferred embodiments the coolant system incorporates a vacuum source 31 and/or other means, including an upstream flow restriction 42, to maintain a subatmospheric pressure within cooling passages 22.
Referring to FIG. 10A, in certain preferred embodiments a photochemical (PC) etching process is used to form mold cavities 2, coolant passages 22, and other features, such as an alignment keyway for key 41 (FIG. 3). In the embodiment illustrated, mold cavities 2 do not extend through the thickness of mold ring 9. In the ring fabrication process, an etch-resistant photoresist material 31 is fixed to the surfaces of a sheet 82 of mold ring material of the proper thickness and then developed by exposure to ultraviolet light through a mask (not shown) that is cut to produce the desired final surface configuration, including preferably the finished inner and outer diameters of the mold ring. The undeveloped photoresist material in areas beneath the mask remains fixed to the sheet as the developed material 31 is removed. Etching fluid 32 is then sprayed on the surfaces of the sheet, etching the areas not covered by etch-resistant material 31. When the etching process is complete, material 31 is removed from the finished mold ring 9. As a natural result of the PC etching process the etching rate is slower at the bottom of the mold cavity, due in part to the dilution of the etching fluid, thus creating a concave surface 20 at the bottom of molding cavity 2, and useful undercuts (not shown) in some arrangements.
In other preferred embodiments, especially those involving large hook elements and other features, the mold cavities are formed with PC techniques by etching through the thickness of the sheet, either from one side or by etching through both sides.
An advantage of the PC process is that all of the features on a mold ring 9, including the inner and outer diameters, coolant holes 21 and mold cavities 2, can be advantageously produced at the same time or in an appropriate sequence, using precisely positioned masks in accordance with general photo-lithographic techniques, as employed e.g., in the semiconductor industry. In some cases, for instance, one side of a sheet of mold ring stock is appropriately masked to etch all of the features to the depth of the mold cavities 2, and the other side of the sheet is masked by a system that holds registration to complete the etching of the inner and outer diameters and coolant holes 21 through the thickness of mold ring 9.
Referring to FIG. 10B, a laser machining technique is employed in other embodiments to produce mold rings 9 from a sheet 33 of ring stock. Using the laser machining process, hook profiles cut through the thickness of sheet 33 are readily formed, and these can be advantageously of smaller size than those previously formed using wire EDM methods. For instance, hook elements as short as 0.005 to 0.008 inch, with appropriately small radii of 0.001 or 0.002 inch, can be formed. To produce a mold ring by the laser machining process, sheet 33 of the proper thickness is fixtured to be presented to a laser head 34. A beam 35 of energy from laser head 34 removes material from sheet 33, according to a programmed pattern, to produce a finished mold ring. Head 34 is typically mounted on a positionable base, such that the motion of the head can be controlled as desired to form the features of the finished ring. Transverse X-Y motion of a table carrying sheet 33 may also be employed. The depth of the groove produced by the effect of the beam 35 on the sheet 33 is a function of the intensity or power of the beam 35, the material properties of the sheet 33, and the speed at which the head 34 or sheet 33 is moved. Varying these parameters can produce the desired depth of the mold cavities, while also cutting through the entire thickness of the sheet to form the coolant holes 21, the holes 71 for the tie rods, and the ring inner and outer diameters. In the case where a through-cut is not desired, particularly close control of the deposition of laser energy is maintained to limit the vaporization of the ring material to produce, for example, the general cavity shape of FIGS. 5A, 5B and 5C.
Referring to FIG. 11, the structure of the mold roll according to the invention enables an improved mold ring alignment method, using a radial alignment shell 36 and one or more orientation bars 37. Preferably, the rings are sequentially stacked about shaft 15 which is concentrically aligned to shell 36 by the inlet and outlet manifolds (i.e., 25) or other means. Tie rods 16 (or other alignment bars inserted through holes 71) align holes 71 as rings 9 are stacked, also aligning coolant holes 21 in each ring to form the cooling passages of the assembled roll. Particularly useful in the assembly of a mold roll for the production of fastener products with good base thickness consistency, the inner surface 37 of shell 36 aligns the outer surface of the rings, such that the assembled roll has a very cylindrical circumference for producing an even base thickness in the molded fastener product. In addition, the stack of rings is concentrically aligned with shaft 15. The gap (70, FIG. 4) between tie rods 16 and the inner edges of holes 71 enables each ring to be radially aligned by surface 37 of shell 36 without radial restraint from tie rods 16. After rings 9 are stacked, the other manifold is set in place and the stack 38 is compressed and removed from alignment shell 36.
In an alternative embodiment (not shown), the rings are aligned with an expandable center shaft.
Among the advantages of the improved cooled mold roll and methods of manufacture of the present invention, as relates to the production of strip-form plastic products, is that the invention enables faster production rates and therefore lower unit production costs, more accurately formed products, and products with finer features and higher flexibility of the supporting base layer.
In molding machines that employ substantially the Fischer process, other systems from that shown in FIG. 1 may introduce pressurized heat softened or molten synthetic resin to the surface of the mold roll under conditions that fill the mold cavities and form a base layer integral with features molded in the cavities. For instance an extruder may be moved closer to the roll from what is shown in FIG. 1 and the extruder nozzle may confine the resin so that it is applied with pressure directly to the mold roll, filling the cavities and forming a base layer of desired thickness. In such a configuration, the structure of the mold roll of the invention can advantageously stiffen and align the roll for improved base thickness consistency, enabling the production of thinner bases, and wider products.
FIG. 12 shows a mold roll according to the invention arranged to make a product with molded fastener elements on one side and engageable loops on the other side, in accordance with the teachings of U.S. Pat. No. 5,260,015 and U.S. Pat. No. 5,518,795, which are hereby incorporated by reference as if fully set forth herein.
FIG. 13 shows mold rolls according to the invention employed in making a so called back-to-back product in accordance with the teachings of WO 94/07556, which is hereby incorporated by reference as if fully set forth herein. In this case both mold roll 1 and pressure roll 46 are constructed and cooled in accordance with the invention. As seen in FIG. 14, both rolls have mold cavities to form features on the finished product.
In some cases sufficient cooling can be obtained in the forming area that the product is removed directly from the forming area after being carried for a short distance on the periphery of the cooled mold roll, without need for additional cooling. This may be assisted by employing cooling passages in the pressure roll 6 as well as the mold roll 1, as shown in FIG. 13.
These and other features and advantages will be understood from the following claims, taken in conjunction with the foregoing specification and accompanying drawings. | Molding apparatus and method for continuous molding of features integral with a base, such as in the production of fastener elements for hook-and-loop type touch fasteners, e.g. by the Fischer process, employs a mold roll formed of rings that have coolant passages formed within the ring components themselves for substantially direct contact with cooling liquid. Axial tie rods compress the mold rings together, contributing to the sealing of the coolant passages and the stiffness of the mold roll. Other types of sealing are disclosed. Mold cavities and cooling passages formed by photo-chemical etching, laser machining and other techniques are disclosed. Various machines and methods taking unique advantage of these features are disclosed, including ring alignment methods. | 8 |
BACKGROUND OF THE INVENTION
The invention relates to an apparatus for freezing liquid-carrying pipes, with an annular casing having an inwardly open cross-section, with a supply line, provided with a valve, for supplying a refrigerant to the interior of the casing.
In the case of repairs or installation measures on liquid-carrying pipes or lines, particularly heating pipes, such as when fitting regulating or control valves or replacing heaters and the like, to avoid the need for shutting down the complete heating plant and emptying the pipe or line is frozen, so that a solid plug is formed therein. This is brought about in that a sleeve is placed around the pipe and into it is introduced the refrigerant. Apparatuses exist in which the refrigerant is produced by a heat pump and circulates in a closed circuit through the sleeve and is conveyed back to the heat pump. In another construction there is no circulation of the refrigerant and it instead passes out of a storage bottle or cylinder through the sleeve and an outlet port therein into the environment. The outlet port can optionally be provided with a hose, so that part of the refrigerant can be led away into the open from the freezing and working point and optionally out of a room or the like. The non-removed quantity, of refrigerant such as chlorinated hydrocarbons, constitute a potential hazard for workers, particularly when carrying out soldering and/or welding. The known sleeve-like casing of the apparatus can be open towards the pipe and together with the latter forms a cavity around the same, into which the refrigerant is introduced and can come into direct contact with the outer wall of the pipe, which increases effectiveness. Known apparatuses, which in part do not fulfill the latter requirement are known from the following publications U.S. Pat. Nos. 2,483,082, 2,572,555 and 3,559,423DE-OS No. 16 00 607, DE-OS No. 23 30 807, German utility model 81 06 063 and British Patent No. 1 209 144.
All these apparatuses operate with a liquid refrigerant, which optionally evaporates and in part, particularly in the case of circulation, remains in the liquid phase, but in no case solidifies.
The need to recirculate the refrigerant is disadvantages due to the costs involved, whereas, if the refrigerant, namely the chlorinated hydrocarbons have to be discharged into the environment, it is prejudicial to the latter, so that the use of chlorinated hydrocarbons is no longer desired and is in part forbidden. If the casing of the sleeve surrounding the pipes as such, without the pipe, is completely closed and, consequently, has an inner wall, the action is made worse, because the heat transfer must take place via the inner wall.
The latter disadvantage also remains in the apparatus according to German Patent No. 601 278, which operates with solid carbon dioxide. The latter is introduced in this form through the relatively large openings provided on the end walls of the casing and which are subsequently closed. The casing has vents in the form of vent valves.
The use of liquid carbon dioxide, which only ices in the vicinity of the pipe line to be frozen and forms carbon dioxide snow is possible as a result of a stable sleeve placed around the pipe and with a flexibile pipe seal formed as a function of the pipe diameter. It has proved that such a sleeve is not practical and is disadvantageous, which is partly due to the aforementioned construction. As the carbon dioxide in the vicinity of the outer jacket of the sleeve enters the cavity formed between the sleeve and the pipe and therefore remote from the actual pipe, the dry ice initially preferably forms directly around the pipe and between the latter and the supply opening, so that an insulating layer is formed round the pipe. The dry ice layer on the pipe surface initially evaporates, but is still enveloped by the dry ice and can consequently not escape. Thus, it forms a gas gap insulating layer between the dry ice and the pipe, which further reduces the effectiveness of icing. The refrigerant supply opening is located in the outer jacket of the sleeve and is blocked by the formation of the dry ice layer. In order that the ice plug formed can be forced out, the carbon dioxide must be supplied under high pressure. This cannot take place continuously for technical and economic reasons, so that carbon dioxide is only supplied at certain intervals, which also impairs efficiency.
In order to bring about an improvement a flexible, non-self-supporting sleeve in the form of a jacket has been chosen, which is placed around the pipe and fixed round the pipe wall by strings or cords. This leads to a flexible bag sleeve, which only partly removes the disadvantages of the aforementioned sleeve. The gas gap insulating layer between the dry ice and the pipe wall which also forms in the case of the bag sleeve can partly be eliminated in that every so often the outer wall of the bag sleeve is intensely manually kneaded. However, this is very disadvantageous due to the pronounced cooling action of dry ice. The constant kneading also very disadvantageously influences the quality of the bag sleeve. The use of this bag sleeve is very complicated and does not alter anything as regards the long freezing times and the high carbon dioxide requirement of such sleeves. As a result of the clogging and freezing up of the inlet port, it is not possible to supply the carbon dioxide in a regulated, reduced quantity and must instead be supplied at a considerable pressure with a wide open feed valve, with a carbon dioxide quantity which is excessive by the plug icing up the opening, so that here again the supply must take place at intervals.
The aim underlying the invention essentially resides in avoiding the aforementioned disadvantages by an apparatus having a self-supporting casing sleeve, which permits an effective icing of a pipe by liquid carbon dioxide.
According to the invention, an apparatus of the aforementioned type is provided wherein the casing has two parts which can be directly fixed or braced together substantially at right angles to the casing axis with, in each case, end walls kept spaced by a jacket wall and a carbon dioxide supply lance can be engaged with its end face having a nozzle opening with the connecting face of the inside edges of the end walls.
Unlike in the case of one-part casings, the two-part construction leads to a symmetrical bracing in two diametrically facing areas, corresponding sleeve sizes being obtained for corresponding pipe masses, so that a better fixing and sealing can be achieved of the type necessary when using liquid carbon dioxide. Due to the fact that the frontal opening of the lance can be brought up to the circumferential area of the edges of the casing end walls, it is ensured that the opening of the lance issues directly over the wall of the icing pipe. Thus, carbon dioxide constantly flows along the pipe in the form of a film, partly in liquid and partly in gaseous form, whereas solid carbon dioxide only forms as an insulating layer between said film and the outer jacket wall of the casing, but is not deposited directly on the wall of the icing pipe. This leads to higher effectiveness of the icing, in that the heat absorption of the environment is reduced, whereas that of the pipe is increased, the absorbed heat evaporating the liquid supplied carbon dioxide and which, despite a fixing of the casing parts to the pipe, flows out particularly in the resulting connecting area. Additionally it would be possible to provide an outlet port having a regulating valve, which would preferably diametrically face the inlet port for the carbon dioxide. The lance can be fixed in the jacket wall of the casing along its axis and project into the aforementioned area. However, according to a preferred embodiment, the lance is fixed by frictional resistance in an opening of the jacket wall of a casing part, so that it is possible to ensure even under different bracing conditions and different pipe thicknesses for which a casing can be used to a restricted extent, a mounting of the end face of the lance on the wall of the pipe to be iced.
According to another preferred embodiment the valve in the supply line is a ball valve, which has a small passage opening in the ball corresponding to an economic carbon dioxide passage quantity for all pipes to be frozen. Icing makes a conventional poppet valve very difficult and possibly even impossible to operate.
The inlet port in the end face of the carbon dioxide supply lance is preferably a fine nozzle with a diameter between 0.5 and 1.0 mm, because with a given refrigerant supply quantity the latter flows in with an adequate and in particular higher speed than with an earlier opening and therefore improves the flow round the pipe wall.
Although the two casing parts can engage over or in one another in different ways, in that they are e.g. identically constructed and one casing part overlaps on one side and the other on the other side, according to a preferred embodiment the external diameter of the jacket wall of one of the casing parts corresponds to the internal diameter of the jacket wall of the other casing part and the spacing of the outsides of the end walls of one casing part corresponds to the spacing of the insides of the end walls of the other casing part.
This leads to a reliable, tight connection of the two casing parts during and after fixing round a pipe. The fixing of the casing parts to a pipe preferably takes place by screws provided with nuts or screw-nut connections. In preferred manner, the casing parts have substantially radially and longitudinally extending tongues, which are provided with openings, through which can be passed screws and onto which can be screwed nuts. The holes in the tongues of one of the casing parts are in particular elongated slots or holes. So that the heads of the screw and nut are located in a flat and planar manner on the tongues, according to a further development the lateral faces of the tongues remote from the adjacent flange of the in each case other casing part are parallel to one another. The tongues taper from their connection side with the actual casing to the free side thereof in a trapezoidal manner, the facing lateral faces being directed substantially radially by tongues interconnected by a screw. While the circumferential extension of the two casing parts can fundamentally differ and e.g. the circumferential extension of the casing part engaging in the other part is greater than the part overlapping it, so that the tongues can be substantially aligned on in each case one casing part, according to a preferred development the casing parts extend substantially over the same circumferential angle range. To ensure an adequate fixing area, the tongues are arranged in angularly displaced manner on the casing parts, so that the circumferential spacing of the tongues of the inner casing part is smaller than that of the overlapping casing part. An optimum angular range for the circumferential extension of the casing parts is 210°.
The inventive apparatus provides the possibility of an all-around icing of pipes by carbon dioxide, which obviates the disadvantages of the prior art and, in particular, permits an effective icing also with respect to the aforementioned crimped sleeve. For the same test conditions, shorter icing times and carbon dioxide consumption quantities have been noted. Compared with the known self-supporting sleeves only usable with other liquid refrigerants, the inventive construction of the icing casing significantly reduces the icing time and offers considerable economy with the refrigerant costs involved. As a result of the ball valve provided it is possible to have a continuous regulated supply also of carbon dioxide with a constant supply rate. This ensures that the frozen ice plug will remain in the pipe throughout the working period.
Further advantages and features of the invention can be gathered from the claims and description relative to a non-limitative embodiment and the attached drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a cross sectional view of an apparatus for freezing liquid pipes constructed in accordance with the present invention taken at right angles to an axis of symmetry of the apparatus; and
FIG. 2 is a partial cross-sectional plan view of the apparatus of FIG. 1.
DETAILED DESCRIPTION
Referring now to the drawings wherein like reference numerals are used in both views to designate like parts and, more particularly, to FIG. 1, according to this figure, an apparatus generally designated by the reference numeral 1, constructed in accordance with the present invention, includes two casing parts 2, 3, which are, in each.
The inventive apparatus 1 has two casing parts 2,3, which are in each case, part ring-shaped and have two end walls 4,6 or 7,8, which are axially spaced and between which is located a jacket wall 9 or 11, so that in radial section the casing 2,3 has a U-profile opening towards its inside or concave side and surrounds an inner area 12 or 13, which is bounded by a liquid-carrying pipe 14, on which the apparatus 1 is mounted.
In the represented embodiment both casing parts 2,3 extend to the same extent over a pipe 14 by an angular range of more than 180°, here to 210°. Casing part 2 overlaps casing part 3 in the manner shown in FIG. 1. The external radius of part 3 corresponds to the radius of the inside of jacket wall 9 of part 2. The spacing of the outsides of end walls 7,8 of part 3 corresponds to the axial spacing of the insides of end walls 4,6 of part 2.
Both casing parts 2,3 are symmetrically provided with in each case approximately radially outwardly extending tongues 21,22 or 23,24, which extend substantially over the width of the apparatus 1 in the direction of the axis of symmetry. In section at right angles to axis of symmetry 15, the tongues are trapezoidal and taper outwards. The side 26 of the tongue of one part facing the tongue of another part extends substantially radially, while the wall face 27 of the tongue of one part, remote from the tongue of the other part is substantially parallel to the remote wall 28 of the other part. The tongues have openings 29, which can optionally be constructed as elongated holes 32 open towards the free end side 31 of the corresponding tongue (here 23,24). Screws 34 provided with nuts 33 are passed through the holes 28 and into the elongated holes 32, in such a way that the heads 36,37 of nut 33 or screw 34 engage on the larger lateral faces 27,28 of tongues 21, 23. By fastening them screw 34 and the nut 33 against one another, the two casing parts 2,3 can be braced together, the abutment being constituted by the pipe 14 embraced by them.
Only the left-handside of FIG. 1 was described hereinbefore in connection with the fixing and bracing means. As shown, on the right-handside there are also tongues 22,24, which are constructed in the same way as on the other side and to which in the same way can be fitted a not shown screw-nut connection 33,34 for bracing the two parts 2,3. This leads to a symmetrical bracing, which is important for the intended use. After fixing the apparatus 1 on a pipe 14, the inner terminal edges of end walls 7,8 or 4,6 are fixed in the outer circumference of pipe 14, so that the internal radius R of the terminal edges 41 of the end walls coincides with the external radius of pipe 14.
At least the jacket wall 11 of one of the casing parts (here 3) has a radially directed connecting opening 42, in which is located by frictional resistance in the represented embodiment a carbon dioxide-supplying lance 43, so that the latter is longitudinally displaceable in the connection opening at right angles to axis 15 and particularly after mounting the apparatus 1 on a pipe 14 and fixing to the pipe can be inserted until it abuts with the surface of pipe 14. Thus, the end face 44 of lance 43 projects up to the inner circumference of end walls of parts 2,3 or their surface connecting their ends 41. Lance 43 has a ball valve 47 operable by a level 46, because in the case of the refrigerant used, namely liquid carbon dioxide, the dry ice (carbon dioxide snow) formed through expansion by rapid pressure reduction, ices up conventional poppet valves, so that the latter are difficult or impossible to operate.
Lance 43 is connected by a preferably flexible hose 48, which is optionally a spiral hose, to the refrigerant means, in this case a bottle containing liquid carbon dioxide under high pressure (carbon dioxide bottle or cylinder). The frontal opening lance 43 has a very fine nozzle with a diameter of less than 1 mm and, preferably, approximately 0.5 mm.
After mounting and fixing the apparatus 1 to a pipe 14, placing lance 43 with its end 44 on pipe 14 and therefore moving it up to the inner radius of the end walls of the casing part, initially the stop valve of the liquid gas cylinder is opened and then ball valve 47 is completely opened by the lever 46. Thus, liquid carbon dioxide passes from the carbon dioxide bottle via hose 48 and lance 43 directly onto the surface of pipe 14 and along and over the circumference thereof, so that in the cavity 12 between the apparatus 1 and pipe 14 carbon dioxide dry ice forms in known manner as a result of the rapid pressure reduction, while as a result of the continuous flow under high pressure and the provision of lance 43 and particularly its end face provided with the nozzle, carbon dioxide flows directly onto the surface of pipe 14 and is therefore in contact with the latter, absorbed by it and can evaporate. A thermally insulating dry ice layer is formed on the radial outside, so that the heat losses due to the heat absorption of the carbon dioxide from the environment are kept low and can preferably and directly take up heat from pipe 14. Evaporated carbon dioxide passes out, even in the case of high bracing of the apparatus 1, fashioned of a plastic material particularly at the contact line between casing part 2,3 and wall of the pipe 14. | Apparatus for freezing liquid-carrying pipes, with an annular casing having an inwardly open cross-section, with a supply line, provided with a valve, for supplying a refrigerant to the interior of the casing, which is improved in that the casing (1) has two parts (2,3) which can be directly fixed together at right angles to the casing axis and with end walls (4,6;7,8) kept spaced by a jacket wall (9,11) and that a carbon dioxide supply lance (43) with its end face (44) having an opening can be brought up to the connecting face of the inside edges (41) of end walls (4,6;7,8). | 5 |
CROSS-REFERENCE TO PRIOR APPLICATIONS
[0001] This application is a U.S. National Phase application under 35 U.S.C. §371 of International Application No. PCT/EP2011/000073, filed on Jan. 11, 2011, and claims benefit to German Patent Application No. DE 10 2010 007 303.2, filed on Feb. 8, 2010. The International Application was published in English on Aug. 11, 2011 as WO 2011/095271 under PCT Article 21(2).
FIELD
[0002] The present invention relates to the adjustment of the concentration of acids or lyes, in particular of sulfuric acid, wherein the acid or lye is supplied through an inlet to a mixing chamber and is mixed therein with a medium for adjusting the concentration, and wherein the concentration-adjusted acid or lye is discharged from the mixing chamber through an outlet.
[0003] Subsequently, the concentration adjustment is described with reference to sulfuric acid. However, the present invention is not limited thereto and can generally be applied for adjusting the concentration of acids or lyes.
BACKGROUND
[0004] Sulfuric acid, which is a very important starting material for the chemical industry, usually is produced by the so-called double absorption process as it is described for example in Ullmann's Encyclopedia of Industrial Chemistry, 5th edition, vol. A25, pages 635 to 700. Sulfur dioxide (SO 2 ) is converted to sulfur trioxide (SO 3 ) in a converter by means of a catalyst. The sulfur trioxide obtained is withdrawn after the converter and supplied to an intermediate absorber or a final absorber (e.g. hot absorber), in which the gas containing sulfur trioxide is guided in counterflow to concentrated sulfuric acid (H 2 SO 4 ) and absorbed in the same. The resulting highly concentrated sulfuric acid is partly withdrawn as product and upon dilution with water partly recirculated to the absorber for renewed absorption.
[0005] To adjust the acid concentration for the absorber circuit, apparatuses as shown in FIG. 1 have been used so far. In these apparatuses, concentrated sulfuric acid is supplied through a supply conduit via an inlet to a mixing chamber which substantially is disposed at right angles to the supply conduit. Into the end adjacent to the inlet a lance with nozzle openings (so-called “clarinet”) extends, through which water is charged to the sulfuric acid stream for adjusting the concentration, i.e. for dilution. In the mixing chamber concentrated sulfuric acid and water are mixed and the concentration-adjusted sulfuric acid is removed through a discharge conduit via an outlet at the end opposite to the supply conduit. For intermixing concentrated sulfuric acid and water, static mixers can also be incorporated in the mixing chamber. However, the flow cross-section is reduced thereby, which leads to a pressure loss. Despite the comparatively large amount of equipment, no uniform concentration can be achieved at the entrance to the outlet conduit. As seen over the cross-section of the conduit, the concentration deviations are about 0.5 wt-%.
SUMMARY
[0006] In an embodiment, the present invention provides a method for adjusting a concentration of an acid or lye. A medium for adjusting the concentration of the acid or lye is charged into a supply conduit of the acid or lye so as to provide a combined stream. The combined stream is supplied through an inlet to a mixing chamber such that the combined stream is deflected upon entering the mixing chamber. The combined stream is mixed in the mixing chamber. The combined stream is discharged through an outlet of the mixing chamber such that the combined stream is deflected upon being discharged from the mixing chamber.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] The present invention will be described in even greater detail below based on the exemplary figures. The invention is not limited to the exemplary embodiments. Features described and/or represented in the various figures can be used alone or combined in embodiments of the present invention. Other features and advantages of various embodiments of the present invention will become apparent by reading the following detailed description with reference to the attached drawings which illustrate the following:
[0008] FIG. 1 shows an apparatus for concentration adjustment according to the prior art in a schematic view.
[0009] FIG. 2 shows an inventive apparatus for concentration adjustment according to a first embodiment of the invention in a schematic view.
[0010] FIG. 3 shows a configuration of a nozzle device in a second embodiment as nozzle ring.
[0011] FIG. 4 shows an enlarged partial view of the nozzle ring shown in FIG. 3 .
DETAILED DESCRIPTION
[0012] In an embodiment, the present invention provides a uniform dilution of the acid or lye and small concentration deviations with low pressure loss.
[0013] In the method according to an embodiment of the invention, a uniform dilution of the acid or lye and small concentration deviations with low pressure loss substantially is provided in that the medium for adjusting the concentration, in particular water, is charged to the acid or lye before the inlet to the mixing chamber and the acid stream or lye stream and the stream of the medium subsequently are deflected preferably by 90°.
[0014] By charging the medium still before the mixing chamber and subsequently deflecting the streams at the inlet of the mixing chamber an intensive intermixing is achieved, which leads to a distinctly more homogeneous concentration distribution in the acid or lye as compared to conventional methods.
[0015] In an advantageous development of the process of an embodiment of the invention, the medium for adjusting the concentration preferably is charged via a nozzle device, substantially uniformly distributed over the cross-section of the acid stream or lye stream. Beside the above-mentioned advantage of intensive intermixing, this involves the further advantage that only a small concentration deviation is obtained at the outlet of the mixing chamber.
[0016] The present invention furthermore relates to an apparatus suitable for performing the above method, comprising a supply conduit for the acid or lye, a mixing chamber adjoining the supply conduit substantially at right angles, and a discharge conduit leaving the mixing chamber at the end opposite to the supply conduit. In accordance with an embodiment of the invention, between the supply conduit and the mixing chamber a nozzle device is provided for charging a medium for adjusting the concentration.
[0017] Due to the inventive arrangement of the nozzle device, the medium is charged to the acid stream or lye stream earlier than in conventional apparatuses, and said stream is also forced to a deflection at the inlet of the mixing chamber, whereby an intensive intermixing and hence a homogeneous concentration distribution in the acid or lye is achieved.
[0018] In accordance with an embodiment of the invention, it was found to be advantageous to arrange the nozzle device substantially at right angles with respect to the axis (A) of the supply conduit.
[0019] Beside the effect that the acid stream or lye stream is forced to a deflection, it can be omitted to incorporate static mixers in the mixing chamber as in the prior art and thus increase the flow resistance. The pressure loss in the mixing chamber is reduced correspondingly.
[0020] In accordance with a first embodiment of the invention, the nozzle device includes at least one, but preferably a plurality of nozzle tube(s), which is/are arranged transversely through the supply conduit and include(s) a plurality of nozzle openings.
[0021] In another, particularly preferred embodiment the nozzle device is configured as a substantially ring-shaped flange (nozzle ring) and includes at least one web with nozzle openings. The nozzle device preferably includes several, for example three or four webs with nozzle openings, which are aligned in a fan-shaped manner. Depending on the design of the plant and the intended flow rate, the number of webs can however be varied in almost any way. It likewise lies within the scope of the invention to also provide nozzle openings in the nozzle ring itself, in order to also charge the medium from the side to the acid stream or lye stream.
[0022] By supplying the medium via the nozzle ring and the at least one web, it is already uniformly distributed over the cross-section of the acid stream or lye stream when being charged, so that only a small concentration deviation is present at the outlet of the mixing chamber. At the same time, only a small flow resistance is produced by the arrangement, so that the pressure loss in the acid stream or lye stream is kept low.
[0023] In accordance with an embodiment of the invention, the nozzle openings are directed in or against the flow direction of the acid or lye, the latter variant being preferred, as intermixing is promoted by the additional deflection and turbulent mixing.
[0024] By means of the invention, the concentration deviation of the acid or lye of about 0.5 wt-% as known from the prior art can be reduced to below 0.1 wt-%.
[0025] A plant for the concentration adjustment of sulfuric acid, as it is known from the prior art, is shown in FIG. 1 . The apparatus comprises a supply conduit 1 for concentrated sulfuric acid, which is connected with an inlet 2 of a mixing chamber 3 . The mixing chamber 3 is disposed substantially at right angles to the supply conduit 1 and has an outlet 4 at the end opposite to the supply conduit 1 , which is connected with a discharge conduit 5 . The discharge conduit 5 likewise is disposed substantially at right angles to the mixing chamber 3 and substantially is located in the same plane as the supply conduit 1 .
[0026] In the end of the mixing chamber 3 adjacent to the inlet 2 , a lance 6 with nozzle openings (so-called “clarinet”) is arranged, through which water can be injected into the sulfuric acid stream. In addition, static mixers can also be incorporated in the mixing chamber 3 , which are not shown in the Figure.
[0027] FIG. 2 shows a plant for concentration adjustment in accordance with the invention, whose basic elements correspond with those of the plant from the prior art as shown in FIG. 1 and therefore are provided with the same reference numerals, so that in so far reference is made to the above description.
[0028] In contrast to the prior art, the so-called clarinet protruding into the mixing chamber 3 and possible static mixers are omitted. Instead, a nozzle device in the form of a plurality of nozzle tubes 7 is mounted between the end of the supply conduit 1 and the inlet 2 of the mixing chamber 3 , through which water is injected into the sulfuric acid stream. The nozzle openings 11 of the tubes 12 can be arranged in flow direction of the sulfuric acid, but, as shown, preferably are arranged on the opposite side of the nozzle tubes 12 , in order to promote intermixing by the additional deflection and turbulent mixing.
[0029] Instead of one or more nozzle tubes 12 , as depicted in FIG. 2 , the nozzle device 7 can also constitute a ring-shaped flange (nozzle ring) 8 as shown in FIG. 3 , whose dimensions are adjusted to the point of connection between supply conduit 1 and inlet 2 of the mixing chamber 3 . In the nozzle ring 8 , four hollow webs 9 are arranged in a fan-shaped manner. On the base of the fan-shaped arrangement, the hollow webs 9 are connected with a port 10 through the nozzle ring 8 , to which port the water supply can be connected, e.g. flange-mounted.
[0030] FIG. 4 shows a detailed representation of the four hollow webs 9 of the nozzle ring 7 depicted in FIG. 3 . On one side of the hollow webs 9 , which points in or preferably against the flow direction of the sulfuric acid, nozzle openings 11 are arranged, through which the water is injected into the sulfuric acid. Nozzle openings 11 can also be disposed in the nozzle ring 8 itself in accordance with an embodiment the invention.
EXAMPLE
[0031] Proceeding from the basic configuration of the plant for concentration adjustment, as it is shown in FIG. 1 , model calculations and simulations were performed for the apparatus in accordance with the prior art and the apparatus in accordance with the invention. There was used a sulfuric acid stream of 1,623 t/h with 99.5 wt-% H 2 SO 4 , into which 13.6 t/h of water are injected.
[0032] At the outlet of the mixing chamber of the conventional plant, a fluctuation range from 98.458 wt-% to 99.048 wt-% H 2 SO 4 was determined over the cross-section of the outlet from the mixing chamber, i.e. a deviation between 0.4% and 0.5%.
[0033] On the other hand, at the outlet of the mixing chamber of the plant in accordance with the invention a deviation of less than 0.1 wt-% was determined with a fluctuation range of 98.681 wt-% to 98.775 wt-% H 2 SO 4 .
[0034] Consequently, the present invention substantially contributes to a distinct reduction of the concentration deviations.
[0035] While the invention has been described with reference to particular embodiments thereof, it will be understood by those having ordinary skill the art that various changes may be made therein without departing from the scope and spirit of the invention. Further, the present invention is not limited to the embodiments described herein; reference should be had to the appended claims.
LIST OF REFERENCE NUMERALS
[0036] 1 supply conduit
[0037] 2 inlet
[0038] 3 mixing chamber
[0039] 4 outlet
[0040] 5 discharge conduit
[0041] 6 lance (“clarinet”)
[0042] 7 nozzle device
[0043] 8 ring-shaped flange (“nozzle ring”)
[0044] 9 web
[0045] 10 port
[0046] 11 nozzle openings
[0047] 12 nozzle tube | A method for adjusting a concentration of an acid or lye includes charging a medium for adjusting the concentration of the acid or lye into a supply conduit of the acid or lye so as to provide a combined stream. The combined stream is supplied through an inlet to a mixing chamber such that the combined stream is deflected upon entering the mixing chamber. The combined stream is mixed in the mixing chamber. The combined stream is discharged through an outlet of the mixing chamber such that the combined stream is again deflected upon being discharged from the mixing chamber. | 1 |
INTRODUCTION
The present invention relates to process and apparatus for the recovery of elemental sulfur from feed streams containing ammonia and/or other nitrogen compounds. In a particular aspect, the invention relates to process and apparatus for minimizing the amount of ammonia present in a tail gas clean-up unit and thus prevent plugging of the equipment with ammonium compounds.
BACKGROUND OF THE INVENTION
Many crude oils processed by refineries contain varying amounts of nitrogen and sulfur compounds. During the refining process, it frequently becomes necessary to remove such compounds because they impart undesired properties such as disagreeable odor, corrosivity, poor color, and the like, to saleable products. In addition, the compounds may have deleterious effects in various catalytic refining processes applied to oils.
Various processes have been devised for removing the nitrogen and sulfur compounds from oils, one common process being treatment with hydrogen wherein the nitrogen and sulfur compounds are converted to ammonia (NH 3 ) and hydrogen sulfide (H 2 S). Such conversion is usually promoted by use of elevated temperatures and pressures in the presence of hydrogenation catalysts. Reactions of the nitrogen and sulfur compounds with hydrogen to form NH 3 and H 2 S can also occur in other processes such as thermal and catalytic cracking, reforming, and hydrocracking, which are not specifically designed for such purpose. There are thus produced various effluent gas streams containing NH 3 and H 2 S.
The removal of some NH 3 and H 2 S from such effluent streams may be accomplished by scrubbing with water, preferably at elevated pressure and low temperature. To obtain the desired extent of removal, however, it is often necessary to use a rather large amount of water so that a dilute aqueous solution of ammonia and H 2 S is formed. With increasing urbanization and concentration of industrial complexes, the situation is rapidly developing where pollution of water near population centers with such compounds is not desirable. The refiner thus may be compelled to remove the NH 3 and H 2 S from such waters in, for example, a sour water stripper resulting in a need to then dispose of the resulting NH 3 and H 2 S vapor.
In many cases, it is desirable to use the hydrogen sulfide present in such mixtures as feed to a sulfur recovery operation; however, the presence of ammonia can give rise to complications such as, for example, the formation of ammonium sulfite and ammonium sulfate in a sulfur recovery system where cooling occurs, resulting in fouling of the catalyst and plugging of the equipment. While processes exist which are capable of effecting separation of ammonia from hydrogen sulfide, such methods require a large capital investment and the operating costs are relatively high.
In conventional sulfur recovery operations in which the feed gas typically contains more than 50 mole percent hydrogen sulfide, all of the acid gas feed is introduced into a noncatalytic combustion zone or furnace together with enough oxygen ordinarily in the form of air to convert about one-third of the hydrogen sulfide into sulfur dioxide. In the case of ammonia-contaminated hydrogen sulfide streams, even when sufficient additional air to burn ammonia is added, the hydrogen sulfide present competes with the ammonia for the extra oxygen, resulting oftentimes in incomplete combustion of the ammonia. The presence of excessive concentrations of ammonia in the combustion products creates conditions downstream for the formation of ammonium salts, such as, for example, those mentioned above, in the condenser tubes, the tail gas scrubber system, separator seal legs, etc. The failure of oxygen to effect complete combustion was borne out in tests performed where ammonia was purposely added to the feed. In a plant test, ammonia was present in the feed to the extent of about 23 volume percent or 230,000 ppm (dry basis). A conversion of about 99.9% was achieved in the furnace and the effluent had an ammonia concentration of about 200 ppm. In a second case (a laboratory run in which the feed contained 15 volume percent (dry basis) NH 3 ), the ammonia conversion exceeded 99.9% and the furnace effluent had an ammonia concentration of about 35 ppm.
We have found in the past that one preferred method for handling a gas stream which contains ammonia in a conventional sulfur plant is to feed all of the ammonia-containing gas to the burner of the furnace together with a portion of ammonia-free acid gas, while the remaining ammonia-free acid gas is fed to a downstream point. This makes it possible to achieve ammonia conversions in a plant furnace as high as indicated above for the laboratory test. In plant units with this design which do not have a tail gas clean-up unit, the resulting ammonia at low concentration has passed through the condensers and catalyst beds without causing problems. However, as discussed below, even this low concentration of ammonia can cause problems in tail gas clean-up units.
Moreover, sulfur plants are employed to process H 2 S-containing gases from various types of industrial operations other than petroleum refining. Hydrogen sulfide from certain operations may contain nitrogen-containing compounds which can form ammonia in the sulfur plant noncatalytic combustion zone or thermal reactor. An example is the hydrogen sulfide which is recovered from coal gas, also known as coke-oven gas, which is formed from destructive distillation of bituminous coal. This gas often contains hydrogen cyanide (HCN) which is partially combusted in the thermal reactor but may be partially hydrolyzed therein to form gaseous ammonia. We have found that the combustion system can be designed to result in a high efficiency for combustion of HCN, with the ammonia concentration in the effluent being low enough that it does not cause a problem in the condensers and catalytic reactors of a conventional sulfur plant; however, as discussed below, it may cause a problem in certain tail gas clean-up units.
In order to comply with the regulations of the Environmental Protection Agency, many sulfur plants now in operation of being designed employ some type of tail gas treating process to minimize the amount of sulfur compounds ultimately discharged into the atmosphere. One such treating process is known as the Cold Bed Adsorption (CBA) method which involves taking the sulfur plant tail gas and alternately feeding it to one of at least two catalytic reactors, at least one reactor being operated at about 260° F. to 300° F. on the adsorption cycle (for example, about 18 hours), allowing H 2 S and SO 2 to further react at this relatively low temperature to produce free sulfur, while at least one other reactor is undergoing a regeneration cycle of, for example, about 12 hours followed by a cooling cycle of, for example, about 6 hours. In regeneration of, for example, the CBA catalyst beds, adsorbed sulfur is driven off the catalyst by the use, for example, of hot (650° F.) effluent from the first reactor in the sulfur plant. The CBA process is described in detail in U.S. Pat. No. 4,035,474. When NH 3 is present in the feed stream to the sulfur plant, however, a certain amount of NH 3 remains in the sulfur plant tail gas, i.e., the feed to the tail gas clean-up process, for example, the CBA unit. Ammonia present in the feed to the tail gas clean up process can react with SO 2 present to form ammonium sulfite which is adsorbed on the catalyst during adsorption cycle. Later in the regeneration cycle when the catalyst is heated with regeneration gas, NH 3 is liberated. The liberated NH 3 can return in the regeneration gas to pass through the second Claus reactor and thence to the low temperature reactor in adsorption cycle, where it can be again adsorbed on the catalyst. Thus the ammonia can be repetitively adsorbed on the first catalyst bed, then desorbed from the first bed but readsorbed on the second bed, then desorbed from the second but readsorbed on the first in the next cycle, and so forth. Continued operation in this manner can eventually cause the deposition of ammonium salts on the catalyst to be excessive and result in deactivation and plugging of the catalyst.
BRIEF DESCRIPTION OF THE INVENTION
We have now discovered that such deactivation and plugging with ammonium compounds of catalyst on which free sulfur is deposited and which is regenerated by passing a hot regeneration stream in contact therewith can be avoided by subjecting the regeneration effluent gas from the catalyst undergoing regeneration to a procedure which at least reduces the concentration of the ammonia contained therein. Various procedures can be used to treat the regeneration effluent gas. One method is to return a portion of the regeneration effluent gas to a noncatalytic combustion zone or thermal reactor (furnace) of a sulfur plant. Alternatively, a second combustion zone or thermal reactor (furnace) of smaller size may be furnished, to which a portion of the regeneration effluent gas is fed. Yet another alternative is to feed a portion of the regeneration effluent gas to a catalytic reactor for destruction of the ammonia.
In the first method, in which a portion, for example, 5 to 15 percent of the regeneration gas effluent, is recycled to the noncatalytic thermal reactor (furnace) of a sulfur plant, a major portion of the ammonia will be decomposed therein to form nitrogen and water. For example, we have found that with a residence time of 0.9 second and a temperature of about 2570° F. the NH 3 content of the regeneration recycle gas can be reduced from 440 ppm to 40 ppm, when 15% of the regeneration effluent gas is recycled to the furnace and one-half of the ammonia in the adsorption reactor feed gas is adsorbed on the catalyst. In order to maintain the proper temperature in the thermal reactor, preheating of the acid gas and air to the burner may be desirable.
Alternatively, a second furnace which is employed to decompose the ammonia may be operated in a manner similar to a thermal incinerator or an inline heater in which fuel gas, such as, for example, methane, is burned using air to supply heat to increase the regeneration gas temperature to, for example, about 2400° F. to 2600° F. The air may be preheated if desired to reduce the amount of fuel gas required. Acid gas (either preheated or not preheated) may be used in place of fuel gas. After combustion, the effluent from the second furnace can be returned to some point in the sulfur plant, for example, upstream from the second Claus reactor. By decomposing a portion of the ammonia in the regeneration effluent gas, the concentration of ammonia in the feed gas to the catalyst bed on the adsorption cycle is reduced, thus preventing an excessive buildup of ammonium deposits.
DESCRIPTION OF THE DRAWINGS
Our invention is further illustrated by reference to the accompanying drawings in which:
FIG. 1 is a flow diagram illustrating methods and apparatus according to the invention by which the NH 3 content of process streams fed to the catalyst beds during regeneration can be minimized; and
FIG. 2 is a time-temperature curve illustrating what happens during various stages of the process in a catalytic reactor that is being regenerated.
DETAILED DESCRIPTION OF THE INVENTION
According to a preferred embodiment of the invention, a gas stream containing ammonia and hydrogen sulfide is combusted in a noncatalytic combustion zone, designated generally as A, to produce a hot effluent stream. The hot effluent stream after cooling to remove free sulfur therefrom is reheated and provided to a Claus type catalytic reaction zone, designated generally as B, comprising one or more catalytic reactors operated at a temperature above the dew point of sulfur. The effluent stream from the Claus catalytic zone is provided to a second catalytic zone for sulfur removal, designated generally as C, comprising one or more catalytic reactors operated at a temperature such that a preponderance of the free sulfur thus formed is deposited on the catalyst, along with ammonium compounds, which can be formed simultaneously.
Preferably, the temperature of the adsorption reactor feedstream is in the range of about 250° F. to about 280° F. although, of course, higher temperatures can be used with less recovery. The adsorption reactor effluent stream, due to temperature rise within the reactor, thus preferably has a temperature in the range of about 270° F. to about 300° F. A preponderance and as high as 90% or better, of the sulfur in the adsorption reactor feedstream is thus removed by adsorption. The catalyst in the second catalytic zone C is periodically regenerated, preferably using a portion of hot effluent from the Claus type catalytic reaction zone, although other hot gas streams can also be used. Free sulfur and ammonium compounds deposited on the catalyst are released during regeneration to produce a regeneration effluent stream containing free sulfur and ammonia. At least a portion of the regeneration effluent stream can be combusted, or catalytically treated, for example, in combustion zone A, or in an ammonia removal zone designated generally as D to convert at least a portion of the ammonia in the gas, preferably substantially all of the ammonia therein, into nitrogen and water to prevent buildup of ammonia in the regeneration gas stream and thereby avoid catalyst deactivation and plugging.
Referring now to the Figures in detail and in particular to FIG. 1, a gaseous stream containing primarily NH 3 , H 2 S and water vapor can be introduced, for example, at the rate of 18 moles per hour into burner 4 via line 2. The stream in line 2 can contain, for example, approximately 21 volume percent NH 3 and 52 volume percent H 2 S. The 52 volume percent H 2 S may represent, for example, about 30% of the total H 2 S being charged to the plant. The stream in line 6 (for example, at the rate of 27 moles per hour) contains, for example, 54 volume percent H 2 S with the balance being CO 2 and H 2 O. A portion (for example, 13 moles per hour) of the gas in line 6 is diverted to the furnace 8, bypassing burner 4, through line 10. Thus bypassing burner 4 with regard to a portion of the acid gas stream 6 takes advantage of the strong oxidizing conditions in the flame to enhance combustion of NH 3 but permits the noncatalytic reaction of H 2 S with SO 2 in the furnace downstream of the flame zone to produce elemental sulfur. Air is supplied to burner 4 through line 12, for example, at the rate of 65 moles per hour. The flow of air into the burner preferably is such as to correspond to approximately 0.75 mole of oxygen for each mole of ammonia present in furnace 8, and about 0.5 mole of oxygen for each mole of H 2 S in the total feed to the plant. Burner 4 discharges acid gas and air into the thermal reactor or furnace 8 with proper mixing. The NH 3 is converted principally to nitrogen and water in the combustion zone and approximately one-third of the H 2 S is burned to SO 2 and water at a temperature preferably in the neighborhood of about 2600° F. This temperature may be higher or lower but we prefer to use the highest temperature that can be tolerated by the commonly used furnace construction materials. These hot products of combustion are then, in the illustrated embodiment, directly transferred to waste heat boiler 14 where a portion thereof is cooled to about 500° F. to 600° F. and conducted therefrom through line 24 into condenser 18 where most of the free sulfur produced in the furnace is converted into liquid form and removed through line 20. The uncondensed gas phase which is at a temperature, for example, of about 325° F. to 375° F. is taken off condenser 18 through line 22. The gas in line 22 is preheated to a temperature of 450° F. to 500° F. by means of hot gas (for example, about 1000° F.) coming from, for example, the first pass of boiler 14 via line 16.
The resulting preheated reactants in stream 22 enter a first Claus catalytic reactor 26 and are withdrawn therefrom at a temperature of, for example, about 600° F.-700° F., preferably 650° F., at the approximate rate, for example, of 108 moles per hour via line 28. This stream is then split with one portion, for example, at the rate of about 54 moles per hour being taken off through line 30 and used for regeneration of reactor 32, for example, a CBA reactor, which will be described later in more detail. The remaining portion, for example, at the rate of about 54 moles per hour via line 29 and valve 29V is introduced into condenser 34 operated, for example, at a gas effluent temperature of about 350° F. and product sulfur is withdrawn through line 36. The gas effluent phase from condenser 34 is taken through line 38 and heated to, for example, about 425° F. in heater 40 before being introduced via line 42 into a second Claus catalytic reactor 44. Reaction products from reactor 44 are removed therefrom via line 46, for example, at about 460° F. and cooled in condenser 48 to about 260° F. Product sulfur is withdrawn through line 50 while the uncondensed phase is taken off through line 52 and fed to low temperature reactor 54, for example, a CBA reactor, which is on adsorption cycle. Elemental sulfur is adsorbed on the catalyst bed in reactor 54 operated, for example, at a temperature between about 270° F. and 300° F., while tail gas from reactor 54 is discharged to a tail gas incinerator through line 56.
In the regeneration of the catalyst bed in reactor 32, gas at a temperature of, for example, about 650° F. is introduced through lines 30 and 58, for example, at a rate of 108 moles per hour. The origin of the gas in line 58 will be described in detail below. Hot gas used in the regeneration step is withdrawn through line 60 and sent to condenser 62 operated, for example, at an effluent temperature of 350° F. where free sulfur is taken off through line 64. The uncondensed phase is withdrawn through line 66 and sent to blower 68 with the blower outlet stream 70 at 390° F. divided into three streams, 72, 74, and 76, having associated valves 72V, 74V and 76V, respectively, therein to control flow rate. Gas in line 72 is introduced into burner 78, at a rate, for example, of 2.1 moles per hour where it is mixed with fuel gas added via line 80 at the rate, for example, of 0.2 mole per hour and 4.6 moles of air per hour are introduced through line 82. This mixture of gases is burned in ammonia combustion furnace 84, then it is further mixed with, for example, 48 moles per hour of 390° F. gas from line 74. Hot effluent (for example, 650° F.) from furnace 84 is removed through line 58 at the rate of, for example, 54 moles per hour. The ammonia content of this gas is less than 51 ppm. The remaining effluent gas in line 76 at a temperature, for example, of about 390° F. is returned to line 29 at a point downstream of line 30. The mixture of gases in lines 30 and 58 is then used for regeneration of the catalyst in reactor 32. The ammonium compounds on the catalyst are decomposed and NH 3 is driven off the catalyst during, for example, the first three hours of the regeneration cycle, as shown in FIG. 2. In the remaining portion of the regeneration cycle, for example, during the next nine hours, free sulfur is removed from the catalyst and the regeneration gas may be derived solely from line 30, or may be derived from line 30 together with gas from line 58 if desired. Thereafter, the cooling portion of the cycle is conducted, for example, for a period of about six hours using procedures which are known to those skilled in the art. After the decomposition of ammonia compounds in reactor 32, flow of regeneration gas through line 58 may be reduced and the flow of air and fuel through burner 78 is continued to hold the temperature of furnace 84 at, for example, about 2000° F. until the next regeneration cycle.
In one embodiment, approximately equal portions of the stream 58 from furnace 84 are combined with about equal portions of hot effluent stream 30 and the resulting mixture used as the regeneration gas stream. Recycling 50% (instead of all) of the regeneration effluent stream can permit some recycle of NH 3 and some build-up of ammonium salts on the catalyst. It is expected, however, that the amount of build-up should be insignificant and that plugging should not occur.
A modification of the above flow pattern can be employed by returning the products of combustion from ammonia furnace 84 through line 58 and line 90 with associated valve 90V therein to the inlet line 29 of condenser 34 and thence via line 38, heater 40, and line 42 to the second Claus catalytic reaction vessel 44. Another modification of the above flow diagram which can be employed involves eliminating streams 72, 74, 80, 82, and 58, burner 78, and combustion furnace 84, then returning a major portion of effluent gas from line 70 through line 76 to the inlet line 29 of condenser 34, while taking a portion, for example, 10 to 15 percent thereof, and returning it through a line represented by dashed line 86 to burner 4 and furnace 8 where the NH 3 present therein is decomposed to form nitrogen and water. In the modification just mentioned, the proportion of acid gas in stream 6 that is bypassed through line 10 to the second zone of the thermal reactor 8 is increased in proportion to the flow rate in stream 86, to maintain temperature in the first zone of the thermal reactor 8 as required for proper combustion of the ammonia.
According to the invention, ammonia in the regeneration effluent stream can be reduced by passing at least a portion of the regeneration effluent stream through a catalyst bed to decompose the ammonia. The catalyst can be any suitable catalyst effective for decomposition of the ammonia. Such catalysts can include, for example, catalysts as described in Canadian Pat. No. 1,004,030 (1977) comprising at least one sulfided metal of Group VA, Group VIA, the third period of Group VIII and the Rare Earth Series supported on an alumina, silica, or silica alumina support at a temperature of at least about 1000° F. Preferably, the catalyst employed contains one or more sulfides of the metals iron, nickel, cobalt, molybdenum, vanadium, and thorium deposited or co-precipitated on the support. This embodiment of the invention is represented in FIG. 1 by dashed line 91, inline heater 92, line 93, catalytic reactor 94, and line 95. Dashed line 91 feeds at least a portion of the regeneration effluent stream to inline heater 92 to raise the temperature to a temperature preferably in the range of about 1200° F. to about 1500° F. The output of heater 92 is fed through line 93 to catalytic reactor 94 where ammonia is decomposed in the presence of a catalyst as described above. The output of reactor 94 is provided through line 95 to line 58 and can be treated further as described above.
Certain sulfur plant feed gas streams contain diluents such as, for example, carbon dioxide which make it difficult to obtain a high enough thermal reaction temperature to thermally decompose ammonia and/or hydrogen cyanide which can be present. Such gas streams occur, for example, in the coke oven gas process. In this situation, an alternative flow path using a catalytic process as described above can be employed to decompose the ammonia and/or hydrogen cyanide which may be present in the effluent from a sulfur plant furnace such as, for example, thermal reactor 8 in FIG. 1.
From the foregoing description, it will be apparent that we have provided a practical process for handling ammonia-containing H 2 S streams in sulfur recovery plant tail gas treating systems by minimizing the ammonia content of the feed gas to the tail gas treating system. In addition, by employing an ammonia combustion furnace 84, it is possible to maintain high regeneration capacity at extreme turndown, i.e., where the ratio of design feed rate to available feed rate is high.
Although the invention has been described in detailed embodiments as required and illustrated by exemplary flow rates and compositions, it is of course intended not to limit the invention thereby, but by the claims appended hereto. | Ammonium compounds deposited on catalyst in a sulfur recovery facility are removed by passing a hot regeneration stream in contact with the catalyst to produce a regeneration effluent stream containing ammonia followed by combustion or catalysis to reduce the concentration of ammonia in the regeneration effluent stream. | 8 |
BACKGROUND OF THE INVENTION
This invention relates to electrical connectors and more particularly to waterproof plugs and receptacles.
Connectors of the type to which the invention particularly relates are those in which electrical contacts are contained within an insulating housing, and joined with an external electrical conductor in a manner that permits the electrical terminations to be isolated from water, dust and the like. It is desirable also to have a cord grip so the assembled connector and conductor are not susceptible of damage or disassembly by reason of a pull on the conductor.
Various forms of connectors with cord grips or weatherproof features are heretofore known. For example, Smith U.S. Pat. No. 3,437,980, issued Apr. 8, 1979, illustrates a cord grip element of a plurality of fingers, which may be integrally formed with the contact housing, for gripping a conductor within a connector to insure its retention; Lawrence U.S. Pat. No. 4,114,974, issued Sept. 19, 1978 shows a connector having an annular sealing element extending around a cord that bears against the cord as it is assembled with a clamp element to bear against the sealing elements and the cord within. As additional background, reference is made to Bidoni et al. U.S. Pat. No. 4,030,800, issued June 21, 1977, illustrating another form of connector cap with cord grip and to Fuller U.S. Pat. No. 3,792,415, issued Feb. 12, 1974, which is representative of art in which a connector is provided with weatherproof qualities by the utilization of a rubber or other sealing element over its exterior.
While various forms of prior art devices are generally effective for their intended purposes, there remains interest in improvements in the design of connectors in order that they perform more reliably with long life while achieving the functions of a watertight and dustproof construction with positive retention of the conductor from pull-out, all of which is desirably to be in a configuration of relatively few and simple parts that can be quickly and simply assembled for overall economy.
SUMMARY OF THE INVENTION
In accordance with the present invention, a connector is provided including a terminal housing, a cap, and a sealing element of yieldable material such as rubber in a new and improved configuration. The terminal housing is of insulating material, preferably of molded plastic material, and contains a plurality of electrical contacts which may be either part of or related to the male prongs of a plug or the female contacts of a receptacle connector. The front of the connector is preferably of dead front design while the rear of the housing is the portion which is particularly improved in importance with this invention. Access is provided, for connecting wire leads of a conductor with the contacts within the housing, by one or more apertures for the entrance of a plurality of wire leads. The housing may have usual screw terminals or other forms of terminals for connection of the wire leads to the internal contacts. The housing also has a plurality of rearwardly projecting flexible fingers, preferably molded integrally therewith, that comprise part of the weatherproof cord connection means in accordance with this invention.
The cap is configured for securely fitting over the rear end of the terminal housing and has a central aperture permitting the sheathed conductor to extend therethrough. The inner surface of the cap is configured to provide a centrally located recess in which is fit a cylindrical rubber bushing or sealing element for fitting in close engagement with the conductor that passes through it. The cap also has a plurality of recesses that run alongside the location of the bushing and are open to the exterior surface of the bushing. These recesses each have a tapered end surface tapering toward the central aperture. The assembly of the cap with the housing after attachment of wire leads thereto results in the plurality of flexible fingers engaging the tapered end surfaces within the recesses of the cap so as to be forced into firm engagement with the bushing and the bushing in turn in firm engagement with a conductor extending therethrough. Additional means, such as screw fasteners, are provided for firmly retaining the terminal housing and cap together.
It is found that the connector as described is not only quite effective in providing the desired waterproof and dustproof qualities with assurance of positive cord retention but also that it is favorable in that the parts are relatively simple in their configuration, economical, and permit ease of formation and assembly. For example, since the rubber bushing is a simple cylindrical element, its location within the cap is permitted at any angular location and the assembly of the cap to the housing is achieved merely by placing the fingers of the housing within the recesses of the cap.
BRIEF DESCRIPTION OF THE DRAWING
FIGS. 1 and 2 respectively illustrate disassembled and assembled perspective views of a connector in accordance with the present invention, FIG. 2 being partly broken away;
FIG. 3 shows an end view from within the cap of the device of FIGS. 1 and 2; and
FIG. 4 illustrates a perspective view of the rubber bushing employed in the arrangement of FIGS. 1 and 2.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIGS. 1 and 2 show a connector comprising an insulating terminal housing 10 including a housing body 10a containing a plurality of electrical contacts within it, but which are not illustrated here and a terminal cover 10b. The contacts may be of generally conventional form and are in this example those of a female receptacle connector element for receiving the prongs of a mating plug connector. The back end of the housing includes a set of apertures 12 for fasteners (not shown) that join the cap, to be described, and housing 10 as well as apertures 14 for receiving the wire elements 16 of a sheathed conductor 18 to be joined with the connector as shown in FIG. 2.
A cap 20, which is also shown in FIG. 3, is provided for fitting over the end of the housing 10 and running along its sides in close relation thereto with a central aperture 22 for receiving the cord 18. A simple cylindrical rubber bushing 24, also shown in FIG. 4, is located with the cap 20 and encircles the position of the sheathed conductor 18. Within the cap 20 there are also a plurality of recesses 26 that run alongside the bushing 24 and are open to the exterior surface of the bushing. These recesses each have a tapered end surface 26a tapering toward the central aperture 22.
As part of the terminal housing 10 there is also included a plurality of flexible projecting fingers 28 extending toward the rear thereof that are received respectively within the recesses 26 of the cap and engage the tapered end surfaces 26a so as to be forced into firm engagement with the bushing 24 and the bushing in turn with the cord 18 extending therethrough. The assembled cap 20 and housing 10 are secured together by screw fasteners or some other means for which purpose the cap is provided with apertures 12a in alignment with apertures 12 of the housing.
It is preferred that the housing 10 and the cap 20 are each of molded plastic material, such as nylon or other high impact resistant material, and that the flexible fingers 28 are integrally with the remainder of the housing. This unit 10b and 28 is molded together and the thinness of the portion 28a at which the fingers are joined with the main part of the housing provides the necessary flexibility so that the bearing of the fingers against the tapered or cam surface 26a within the recesses 26 of the cap flexes them inwardly to bear securely against the bushing 24 and the conductor within it.
For simplicity of design the apertures 14 for receiving the wire leads of the conductor in the housing are in uniform spaced arrangement in the central portion thereof while the flexible fingers 28 are also in uniform spaced relation concentric with the circle of the wire lead apertures. Necessarily, the pattern of the recesses 26 within the cap matches that of the fingers of the housing.
In the event that any contamination enters between the cap 20 and the housing 10, it is prevented from penetrating to the electrical contacts within the housing by reason of the rubber bushing 24 which has one end face 24a fitting down tightly on the housing 10 and its rear end face 24b fitting against a shoulder 20a or a portion of the cap surrounding the central aperture 22. Additionally, pulling of the cord 18 does not result in separation or damage because of the firm securance of it by means of the flexible fingers 28 and the rubber bushing 24. In addition to restraining the wire leads 16 from pulling out of the device, this arrangement protects the conductor 18 from damage of wear or splitting at the points of restraint as is caused by some previous devices where finger elements of a cord grip arrangement bear directly against the conductor. Here, the rubber bushing provides a yielding but firm restraint on the conductor that does not subject it to surface wear or other damage.
Of course, the number and precise pattern of the recesses 26 and fingers 28 may be varied from the uniform arrangement of three as shown. However, three is found effective without need of additional numbers of such elements.
It is consequently believed that the present invention provides a design for a connector that achieves the multiple purposes of reliability and performance including weatherproofing and cord retention in an arrangement that is simple and economical to form and assemble. Various changes and modifications may be made from the specific embodiment disclosed while retaining the essential features of the invention. | An electrical connector with weatherproofing and cord gripping qualities provided by a terminal housing having rearwardly projecting fingers that mate within recesses of a cap member, which recesses have tapered rear surfaces so that the fingers are forced inwardly radially to bear against a rubber bushing surrounding a contained conductor that has wire leads connected with contacts within the housing. | 7 |
BACKGROUND
[0001] The present invention relates generally to on-line product and service review analysis, and more particularly to automatically updating on-line product and service reviews based upon textual analysis and post-review changes to the reviewed products and services.
[0002] Products and services rely heavily upon on-line reviews provided by their customers and users. Over time, however, product and service reviews become stale, outdated, and potentially inaccurate representations of the current state of the product or service to which the review applies. For example, hotels rely quite heavily upon their customers' on-line reviews. A negative review can adversely impact the hotels business for a long period of time. If, however, the poor review was attributable to a feature that has been updated/fixed (e.g., old decor in the rooms where the rooms were all remodeled after the posting of the review), the poor review is unfairly impacting the business of the hotel. Likewise for product reviews, when a poor review of a product is based upon a feature that has been updated or fixed by the manufacturer, the perpetual existence of that negative review, despite its up to the date lack of relevance and accuracy, remains and adversely impacts sales of that product.
[0003] It would be useful to provide a system that analyzes on-line reviews of products and services and, based upon the text of the review, provides corrective information and/or diminished weight to the outdated review.
[0004] It would also be useful to provide a system that updates on-line product and service reviews based upon a reviewer's personal biases.
[0005] It would further be useful to provide a system that updates on-line product and service reviews based upon a reviewer's personal preferences.
SUMMARY
[0006] In accordance with the foregoing objects and advantages, the present invention provides a computerized system that analyzes the text of on-line product and service reviews, compares the textual components of the review with a database of manufacturer/service producer updates to the product or service to which the review pertains, provides corrective commentary to the review based upon post-review action taken by the manufacture/service provider, and adjusts the weighting of the review on the basis of the outdated information.
[0007] In one aspect of the invention, a system is provided for updating on-line product/service reviews for a given product/service, comprising: a server computer; a web server on which the on-line product/service reviews and the dates on which the on-line product/service reviews were entered are stored in non-transitory memory; a database on which is stored data representative of: products/services subject to on-line review, and updated and fixed features of the products/services subject to review and the dates from which the updated and fixed features are effective, wherein the data representative of updated and fixed features is automatically updated within the database on a predetermined periodic basis; software stored in non-transitory memory on the server computer, the software comprising program executable code for performing: natural language processing, including classification, lemmatization and sentiment break-down for each of the on-line product/service reviews to generate analyzed on-line product/service reviews; comparison of the data representative of said updated and fixed features with the analyzed on-line product/service reviews; comparison of the data representative of the effective date from which the updated and fixed features are effective with the dates on which the on-line product/service reviews were entered; and inserting text in the on-line product/service review representative of the updated and fixed feature and the date from which said updated and fixed feature is effective to generate an altered on-line product/service review if the data representative of the updated and fixed features matches said analyzed on-line product/service reviews
[0008] In another aspect of the invention, a method is provided for updating on-line product/service reviews for a given product/service, comprising the steps of: analyzing the on-line product/service reviews by: performing natural language processing techniques to classify the on-line product/service reviews; performing natural language processing techniques to lemmatize the on-line product/service reviews; and separating sentiment from the on-line product/service reviews; comparing the analyzed product/service reviews to data stored on a database representative of updated and fixed features of the products/services subject to review and the dates from which the updated and fixed features are effective; and inserting text into any product/service review which contained negative sentiment regarding a product/service feature that was subsequently updated or fixed that indicates the product/service feature has been updated and fixed.
[0009] In another aspect of the invention, a software product stored in non-transitory memory of a computer is provided for updating on-line product/service reviews for a given product/service and that communicates with a database on which is stored data representative of products/services subject to on-line review, and updated and fixed features of the products/services subject to review and the dates from which the updated and fixed features are effective, wherein the data representative of updated and fixed features is automatically updated within the database on a predetermined periodic basis, the software product comprising executable program code for performing: natural language processing, including classification, lemmatization and sentiment break-down for each of the on-line product/service reviews to generate analyzed on-line product/service reviews; comparison of the data representative of the updated and fixed features with the analyzed on-line product/service reviews; comparison of the data representative of the effective date from which the updated and fixed features are effective with the dates on which the on-line product/service reviews were entered; and inserting text in the on-line product/service review representative of the updated and fixed feature and the date from which said updated and fixed feature is effective to generate an altered on-line product/service review if the data representative of the updated and fixed features matches the analyzed on-line product/service reviews.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] The present invention will be more fully understood and appreciated by reading the following Detailed Description in conjunction with the accompanying drawings, in which:
[0011] FIG. 1 is a high level block diagram in accordance with an aspect of the present invention;
[0012] FIG. 2 is a high level block diagram of software used in accordance with an aspect of the present invention;
[0013] FIG. 3 is a first partial flow chart in accordance with an aspect of the present invention;
[0014] FIG. 4 is a second partial flow chart in accordance with an aspect of the present invention;
[0015] FIG. 5 is a third partial flow chart in accordance with an aspect of the invention;
[0016] FIG. 6 is a block diagram schematically illustrating a system in accordance with an aspect of the present invention;
[0017] FIG. 7 is a first illustrative graphical output generated in accordance with an aspect of the present invention; and
[0018] FIG. 8 is a second illustrative graphical output generated in accordance with an aspect of the present invention.
DETAILED DESCRIPTION
[0019] Referring now to the drawings the present invention provides a system 10 for analyzing using, for example, natural language processing (NLP) classification techniques, and, when appropriate, annotating and/or altering on-line product and/or service reviews and rankings (“ORR”) for purposes of making the ORR reflective and accurate of the current state of the product or service to which it applies. Ultimately, once analysis is completed and assessed, the system software will aggregate all of the review feedback from all reviewers based on the NLP classification techniques and present the aggregated data on a visual graph, such as, for example, a color coded graph with commentary and indications as to when product/service issues have been or will be addressed/fixed. Such aggregation will continue in real time on an on-going basis.
[0020] System 10 comprises a server computer 12 which may, for example, be that of a company that operates an on-line website that offers a particular product(s) and/or service(s) for which users are invited and able to submit on-line reviews, a web server computer 14 (which may be the same as server computer 12 or a different computer) that serves the web page associated with the company's product(s)/service(s) and contains the ORR's, a database 16 stored in the non-transitory memory of a computer (it could be computer 12 / 14 or a different computer) and on which is stored a repository of data representative of the: (1) product(s)/service(s) subject to on-line review, (2) updated and fixed features of the product(s)/service(s) subject to review and the dates from which the updated and fixed features are effective, (3) reviewer data indicative of a reviewer's product/service biases (which is updated by the software as it continues to learn more about each reviewer's biases), and (4) user data indicative of a user's product/service preferences (e.g., what each user considers important or unimportant about a product/service) (and which also continues to be updated as the software continues to learn more about each user's product/service preferences), wherein the data representative of updated and fixed features is automatically updated within the database on a predetermined periodic basis, and software that is stored in the non-transitory memory of computer server 12 (or another computer that could be integrated into system 10 ). Collectively, the software communicates with the database 16 and web server 14 to cause computer 12 / 14 to read and analyze the ORRs 100 using NLP techniques in step 200 , and then edit or augment each ORR that contains outdated information through insertion of corrective text in the ORR (or in association therewith (e.g., a “bubble text” or other expressive feature that a reader of the ORR could see in connection with the ORR)) in step 300 . In addition, in step 400 the software can edit any ranking of the product/service if its associated ORR was premised upon a feature that has since been corrected and/or was based on a reviewer's bias or other reviewer trait. Finally, the software can generate graphical output in step 500 that provides the user with a visual timeline of ORR's and product/service updates.
[0021] More specifically, the software contains a cognitive system 200 , as shown in FIG. 2 , that communicates with the repository of product/service information contained in database 16 . The cognitive system 200 is enabled through use of NLP techniques of machine intelligence 202 that facilitate concise understanding of the text of any ORR. The NLP techniques include server side software with machine intelligence 202 that facilitate reading and understanding a body of text and determine the sentiment about specific aspects of any reviewed product/service. Lemmatization 204 breaks down the text of an ORR to the Lemma level (e.g., “walking,” “walks,” “walked” all have a lemma of “walk.”). Next, subject classification techniques 206 are applied; a variety of models that are understood to one of ordinary skill in the art can be used to achieve classification (e.g., “Maximum Entropy” (also known as “max-ent”) or “Deep Learning/”Neural Net” models are two such examples). Once the text from any ORR is broken down by part and simplified according to these techniques, sentiment break-down 208 from the ORR can be done. For example, if the subject of the text in an ORR is the heart rate monitor feature and the reviewer's sentiment is low because of product inaccuracy, and the ORR was written, for example, more than one year ago, the software will compare features of the heart rate monitor stored on the database 16 to determine if the accuracy was improved through changes made since the time the ORR was made (e.g., determine whether the database 16 contains data representing that the heart rate monitor was made more accurate in all conditions in the, e.g., Model 2.11 Release from 4 months ago).
[0022] As briefly described above, database 16 contains a repository of product/service information. For a large on-line retail site, database 16 would contain in memory a repository of information about products sold on the site (or at least some subset thereof). The repository would contain concise information about product updates/fixes and when any issues or features with the products were added, and product manufacturers whose products are included on the database 16 could have their computers 18 that contain product/service data stored thereon access thereto to update such information in real time. The standard repository of database 16 could be updated on a periodic basis, such as once per day.
[0023] With reference to FIGS. 3-5 , the server side software will first execute its NLP techniques on an ORR in step 302 , and then compare the semantic break-down with the product/serve features included in the database 16 in step 304 and will determine whether the semantic break-down matches any of the updated/fixed product/service features included in database 16 in step 306 . If the semantic break down is determined by the software not to have any matches in the database 16 in regard to product/service updates/fixes, then it will return an unedited ORR in step 308 and continue its process of determining whether the reviewer is one for whom the database 16 has any data in step 310 . If there is a match between semantic break-down and the product/service fixes/updates in database 16 , the software will retrieve the updated product/service information from database 16 in step 312 and provide an updated ORR in step 314 with the updated information before carrying forward to determining whether the reviewer is one for whom data has been stored in database 16 in step 310 . If the reviewer is not one for whom database 16 has data, no further editing of the ORR will occur at this time per step 316 . If the reviewer is one for whom data is contained within database 16 , the software can then execute code that will communicate with database 16 for purposes of determining whether the reviewer in one who regularly gives adverse reviews in step 318 . If it is determined that the reviewer is not one whom regularly gives adverse reviews, no further editing of the ORR is necessary, in step 320 . If, however, it is determined that the reviewer is one who regularly gives adverse reviews, the weight of the ORR can be adjusted accordingly, in step 322 . Next, the software will execute code that will communicate with database 16 for purposes of determining whether the reviewer has a particular bias, in step 324 . If no bias is found to exist, then no further editing of the ORR is necessary at this stage per step 326 . If a bias is found to exist, then in step 328 the weight of the ORR can be adjusted accordingly. Finally, in step 330 the software can execute code to communicate with database 16 to determine whether there is any data for the user that reveals preferences of that user. If no preferences are found to exist, no further editing of the ORR is necessary, as in step 332 . If the user is one who has preferences that data for which is stored in database 16 , the ORR can be adjusted to reflect this particular user's preferences more accurately, in step 334 .
[0024] With regard to adjusting the weight based on the sentiment of a particular reviewer and/or the bias of a particular reviewer in steps 318 and 324 , the server side software will process linear algebraic equations that perform operations on vectors set up for the reviewer sentiment (e.g., S (x, y) for a 2-dimensional sentiment vector representing, for example, positive and negative sentiments across its dimensions and the bias (e.g., B (x, y)) for a 2-dimensional bias vector. The algebraic relationships and degree of effect on weighting are a purely matter of design choice for the particular implementation of the embodiment of the present invention.
[0025] More summarily, in implementing the present invention, one aspect is for the software to take corrective action within an ORR. For example, if an ORR says “I can't stand the way the right mouse click delay's two seconds” a tag of desired format (e.g., bubble with text in a preferred embodiment) can be inserted into the ORR by instructions provided by the software to indicate “The delay was due to a firmware issue which was fixed in all products sold after August 16, 2012.” This corrective action is achieved in step 302 through the software using the machine intelligence program code to read the text, understand what it is saying, and see/compare if there is information on this feature in the database 16 starting at step 304 , 306 , et seq., as described above. This analysis/assessment of the ORR can be done in real time as a user brings up a web page with the specific ORR. At that time, the software on the web server 14 will be executed to read the ORR, break down the ORR and classify it per subject and sentiment. Any negative comments in the ORR can then automatically be compared to the repository of data in database 16 . The time period in which analysis can be performed may also be represented by a vector T (x, y) that can be factored into the linear algebraic equation that is used for a particular implementation.
[0026] Next, based on features that have been updated/corrected, if a ranking was also a part of the ORR, it is assessed and, if appropriate, amended based upon the updated/fixed feature in step. While the software cannot “guess” at what a reviewer might have rated any aspect if the problem cited did not exist, it can devalue the particular aspect of the ranking As an example, if a reviewer ranked three aspects of a product as follows: hear rate monitor (1 out of 5)—associated to the 1 out of 5 ranking is a comment that the heart rate monitor freezes on the screen and ceases to work (i.e., in the ORR the reviewer has made that comment). After breaking down the ORR and comparing to database 16 , bubble text has been inserted that states “The review is from June 2012. Meanwhile, release 3.1 fixed this issue in February 2014 and the heart rate function is reviewed positively since that time.”; GPS accuracy (4 out of 5); and look and feel of the watch (5 out of 5). Now, based on the fact that the issue appears to have been fixed subsequent to the user's ORR, the heart rate monitor rating would be devalued and not count towards the average ratings being determined, and the overall score may be slightly affected as well.
[0027] The numeric rating could be adjusted by other factors known in the art. For example, the present system could be combined with personal preference algorithms such that the ratings for certain features could be weighted more highly than other features based on what the system has come to know about the user. Multiple scores may be provided in a given user interface. For instance, the average rating as known today; configurable, the average rating as per important features to any user based on devaluing the weight of non-important features; configurable by calculating in an understanding of the reviewer and identifying biases of the reviewer against any product (i.e., the user always gives low scores to Apple products no matter what the product is, the weight of any score may be adjusted and devalued).
[0028] To determine bias, data representative of bias based on the semantic breakdown of text by the software is gathered. This data may be based on historical records of a user's on-line comments and/or gathered in a real-time stream if needed. Regardless, this aspect of the invention relies in part on the bias data collection, and the timing of the collection is not directly material to the processing of the data done by the software. In addition, it is worth noting that it is the data that is collected, how it is collected, and how that data is then organized into vectors that is important for the analytical processing performed by an embodiment of the software of the present invention; once the data is in its preferred format, it is computationally enabled for the analytical processing associated with an aspect of the present invention.
[0029] With regard to an aspect of the present invention wherein a user gives a high numerical ranking in an ORR, but provides negative sentiment in comments within the ORR, an embodiment of the present invention can address this conflicting ORR (i.e., an ORR having both positive attributes and negative attributes). For example, on an on-line retail website, a user may give a movie 1/5 stars. The user loved the movie, but hated the DVD transfer. In such an instance, the cognitive system 200 would break this out into multiple ratings by a user for specific things. So, if a user Bob says: 1/5 stars “I loved this movie, but the DVD transfer was terrible . . . the extras were OK,” the cognitive system would break this up as: Bob, loved this movie, positive sentiment 5/5 stars; Bob, DVD transfer terrible, negative sentiment, 1/5 stars; Bob, extras were ok, neutral sentiment 3/5 stars. The software would start its analytical processing with the initial basis (in this case 1/5) and forward-engineer into the other sentiment categories that may have been extracted. In this case, it would likely be 3/5 for the neutral and 5/5 for the positive. If the user had given the same review a 3/5 instead of 1/5, then the negative sentiment would have been scored 3/5, neutral 4/5, positive 5/5. In this manner, the software will extrapolate multiple reviews from a single review.
[0030] Finally, a visual summary representation as seen in FIGS. 7 and 8 is provided. The software will aggregate the review feedback from all users based on the NLP classification techniques described above. The prevalent commentary for any time period will be aggregated and shown on the graph in any preferred format (e.g., as bubble commentary in a preferred embodiment). An indication will be provided for when any such issue is fixed or will be fixed by pulling that data directly from database 16 . In one embodiment, the chart would be color coordinated to permit easy visual discernment of the information expressed thereby. Of course, other visual display formats could be used (e.g., box plots, bubble charts, calendar views, Voronoi diagrams, population pyramid diagrams, tree maps, etc.). More specifically, FIG. 7 provides a timeline of product permutations, while FIG. 8 adds to this more detailed information taken from an individual cell within the graph. The graphical representations permit the user to have an immediate understanding of what product features are already implemented, which are pending, which have not been addressed, and the like, and users will have an understanding of any issues not yet implemented.
[0031] The present invention may be a system, a method, and/or a computer program product. The computer program product may include a computer readable storage medium (or media) having computer readable program instructions thereon for causing a processor to carry out aspects of the present invention.
[0032] The computer readable storage medium can be a tangible device that can retain and store instructions for use by an instruction execution device. The computer readable storage medium may be, for example, but is not limited to, an electronic storage device, a magnetic storage device, an optical storage device, an electromagnetic storage device, a semiconductor storage device, or any suitable combination of the foregoing. A non-exhaustive list of more specific examples of the computer readable storage medium includes the following: a portable computer diskette, a hard disk, a random access memory (RAM), a read-only memory (ROM), an erasable programmable read-only memory (EPROM or Flash memory), a static random access memory (SRAM), a portable compact disc read-only memory (CD-ROM), a digital versatile disk (DVD), a memory stick, a floppy disk, a mechanically encoded device such as punch-cards or raised structures in a groove having instructions recorded thereon, and any suitable combination of the foregoing. A computer readable storage medium, as used herein, is not to be construed as being transitory signals per se, such as radio waves or other freely propagating electromagnetic waves, electromagnetic waves propagating through a waveguide or other transmission media (e.g., light pulses passing through a fiber-optic cable), or electrical signals transmitted through a wire.
[0033] Computer readable program instructions described herein can be downloaded to respective computing/processing devices from a computer readable storage medium or to an external computer or external storage device via a network, for example, the Internet, a local area network, a wide area network and/or a wireless network. The network may comprise copper transmission cables, optical transmission fibers, wireless transmission, routers, firewalls, switches, gateway computers and/or edge servers. A network adapter card or network interface in each computing/processing device receives computer readable program instructions from the network and forwards the computer readable program instructions for storage in a computer readable storage medium within the respective computing/processing device.
[0034] Computer readable program instructions for carrying out operations of the present invention may be assembler instructions, instruction-set-architecture (ISA) instructions, machine instructions, machine dependent instructions, microcode, firmware instructions, state-setting data, or either source code or object code written in any combination of one or more programming languages, including an object oriented programming language such as Smalltalk, C++ or the like, and conventional procedural programming languages, such as the “C” programming language or similar programming languages. The computer readable program instructions may execute entirely on the user's computer, partly on the user's computer, as a stand-alone software package, partly on the user's computer and partly on a remote computer or entirely on the remote computer or server. In the latter scenario, the remote computer may be connected to the user's computer through any type of network, including a local area network (LAN) or a wide area network (WAN), or the connection may be made to an external computer (for example, through the Internet using an Internet Service Provider). In some embodiments, electronic circuitry including, for example, programmable logic circuitry, field-programmable gate arrays (FPGA), or programmable logic arrays (PLA) may execute the computer readable program instructions by utilizing state information of the computer readable program instructions to personalize the electronic circuitry, in order to perform aspects of the present invention.
[0035] Aspects of the present invention are described herein with reference to flowchart illustrations and/or block diagrams of methods, apparatus (systems), and computer program products according to embodiments of the invention. It will be understood that each block of the flowchart illustrations and/or block diagrams, and combinations of blocks in the flowchart illustrations and/or block diagrams, can be implemented by computer readable program instructions.
[0036] These computer readable program instructions may be provided to a processor of a general purpose computer, special purpose computer, or other programmable data processing apparatus to produce a machine, such that the instructions, which execute via the processor of the computer or other programmable data processing apparatus, create means for implementing the functions/acts specified in the flowchart and/or block diagram block or blocks. These computer readable program instructions may also be stored in a computer readable storage medium that can direct a computer, a programmable data processing apparatus, and/or other devices to function in a particular manner, such that the computer readable storage medium having instructions stored therein comprises an article of manufacture including instructions which implement aspects of the function/act specified in the flowchart and/or block diagram block or blocks.
[0037] The computer readable program instructions may also be loaded onto a computer, other programmable data processing apparatus, or other device to cause a series of operational steps to be performed on the computer, other programmable apparatus or other device to produce a computer implemented process, such that the instructions which execute on the computer, other programmable apparatus, or other device implement the functions/acts specified in the flowchart and/or block diagram block or blocks.
[0038] The flowchart and block diagrams in the Figures illustrate the architecture, functionality, and operation of possible implementations of systems, methods, and computer program products according to various embodiments of the present invention. In this regard, each block in the flowchart or block diagrams may represent a module, segment, or portion of instructions, which comprises one or more executable instructions for implementing the specified logical function(s). In some alternative implementations, the functions noted in the block may occur out of the order noted in the figures. For example, two blocks shown in succession may, in fact, be executed substantially concurrently, or the blocks may sometimes be executed in the reverse order, depending upon the functionality involved. It will also be noted that each block of the block diagrams and/or flowchart illustration, and combinations of blocks in the block diagrams and/or flowchart illustration, can be implemented by special purpose hardware-based systems that perform the specified functions or acts or carry out combinations of special purpose hardware and computer instructions. | The present invention provides a computerized system that analyzes the text of on-line product and service reviews, compares the textual components of the review with a database of manufacturer/service producer updates to the product or service to which the review pertains, provides corrective commentary to the review based upon post-review action taken by the manufacture/service provider, and adjusts the weighting of the review on the basis of the outdated information. | 6 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority to U.S. provisional patent application No. 61/568,786, filed Dec. 9, 2011, the disclosure of which is incorporated herein by reference.
FIELD OF THE INVENTION
[0002] This invention relates generally to medical devices and more specifically to medical devices for determining the presence or absence of contaminants in oral fluid samples.
BACKGROUND OF THE INVENTION
[0003] Oral fluid samples obtained for various biochemical analyses are potentially subject to contamination by ingestion (feeding) activity and/or blood.
BRIEF SUMMARY OF THE INVENTION
[0004] The present invention provides methods, devices and kits useful for determining the presence or absence of a contaminant in the sample of oral fluid. The method generally involves contacting a substrate having a detectable reporter with a sample of oral fluid and, based on determining a signal from the detectable reporter determining the presence or absence of a contaminant in the sample of oral fluid. The invention is useful for detecting a variety of contaminants that could be present in an oral fluid sample obtained from any mammal. The contaminants include but are not limited to lactose, milk, colostrum, blood, hemoglobin, whole cells, and combinations thereof. In one embodiment, the method and kits of the invention including are suitable for detecting contaminants in oral fluid samples obtained from neonatal ungulates.
BRIEF DESCRIPTION OF THE FIGURES
[0005] FIG. 1 . Glucose color chart from the labeling experiments performed.
[0006] FIG. 2 . The top strip, the pad was the normal glucose reagent pad. In the bottom strip, lactase was added. Both strips were used to test colostrum from a llama. The glucose pad showed no reaction (negative for glucose) and the modified glucose pad showed a positive reaction for the glucose released from lactose by the action of the lactase enzyme.
[0007] FIG. 3 . Oral fluid samples from neonatal calf (“Bull 30 ”), colostrum replacer (dried bovine colostrum reconstituted in water and diluted “Col Rep 1:10” ibid.), and bovine colostrum (“Colostrum” ibid.) were applied to the modified glucose test pads of urine test strips (modified by addition of 9 I.U. of lactase). Two samples of oral fluid, collected at the time of birth “0 H”) and 2 days after birth (“48 H”) were negative for glucose whereas colostrum, either as replacer or as collected, were positive for glucose and therefore lactose.
[0008] FIG. 4 . Oral fluid samples were collected from one alpaca cria at two times within the first day of life. They were tested with modified glucose pads. This cria was allowed to nurse from the dam at will before Sample # 2 (bottom pad in figure) was collected. The figure gives an indication sample # 2 (lower strip) was contaminated with colostrum whereas sample # 1 (top) was not.
[0009] FIG. 5 . Oral fluid samples collected from a foal were similarly tested for contamination by colostrum with modified and unmodified glucose reagent pads with the same results as were obtained with cria samples as shown. Foal saliva sample # 76 was collected soon after feeding so contamination by colostrum was expected.
[0010] FIG. 6 . Foal oral fluid sample # 72 was not contaminated with colostrum did not give a color change with modified glucose.
[0011] FIG. 7 . Human oral fluid samples were collected before and after the test subject drank milk. The samples were tested with glucose reagent pads modified as described herein. The result, shown in the figure, shows that the oral fluid sample contaminated with milk developed a color change indicating a positive reaction for glucose (bottom strip) which did not occur with the sample collected before ingesting milk (top strip).
[0012] FIG. 8 . A oral fluid sample (foal # 72 shown in FIG. 6 ) and bovine colostrum were tested with all the test pads except glucose on urine test strips (URS-10 from Teco Diagnostics). The following figure shows the test name on the left and the negative (no reaction, i.e. none detected) color from the comparison chart for the test. Two test strips—oral fluid on the left and colostrum on the right are positioned to allow direct comparison with the color chart. Significant differences between the two samples are clearly visible in three determinations: protein, blood (hemoglobin), and specific gravity.
DETAILED DESCRIPTION OF THE INVENTION
[0013] The present invention provides novel methods using a variety of devices to determine the presence or absence of contaminants in oral fluid samples.
[0014] Briefly, the present invention teaches oral fluid collection with an indication of contamination at or near the time of collection. In various embodiments, the invention includes incorporating into a collection device an absorbent material impregnated with indicator reagents (i.e., detectable reporters) to detect suspected potential alteration of the composition or properties of the sample. For example, the oral fluid may be contaminated with colostrum which could potentially affect analysis of the sample for total protein, specific proteins such as immunoglobulins or antibody activity, carbohydrates, lipids, among other biochemical compounds. Additionally, for example, ingestion of water could result in erroneously low levels of all constituents of oral fluid due to the dilution effect of water. Contamination of oral fluid by blood, as another example, would introduce cells into the sample in addition to adding the constituents of blood serum.
[0015] In one embodiment, the invention provides a collection device comprising a detectable reporter suitable for detecting a contaminant in an oral fluid, and further comprising an oral fluid. Also provided are kits. The kits comprise a collection device of the invention and components for collecting oral fluid.
[0016] Teachings of the present invention provide for a visible or otherwise readable indication that the sample of oral fluid could contain certain undesirable components.
[0017] The following descriptions are presented to demonstrate the invention and its versatility and are not intended to be limiting.
[0018] In one embodiment, the invention provides for determining the presence or absence of colostrum in a sample of oral fluid. For instance, colostrum could readily and rapidly be indicated by detecting, for example, the presence of lactose in the normally lactose free oral fluid. Because lactose is similarly found in milk, the same indicator could be used to identify oral fluid contaminated by milk, or identify oral fluid that is not contaminated by milk, or to identify colostrum. In another embodiment, contamination of an oral fluid sample by blood would be indicated by the unexpectedly increased presence of hemoglobin in the sample. Contamination by either blood or colostrum would also be expected to increase the specific gravity of the oral fluid sample and such an increase would indicate potential alteration of the integrity of the sample. Additionally, colostrum, milk, or blood contamination would increase the protein content of oral fluid and, therefore, a protein measurement would indicate contamination. Recent ingestion of water could dilute the oral fluid which could be indicated by abnormally low specific gravity.
[0019] The descriptive examples in the immediately foregoing paragraph were selected because very simple and rapid colorimetric tests currently exist for use with urine samples. The reagents can be put to novel use to help assure the integrity of oral fluid or saliva samples. Use of these single-step, point-of-sample-collection, and single-use chemistry reagents would be reliable and cost effective. For example, blood contamination in an oral fluid sample could be indicated using the hemoglobin pad of urine strips. Also using standard urine strip chemistries, blood contamination might also be indicated by higher than expected protein or glucose, both of which would enter the sample with the blood contamination and not oral fluid. Dilution of oral fluid by water could be indicated by specific gravity measurements using, for example, urine test strip chemistry. Colostrum contamination would be expected to increase protein concentration in, for example, neonatal mammal oral fluid. By combining standard urine test strip test for glucose with lactase would allow for detecting mammary fluid contamination of oral fluid samples due to the presence of lactose.
[0020] The present invention is not intended to be solely dependent upon urine test strip chemistry to provide time-of-collection indication of a contaminated oral fluid sample. Any rapid test that would identify contamination of oral fluid samples at, for example, the time and site of collection could be employed.
[0021] Practice of the present invention would be advantageously employed in combination with, for example, measurement of immunoglobulins in the oral fluid of neonatal ungulates as disclosed in U.S. patent publication no. 2010/0111934, the disclosure of which is incorporated herein by reference, in addition to other instances of oral fluid collection.
[0022] The following example is presented to illustrate the present invention. It is not intended to limiting in any manner.
EXAMPLE 1
[0023] This Example demonstrates an embodiment of the invention using oral fluid samples collected from calves, foals, humans, and cria for colostrum and milk. Urine test strips (Chemstrip 10 manufactured by Roche Diagnostics unless otherwise noted) were used. These commercially available in-vitro diagnostic devices have ten individual pads, each of which contains chemical reagents to perform a specific test. For the individual chemistry testing described herein, the glucose pad was used. To meet the requirements of the present invention, the glucose pads were used as provided or modified by adding the lactose hydrolyzing enzyme “Lactase”, more specifically commercially available E. coli (β-galactosidase (purchased from ABD Serotec), Approximately 10 I.U. of lactase was added prior to applying the sample to be tested.
[0024] The figures presented herein were edited to show only the glucose pad. In all cases the results were read visually as directed by the instructions provided by the manufacturer. After reading, interpreting, and recording the result photographs (shown in FIGS. 2-8 ) were taken. These photographs (shown in FIGS. 2-8 ) are indicative of the test results but are not always as clear as by reading by eye. In the results presented herein, the visual interpretation is given along with the photographic representation of the test (shown in FIGS. 2-8 ). With the glucose pad and the modified glucose pad, prepared by adding lactase as described, the yellow color indicates no reaction, i.e., negative for detectable glucose. The green/blue indicates positive detection of glucose and the intensity of the darker color is proportional to the amount of glucose present ( FIG. 1 ). Using this correlation between visible color and amount of glucose detected, the manufacturer permits the user to interpret the test result quantitatively. The glucose color chart from the labeling is shown in FIG. 1 .
[0025] For the purpose of these examples, the presence of color development in the modified glucose pads represents a glucose detection either from glucose itself or that hydrolyzed from lactose.
[0026] Lactose, known as “milk sugar”, is present in the mammary gland products colostrum and milk. Lactose, a disaccharide of galactose and glucose does not react with the urine strip chemistry for glucose as shown in FIG. 2 . In order to test for lactose, the lactose hydrolyzing enzyme lactase (β-galactosidase) was added to the glucose pad to produce glucose from lactose and, if lactose were present, provide a positive reaction with the thus modified glucose pad. In FIG. 2 , the top strip, the pad was the normal glucose reagent pad. In the bottom strip, lactase was added. Both strips were used to test colostrum from a llama. The glucose pad showed no reaction (negative for glucose) and the modified glucose pad showed a positive reaction for the glucose released from lactose by the action of the lactase enzyme ( FIG. 2 ).
[0027] Oral fluid samples from neonatal calf (“Bull 30 ” in FIG. 3 ), colostrum replacer (dried bovine colostrum reconstituted in water and diluted “Col Rep 1:10” ibid.), and bovine colostrum (“Colostrum” ibid.) were applied to the modified glucose test pads of urine test strips (modified by addition of 9 I.U. of lactase). Two samples of oral fluid, collected at the time of birth “0 H”) and 2 days after birth (“48 H”) were negative for glucose whereas colostrum, either as replacer or as collected, were positive for glucose and therefore lactose ( FIG. 3 ). These results show that oral fluid contains neither glucose nor lactose in sufficiently high concentration to give positive reaction with the glucose or modified glucose reagent pads.
[0028] Oral fluid samples were collected from one alpaca cria at two times within the first day of life. They were tested with modified glucose pads. This cria was allowed to nurse from the dam at will before Sample # 2 (bottom pad in FIG. 4 ) was collected. FIG. 4 gives an indication sample # 2 (lower strip) was contaminated with colostrum whereas sample # 2 (top) was not.
[0029] Oral fluid samples collected from a foal were similarly tested for contamination by colostrum with modified and unmodified glucose reagent pads with the same results as were obtained with cria samples as shown. Foal saliva sample # 76 was collected soon after feeding so contamination by colostrum was expected ( FIG. 5 ).
[0030] Foal oral fluid sample # 72 was not contaminated with colostrum did not give a color change with modified glucose ( FIG. 6 ).
[0031] Human oral fluid samples were collected before and after the test subject drank milk. The samples were tested with glucose reagent pads modified as described herein. The result, shown in FIG. 7 , shows that the oral fluid sample contaminated with milk developed a color change indicating a positive reaction for glucose (bottom strip) which did not occur with the sample collected before ingesting milk (top strip). The results are shown in FIG. 7 .
[0032] An oral fluid sample (foal # 72 shown in an earlier example) and bovine colostrum were tested with all the test pads except glucose on urine test strips (URS-10 from Teco Diagnostics). FIG. 8 shows the test name on the left and the negative (no reaction, i.e. none detected) color from the comparison chart for the test. Two test strips—oral fluid on the left and colostrum on the right are positioned to allow direct comparison with the color chart ( FIG. 8 ). Significant differences between the two samples are clearly visible in three determinations: protein, blood (hemoglobin), and specific gravity. These results indicate that these pads, in addition to glucose, could be used for identifying contamination of oral fluid samples.
[0033] While the invention has been particularly shown and described with reference to specific embodiments (some of which are preferred embodiments), it should be understood by those having skill in the art that various changes in form and detail may be made therein without departing from the spirit and scope of the present invention as disclosed herein. | Provided are methods and devices used for determining the presence or absence of a contaminant in the sample of oral fluid. The method involves contacting a substrate having a detectable reporter with a sample of oral fluid and, based on determining a signal from the detectable reporter determining the presence or absence of a contaminant in the sample of oral fluid. The invention is useful for detecting lactose, milk, colostrum, blood, hemoglobin, whole cells, and combinations thereof. The method can be used for detecting oral contaminants in oral fluid samples obtained from any mammal, including neonatal ungulates. | 2 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a device for securing a motor to watercraft and, more specifically, relates to such a device adapted to secure both an electric motor and a battery to watercraft including inflatable boats, rafts, pantoon-type vessels and the like.
2. Description of the Prior Art
Various means of securing both gasoline and electric motors to watercraft have been known.
With respect to inflatable boats, rafts and the like, difficulty in securing motors to such craft has frequently resulted in the need to use manual oars as the prime means of moving the craft across a body of water.
Various means have been suggested for securing a motor to an inflatable boat.
U.S. Pat. No. 3,881,442 discloses the use of a coiled metal structure which is adapted to receive the uninflated boat. Inflation of the boat is said to cause uncoiling of the structure.
U.S. Pat. No. 2,456,086 discloses a collapsible boat wherein an attaching plate is said to cooperate with a body and connecting straps.
U.S. Pat. Nos. 2,150,420 and 2,334,072 disclose a curved base plate which is said to fit around the stern portion of the inflatable boat and cooperate with an upward extension member on which a motor is adapted to be clamped. The anchor structures are secured to the boat by means of straps.
U.S. Pat. No. 2,468,287 discloses a motor mount for an inflatable vessel which consists of a pair of jaws which are lever operated employed as a means of establishing desired camming and clamping action to position a mounting plate in the desired location.
U.S. Pat. No. 3,665,534 discloses a fishing float in the nature of an innertube which has secured exteriorly thereto an enlarged housing which is adapted to receive a pair of batteries and have secured to the rearmost portion an electric motor.
U.S. Pat. No. 2,497,490 discloses an outboard motor mount for an inflatable boat which provides a rear mounting bracket and a stabilizer element which is adapted to be secured in underlying position with respect to side portions of the boat.
There remains, therefore, a substantial need for a device which will effectively and economically secure an electrical motor to watercraft such as an inflatable boat, raft or the like while providing support means for a battery and providing such design in a fashion which effects mechanically efficient interrelationship therebetween.
SUMMARY OF THE INVENTION
The present invention has solved the above-described problems by providing a lightweight, economical motor securing device which includes securing means which are generally downwardly open and adapted to secure the device to the watercraft, motor attachment means projecting generally upwardly from a rear portion of the securing means and a battery securing shelf extending forwardly from the securing means to provide a counterbalancing effect between the motor and battery. The securing means preferably are defined by a pair of generally parallel walls and a connecting wall. Restraining means are provided to resist undesired displacement of the battery. Wall means serve to resist undesired displacement of a motor clamp which secures the motor to the device.
It is an object of the present invention to provide an efficient and economical means for securing an electric motor and battery to watercraft, with particular emphasis on inflatable watercraft.
It is another object of this invention to provide such a device which is lightweight and simple to install.
It is yet another object of the present invention to provide such a device which has effective mechanical counterbalancing action.
It is another object of the present invention to provide such a device which can be made as a unitary structure and can be employed while avoiding potentially hazardous damage to the watercraft.
These and other objects of the invention will be more fully understood from the following description of the invention on reference to the illustrations appended hereto.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a fragmentary top-plan view of a portion of a watercraft having a motor securing device of the present invention secured thereto.
FIG. 2 is a cross sectional illustration taken through 2--2 of FIG. 1.
FIG. 3 is a top-plan view of a motor securing device of the present invention.
FIG. 4 is a front-elevational view of the motor securing device shown in FIG. 3.
FIG. 5 is a cross-sectional illustration of the motor securing device of FIG. 3 taken through 5--5 of FIG. 3.
FIG. 6 is a right-side elevational view of the motor securing device shown in FIG. 3.
FIG. 7 is a left-side elevational view of the motor securing device shown in FIG. 3.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to FIGS. 1 and 2 in greater detail, the motor securing device of the present invention is secured to a stern portion of an inflatable raft 2. The motor securing device 6 has means for receiving electric motor 8 which has drive shaft 10 cooperating with gear box 14 to deliver power to propeller 16. An operating handle 12 permits orientation of the propeller so as to provide thrust in the desired direction. A clamp member 18 secures the motor assembly to a portion of the motor securing device. A battery 20 is supported on a shelf 22 which is also a portion of the motor securing device 6. As is shown in FIG. 2, an inflated portion 28 of raft 2 is received within securing means 26 of motor securing device 6.
Referring now in greater detail to FIGS. 4 and 5, it is seen that the securing means for engaging the watercraft includes, in the form shown, a pair of generally parallel sidewalls 40, 42 and a generally circular connecting wall 44. For convenience of reference, the wall 40 will be deemed the rear wall and the wall 42 will be deemed the forward wall. It will be appreciated, however, that as used herein, references to relative direction such as "upwardly", "downwardly", "rearwardly", "forwardly" and related terms shall be used only for clarity of description in a relative sense and shall not be deemed to be limitations on the invention. In attaching the motor securing device to the watercraft, the downwardly open channel 46 defined by walls 40, 42, 44 will receive the portion 28 of the inflatable raft, for example, in intimate mechanical engagement. It is noted that the surfaces of walls 40, 42, 44 are preferably smooth so as to resist potentially damaging puncturing of the inflatable craft. In the preferred form, the width of the channel 46 (defined between walls 40, 42) will be such as to provide for a tight resiliently maintained interfit between section 28 and channel 46. If desired, the device may be made so as to have adjustable channel widths to fit different size vessels. This might readily be accomplished, for example, by providing a split in connecting wall 44 with elongated slots having bolts passing therethrough and fasteners such as wing nuts employed to secure the walls 40, 42 in different relative positions. Alternatively, a series of openings in one portion of a split connecting wall 44 may be aligned with an opening in the other section with the fasteners securing the two sections in the desired relative position.
Referring to FIGS. 3 through 5, the motor transom or wall 50 to which the clamp 18 is secured will now be considered in greater detail. The motor transom or motor attachment wall 50, in the form shown, is generally coplaner with rear wall 40 and may be considered an upward extension thereof. In a preferred form, a block of compressible material such as wood or plastic 52 is secured to the forward surface of wall 50 in order to facilitate intimate engagment by the clamp 18. A pair of lateral walls 54, 56, which in the form shown are generally triangular in shape, are connected to the ends of wall 50 and serve to resist undesired lateral movement of the portion of the clamp 18 disposed forwardly of wall 50. Floor 60 connects wall 50 with connecting wall 44.
For convenience of reference herein, the wall 40 will be deemed to terminate at the junction with wall 44 and, similarly, wall 50 will be deemed to begin at such point. For general reference, in FIG. 4, a line 62 has been positioned so as to provide a general indication as to where this transition occurs. This line is merely for reference purposes in the drawings and need not be a structural element.
Referring still to FIGS. 3 through 5, there is shown the battery supporting shelf 70 which has an area sufficient to support battery 20. As it is, of course, important to restrain the battery against undesired movement which might cause it to fall off of the shelf, the present invention, in the form shown, provides means for resisting undesired movement of this type. Lateral wall sections 72, 74, 76 which preferably provide a generally continuous U-shaped restraint are disposed at or adjacent the periphery of shelf 70. If desired, additional battery securing means, such as straps, for example, may be provided.
FIGS. 6 and 7 illustrate, respectively, the right and left side elevational views of the motor-securing device.
With the exception of block 52 which may be eliminated, if desired, the entire device may advantageously be made as a unitary article. This provides for convenience of handling, integrity of the device and may improve economies. Among the preferred materials are plastic, aluminum and steel. A particularly suitable material is that sold under the trade designation Fiberglas.
The shelf 70 preferably has an average width measured along the direction of peripheral wall 72 of about one-half to one-and-one-half times the width of the securing means measured in the same general direction. In the form shown, the device has a generally uniform width throughout its longitudinal extent which is equal to the width of the securing device.
It will be appreciated that when both the motor and battery are in position as shown in FIGS. 1 and 2, the motor applies a moment in a clockwise direction to the wall 50 and the battery 20 applies a moment in a counterclockwise direction to the shelf 22. As a result of at least partial cancellation of these moments, this provides a stable mechanical system which resists undesired separation of the motor-supporting device from the watercraft.
While for simplicity of disclosure herein, prime reference has been directed toward the use of the invention in connection with inflatable watercraft composed of various materials, it will be appreciated that the device may be employed advantageously in connection with other forms of watercraft whether or not inflatable and whether or not the transom has the dimension or shape of the section 28 shown in FIG. 2. For application to somewhat rigid transom portions, a resilient inner liner may be provided within channel 46 so as to facilitate effective interengagement.
It will be appreciated, therefore, that the present invention provides effective means for economically and securely attaching a motor and battery to watercraft.
Whereas particular embodiments of the invention have been described above for purposes of illustration, it will be appreciated by those skilled in the art that numerous variations of the details may be made without departing from the invention as described in the appended claims. | A motor securing device for watercraft such as inflatable boats and rafts and the like including generally downwardly open securing portion which may be defined by a pair of parallel walls and a connecting wall. A motor attachment portion projects generally upwardly from a rear portion of the securing section. A battery-securing shelf extends forwardly from the securing portion. Securing a motor to the upwardly projecting wall and a battery positioned on the supporting shelf provide a counterbalancing action. Retaining structures may be provided to resist undesired displacement of the battery or motor securing clamp. | 1 |
This is a division, of application Ser. No. 123,913, filed Feb. 22, 1980, abandoned.
BACKGROUND OF THE INVENTION
This invention relates to tufting machines and tufted fabrics and more particularly to a method and apparatus for forming a new fabric having tufted loops in the form of chain links disposed longitudinally in rows on the base fabric.
In the formation of tufted pile a plurality of laterally disposed yarn carrying needles are reciprocablly driven through a base fabric longitudinally fed through the machine to form loops carried down below the fabric to be seized by loopers oscillating in timed relationship with the needles and which cross the needles just above the needle eye to seize the loop of yarn. In a loop pile machine the loopers point in the direction of feed of the base fabric and hold the seized loops while the needles are retracted from the base fabric, thereafter rocking away from the point of loop seizure to release the loops. When the needles start their next descent the loops have been released from the loopers and carried one stitch length away from the needle path. To form cut pile the loopers point in the direction opposite to the direction in which the fabric is being fed and cooperate with respective oscillating knives. Since the fabric and thus the loop is being fed toward the closed end of the looper the loop cannot be released and is cut by the knife as the hook rocks away from the needle path, generally after about three loops have been so seized. The pile height of cut pile fabric depends solely upon the distance that the loopers are disposed below the backing fabric, while the pile height of loop pile depends upon the amount of yarn fed to the needle with the maximum being the distance from the loopers to the backing fabric.
The aesthetic appearance of a tufted fabric to a large extent depends upon what is known as the "cover" or "coverage" of the fabric. This is the amount of the yarn that appears on the base fabric, it being undesireable for the base fabric to be visable. Heretofor, the manner of obtaining greater cover has been to utilize more yarn, either by having higher pile heights or greater density, or both, the latter being determined by the lateral spacing or gauge between adjacent needles and loopers, and by the rate of fabric feed relative to the rate of needle reciprocation. Large utilization of yarn results from obtaining coverage in this manner. Since the largest single factor in the cost of producing tufted fabric is the amount, and thus the weight, of yarn is the fabric, the greater the coverage the higher the cost of the fabric. Consequently, it is highly desireable to have a high coverage product with a low face weight, i.e., small amount of yarn.
Tufted fabric is less expensive to produce than other known pile fabric producing methods and tufted fabric stylists are continually seeking attractive new patterning abilities and yarns for broadloom carpet, wall coverings, upholstery and drapery fabric. Thus, attempts have been made to produce various looks in a tufted fabric that are produced more expensively by for example, weaving and knitting. The knitted look and the crewel look and desireable for certain applications, particularly when the lock can be obtained with the yarns of larger size or heavier deniers. No tufted fabric is presently known with these qualities nor with the unraveling characteristics of the product produced by those methods.
SUMMARY OF THE INVENTION
The present invention provides a tufted pile fabric having the pile tufts disposed on the base fabric in the form of chains extending longitudinally substantially parallel to the base fabric between stitching holes, and a method and apparatus for producing the fabric by concatenating successive tufting loops into a chain using a primary looper and a transfer looper oscillating out of phase with each other. Since the loops lie substantially flat against the base fabric a greater amount of yarn is capable of being placed on the face of the base fabric relative to the amount of yarn utilized, and the amount of yarn coverage while substantial does not result in the high face weight of yarn heretofor necessary for equivalent coverage. Moreover, adjacent rows of chains may be off set laterally to provide a fabric with exceptionally high coverage. The fabric has an attractive knitted appearance with berber or crewel effects suitable for use as a residential carpeting, automobile fabrics, wall coverings, upholstery and rugs. It also provides an excellent print base for carpeting and is ideal in public areas when used with heavier and/or larger yarn sizes because it will not unravel and has virtually no pile crushing possibilities.
In practicing the principles of the invention a base fabric is fed between a reciprocating needle and a pair of oscillating loopers. The needle penetrates the base fabric and forms a loop seized by the first or primary looper having a bill facing in the direction of fabric feed as the looper rocks toward the needle path. As the needle ascends the primary looper rocks away from the needle path and sheds the loop which is thereafter seized by the second or transfer looper having a bill facing oppositely to the direction of fabric feed and oscillating oppositely relatively to the primary looper. The transfer looper holds the loop for entry by the needle as it thereafter descends. The transfer looper thereafter rocks away from the needle path as primary looper rocks into the needle path for seizing a subsequent loop. Thus, each loop is formed within a prior loop and as the needle begins to ascend the transfer looper releases the first loop which is concatenated about the subsequent loop.
The transfer looper has a loop seizing bill spaced above and overlying a portion of the bill of the primary looper and in transverse alignment therewith. The transfer loopers oscillate out of phase with the primary loopers. Preferrably the transfer loopers are mounted on a common looper bar with the primary loopers and have mounting portions longitudinally intermediate adjacent primary loopers, the bill portions of the transfer loopers being bent into the aligned relationship with the primary loopers. The needle passes through the bend of the transfer looper at approximately bottom dead center, but is spaced from the transfer looper as it enters the loop held thereon.
Another feature of the invention contemplates the insertion of a loop pile tuft into each chain using another yarn system. The second yarn system may include a different type yarn with different twists, sizes and colors than that of the chain system. Moreover, it may be separately controlled and provide high and low loops in accordance with a pattern within the chain fabric. To provide this combination additional needles may be mounted for reciprocating into cooperation with loopers pointing in the direction of the fabric feed. The needles may be mounted in the needle bar with the chain producing needles and the loopers may be mounted in the same looper bar with the other loopers.
Consequently, it is a primary object of the present invention to provide a tufted pile fabric having concatenated loops and a method and apparatus for forming the fabric.
It is another object of the present invention to provide in a tufting machine apparatus for producing a pile fabric in the form of a chain against the base fabric and wherein the apparatus includes oscillating primary and secondary loopers, the primary loopers for seizing a loop from a reciprocating needle and subsequently shedding the loop onto the secondary loopers where it is held, concatenated with a subsequent loop and thereafter shed.
It is a further object of the present invention to provide in a tufting machine a pair of loopers cooperating with a reciprocating needle, in which the bill of a first of the loopers points in the direction of fabric feed for seizing a loop of yarn from the needle and in which the second looper points in the direction opposite to fabric feed for receiving a seized loop shed from the first looper and holding the loop for entry by the needle as it descends to form a subsequent loop.
It is a still further object of the present invention to provide in a tufting machine a first oscillating looper having a bill pointing in the direction in which the base fabric is fed and co-operating with a reciprocating needle to seize a loop of yarn and thereafter shed the loop, and a second looper having a bill pointing oppositely to the direction of fabric feed positioned closer to the base fabric than the first looper and aligned with the bill of the first looper in the direction of fabric feed for seizing the loop shed by the first looper, the second looper oscillating out of phase with the first looper and holding the loop for entry by the needle as it descends towards the loop seizing position of the first looper.
It is yet a further object of the present invention to provide in adjacent lateral rows in a tufting machine needles offset from each other in the direction of fabric feed, each needle co-operating with a respective primary looper for seizing a loop of yarn presented by the respective needle and thereafter shedding the loop, and a transfer looper associated with each primary looper for seizing the loop shed by the respective primary looper for concatenation with a subsequently formed loop to produce offset adjacent rows of concatenated loops.
It is yet a still further object of the present invention to provide a transfer looper for a tufting machine for use in combination with a loop pile looper for forming chain tufts wherein the transfer looper has a bill portion bent out of the plane of its mounting portion.
It is still yet a further object of the present invention to provide a fabric having tufted loops disposed within concatenated chain loops and a method and apparatus for forming the fabric.
BRIEF DESCRIPTION OF THE DRAWINGS
The particular features and advantages of the invention as well as other objects will become apparent from the following description taken in connection with the accompanying drawings, in which;
FIG. 1 is a vertical fragmentary sectional view taken transversely through a portion of a multiple needle tufting machine embodying apparatus construction in accordance with the principles of the present invention and illustrating portions of the machine in somewhat diagrammatic form;
FIG. 2 is a fragmentary perspective view of the stitch forming instrumentalities of the tufting machine illustrated in FIG. 1;
FIG. 3 is a perspective view of a transfer looper of the present invention;
FIG. 4 is a sectional view taken substantially along the line 4--4 of FIG. 1 but with the needles in a descended position;
FIG. 5 is a fragmentary plan view of a looper bar constructed in accordance with one aspect of the present invention;
FIG. 6 is a schematic representation of the chain forming instrumentalities in an operative position preparatory to forming a loop;
FIG. 7 is a view similar to FIG. 6 disclosing a second operative position of the chain pile forming instrumentalities;
FIG. 8 is a view similar to FIG. 7 disclosing a third operative position;
FIG. 9 is a view similar to FIG. 8 disclosing a fourth operative position;
FIG. 10 is a view similar to FIG. 9 disclosing a fifth operative position;
FIG. 11 is a fragmentary plan view of a tufted chain loop fabric produced in accordance with the present invention; and
FIG. 12 is a fragmentary plan view of a tufted fabric having loop pile within concatenated chain loops as produced in accordance with the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to the drawings, there is illustrated in FIG. 1 a portion of a tufting machine 10 having a frame comprising a bed 12 and a head 14 disposed above the bed. The bed 12 includes a bed plate 16 across which a fabric F is adapted to be fed by a pair of take-off rolls 18 and feed rolls 20.
Mounted in the head 14 for vertical reciprocation is one of a plurality of push rods 22 to the lower end of which a needle bar 24 is carried and which in turn carries a first set of a plurality of needles 26 and 28 in a first pair of transverse rows and a second set of a plurality of needles 30 and 32 in a second pair of transverse rows spaced downwardly stream of the needles 26 and 28 in the direction of fabric feed. The needles are adapted to penetrate the fabric through wire support fingers 34 positioned across an opening in the bed plate 16 upon reciprocation of the needle bar to carry yarn Y therethrough and projects loops of yarn from the fabric. Endwise reciprocation may be conventionally imparted to the push rods 22 and thus the needle bar by a link 36 pivotably connected at its lower end to the push rods and at its upper end to an eccentric 38 on a driven rotary main shaft 40 that is journalled transversely through the head 14. Yarn jerkers 42 and 44 are carried by the needle bar 24 and operate to engage yarn between the respective rows of needles 26, 28 and 30,32 and respective conventional yarn feed mechanisms (not illustrated) for each transverse pair of needle rows.
Mounted within the bed for cooperation with the needles 26, 28 are a plurality of conventional loop pile loopers 46,48 which have bills which point in the direction of fabric feed, the loopers 46 co-operating with the needles 26 and the loopers 48 cooperating with the needles 28 to seize loops of yarn presented by the needles. The loopers 46,48 have mounting portions receivable within respective slots 50,52 in a looper bar 54. Secured to the looper bar 54 is one half of a plurality of two piece clamps 56 which are secured by screws 58 about a looper shaft 60 journalled in the bed substantially parallel to the main shaft 40. The looper shaft 60 is conventionally oscillated or rocked in a back and forth manner in timed relationship with the reciprocation of the needles so that the hooks of the loopers 46,48 enter the respective loops presented by the needles 26,28, seize the loops, and as the loopers rock away from the needle path as the needles ascend, shed the loops which are moved downstream along with the fabric F. To simplify the disclosure, the means for oscillating the looper shaft is not illustrated since this is notoriously well known in the tufting art and any conventional means can be utilized with the present invention. One means for accomplishing this may be a cam and lever means driven off the main shaft 40.
In accordance with the present invention a second or transfer looper 62 is mounted to cooperate with the looper 46 and a second or transfer looper 64 is mounted to cooperate with the looper 48. The loopers 62 and 64 have respective free end portions 66,68 including bills 70,72 which point oppositely to the direction of fabric feed and thus oppositely to the bill portions of the loopers 46, 48. The loopers 62,64 are positioned downstream of respective loopers 46,48, as hereinafter described in further detail, and are oscillated out of phase with the loopers 46,48. Thus, as the loopers 46, 48 rock toward the center line of the needle path from a first side thereof the loopers 62 and 64 rock away from the center line of the needle path from the same direction. In the preferred embodiment of the invention this out of phase oscillation is simply provided by mounting the loopers 62,64 in the same looper bar 54 as the loopers 46,48.
With the exception of an undercut 74 the shank 76 to form the mounting portion of the loopers 62, for purposes hereafter described, the loopers 62 and 64 are identical in construction and only looper 62 will be described in detail.
As best illustrated in FIG. 3 the loopers 62 comprise an upstanding shank 76 the lower end of which is the mounting portion receivable within slots 78 in the looper bar 54, (slots 79 receiving the loopers 64) and from the top of which the free end 66 in the form of an arm or blade 80, angularly extends and terminates in the bill 70. The blade 80 has a bend 82 such that the plane of the bill 70 is laterally offset from the plane of the shank 76. The leading edge or tip 83 above the bill 70 is disposed downwardly from the top edge and the rear portion of the bill has an edge 84 disposed downwardly beyond the lower edge 86 of the tip of the bill. The edge 84 defines a throat beyond which a loop of yarn seized by the bill 70 is prevented from moving and the bottom edge 86 is the edge against which the loop is seized. The length of the shank 76 is longer than the shanks of the loopers 46 and 48 such that when the loopers 62 and 64 are inserted within their respective slots 78 and 79 in the looper bar 54 the bill 70 is disposed closer to the backing fabric F than the free end bill portions of the loopers 46 and 48. Moreover, the slots 78 and 79 are offset from the slots 50 and 52 with each slot 78,79 transversely intermediate but spaced downstream from respective adjacent slots 50 and 52, the bend 82 being such that although the shanks 76 of the loopers 62,64 are offset from the shanks of corresponding loopers 46,48, the bill portions 70 of the loopers 62, 64 are aligned with the bills of planar loopers 46,48. The bill 70 is not only laterally aligned with the corresponding looper 46, 48 but is of a length such that it is superposed over at least the leading tip of the bill of those loopers. Preferably, the length of the bill 70 is such that it overlays a portion of the bill of the respective looper 46,48 by some finite amount; good results being obtained when the bill 70 overlays about half of the bill of the respective cooperating looper 46,48.
The operation of the machine can best be understood with reference to FIGS. 6 through 10 which illustrate schematically portions of the stitch forming cycle for the system comprising the needle 26, the looper 46, and the transfer looper 62. With reference to FIG. 6, the needle 26 has already penetrated the base fabric F and descended to its maximum or deepest penetration. The looper bar which at this time is rocking in the counter-clockwise direction as illustrated, carries the bill of the looper 46 toward the needle center line, and the looper 62, which has a previous loop 88 held thereon against the throat 84 and the edge 86 of the bill 70, is rocking away from the needle path. The needle 26 during its descent has entered the loop 88 held on the looper 62 and is at the bend 82 of the looper 62 in the position illustrated in FIG. 4. After the needle begins its ascent, as illustrated in FIG. 7, the bill of the looper 46 has entered the new loop presented by the needle 26 as the looper bar 54 continues to rock counter-clockwise. At this point in the cycle the loop 88 is being released from the bill 70 of the looper 62 by the action of the looper 62 being rocked further from the needle center line and the loop being restrained from movement with the looper by the needle 26 and by the needle pushing against the bill 70. In FIG. 8 the looper bar 54 is illustrated at approximately its maximum counter-clockwise extent, and the new loop 90 has been seized by the bill of the looper 46. The loop 88 has been completely shed by the looper 62 and is concatenated as a chain link about the new loop 90. FIG. 9 illustrates the position of the stitch forming instrumentalities just after the needle has begun its descent and the looper bar 54 is rocking clockwise. The looper 46 is illustrated in the position as shedding the loop 90 from its bill onto the bill of the looper 62, while the previously formed loop 88 is secure against the base fabric F. In FIG. 10 the looper bar is continuing to rock clockwise with the looper 46 moving away from the needle center line. The needle 26 as it continues its descent is rearwardly of the bend 82 so easily passes through the loop 90 which has been seized and is being held by the bill 70 of the looper 62. The process is continued to form a succession of concatenated loops.
It should be understood that the needles 28 cooperate with the loopers 48 and the loopers 64 in the same manner as the needles 26 cooperate with the loopers 46 and 62. The needles 28 are offset in the direction transverse to the feed line of the base fabric to provide a staggered needle arrangement. Thus, as best illustrated in FIG. 2 the needles 26 are received within needle holes 92 in the needle bar 24 and the needles 28 are received within the holes 94 offset transversely from the holes 92 downstream along the line of fabric feed. Consequently, the loopers 48 are offset from the loopers 46 by an amount similar to the offset or stagger between the needles 28 and 26, and the loopers 62 and 64 are similarly offset. The slots 50,52, 78 and 79 in the looper bar 54, for manufacturing simplicity are cut into the looper bar the same depth along the line of feed. Thus, the loopers 48 include an undercut at 96 so that the loopers 46 and 48 may be otherwise identical, and the loopers 60 include the undercut 74. The depth of the undercut 74 and 96 being substantially equal to the offset or stagger between respective adjacent loopers.
The apparatus thus far described produces a fabric as illustrated in FIG. 11 wherein the needles 26 produce the concatenated loops L 1 and the needles 28 produce the concatenated loops L 2 . This product has exceptional coverage for the weight of yarn utilized, and when the larger size yarns are tufted the product provides a berber or crewel effect with full coverage and no portions of the base fabric visible. Moreover, when heavier yarns are tufted one leg of each loop overlies the other leg (depending upon the twist of the yarn) and gives a knitted appearance, and with certain yarns a herringbone appearance. Thus, attractive patterns can be produced by the utilization of yarns having different weights, sizes, twists, etc.
Another aspect of the present invention is the provision of the second set of staggered needles 30,32 which cooperate with another set of loopers 98 and 100 respectively. The loopers 98 and 100 being conventional loop pile loopers such as the loopers 46 and 48 and have bills which point in the direction the fabric feed. The loopers 98 and 100 are mounted within slots 102 and 104 respectively in the looper bar 54 at substantially the same downstream location as the loopers 62 and 64, but the slots 102 are substantially transversely aligned with the slots 50, and the slots 104 are similarly aligned with the slots 52, so that the slots 102 and 104 are intermediate the slots 78 and 79 as illustrated in FIG. 5. With this construction a loop pile is formed every stroke of the machine which of course is equal to one stitch, and by proper spacing between the needles 26 and 30 and the needles 28 and 32, a loop tuft may be placed intermediate each pair of chain tufts, which ideally is at the previous penetration point of the base fabric. Thus, a unique fabric may be produced as illustrated in FIG. 12 with a pile loop L 3 at the intersection of each loop L 1 and a pile loop L 4 may be produced at the intersection of each pair of loops L 2 .
Numerous alterations of the structure herein disclosed will suggest themselves to those skilled in the art. However, it is to be understood that the present disclosure relates to the preferred embodiment of the invention which is for purposes of illustration only and not to be construed as a limitation of the invention. All such modifications which do not depart from the spirit of the invention are intended to be included within the scope of the appended claims. | Two tufted pile fabrics have pile tufts disposed on the base fabric in the form of rows of chains, with the chains in adjacent rows offset, one of the fabrics including loop pile that extend from between the chains. A tufting machine and method for producing the fabrics includes two staggered rows of needles with each needle cooperating with a primary looper and a transfer looper. The primary looper points in the direction of fabric feed while the transfer looper points in the opposite direction and has a bill above the bill of the primary looper and overlying a portion of it, the bill of the transfer looper being in a plane offset from its shank. The loopers rock oppositely to each other and when the primary looper sheds each loop it is seized and held by the transfer looper and entered by the needle as it descends to the primary looper. The transfer looper thereafter releases the loop which is concatenated about the succeeding loop. Another set of needles and loop pile loopers downstream from the first set produce the loop pile in the chain loops. | 3 |
FIELD OF THE INVENTION
This invention relates to a panelled ceiling of the type in which a plurality of elongated ceiling supports are arranged in spaced parallel relationship and a plurality of rectangular, usually elongated, ceiling panels are secured thereto by means of holding elements or holders. In one embodiment of such ceilings, each of the panels has its peripheral edges bent upwards towards the supports with two opposite up-turned edges having flanges, one of which is bent inward of the panel and the other of which is bent outwardly thereof.
While, commonly, these panels are relatively long with respect to their width, they can also be quite wide and even have a square shape suggestive of coffers.
In many previous such systems for ceilings, the holding elements or holders are secured to the support or the panels, or both, by means of separate attaching elements, such as rivets, screws or bolts. In other such ceilings, the holders are designed to eliminate the need for such separate fastening elements but, in these instances, the holders are frequently complex in shape or include springable elements which make the holders difficult and time-consuming to install; one such holder is shown in U.S. Pat. No. 3,640,033.
BRIEF SUMMARY OF THE INVENTION
Accordingly, it is one object of the invention to provide a simple holder which may be readily formed on conventional machinery and which may be assembled to the support and to the panel in a convenient manner without tools. To this end, a holder is provided that may be formed out of sheet metal by cutting, punching out or bending, thus making the manufacture thereof simple and very inexpensive.
The holder has a generally rectangular base with a pair of up-struck locking tabs which may pass through suitable openings in the ceiling support and then be bent over to secure the holder to the support. The bending over of these tabs may be accomplished with the fingers. From the base, at least one downwardly protruding flange having a holder projection or hook is provided, although preferably two spaced parallel flanges each having such a hook is used. Also extending downwardly from the base are a pair of spaced prongs. Each of the panels has a pair of support flanges along two opposite edges thereof, one member of the pair being bent inwardly of the panel and the other outwardly. When a plurality of panels are assembled, the inwardly-turned flange of one panel is first engaged over the hooks of the holder and then the outwardly extending flange of a second panel is engaged over the inwardly-turned flange of the adjacent panel, whereby the hooks support both flanges. Each panel has its other marginal edges bent upwardly and, when in place, one marginal edge of each of two adjacent panels is engaged with the prongs of the holder by insertion in the space between the prongs. In the first preferred embodiment of the invention, the downwardly extending flanges having the terminal hooks are positioned along opposite side edges of the base of the hanger while the downwardly extending prongs extend downwardly from the base of the hanger along an edge thereof running transverse to the downwardly projecting flanges.
In one modified embodiment, the downwardly extending flanges having the hooks are one integral flange with the hooks spaced apart at the edge thereof and with the downwardly extending prongs extending downwardly from the same integral flange from a position between the hooks.
The holders may be used to support as many as four adjacent panels where one corner of each is positioned close to a corner of each of the other three panels. The termini of the prongs are curved upwardly to facilitate the assembly or removal of ceiling panels. This is of particular advantage whenever mats of insulating material or the like are placed on the upper sides of the panels; in which event, the prongs have their rounded termini bearing against the mats.
The space between each pair of prongs is chosen to correspond to the desired distance between adjacent ceiling panels, i.e. the distance between the upwardly bent marginal edges of two adjacent ceiling panels.
While normally the holders are used without any attachments, they may be further attached to either one or both of the ceiling supports and the panel flanges, particularly when the panels are used outdoors where they are subject to being impinged upon by wind, which may cause lifting or rattling of the panels. Such further securement being accomplished by rivets, screws, bolts, or the like. Still further, spacers may be located as indicated hereinafter to further prevent rattling or inadvertent dislodgement.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows an illustrative embodiment of a holder in accordance with the present invention in perspective view;
FIG. 2 shows a cross-sectional view through a suspended ceiling, generally along the line 2--2 of FIG. 3;
FIG. 3 is a cross-sectional view taken at right angles to FIG. 2, generally along the line 3--3 of FIG. 2;
FIG. 4 is a view taken generally along the line 4--4 of FIG. 2, which is a top planar view (without the ceiling support) and showing how a series of panels are secured by the holders;
FIG. 5 is a view similar to FIG. 3 showing the use of the holder intermediate the ends of the panel support flanges; and
FIG. 6 is a perspective view of a second embodiment of the holder element.
DETAILED DESCRIPTION OF THE INVENTION
As shown in FIGS. 2 and 3, the suspended ceiling includes a panel holder 10 which secures a plurality of panels 12 to the overhead support 14 which, as shown in FIG. 3, has a generally hat-shape in cross-section. The support 14 is supported from a permanent overhead structure, such as a concrete ceiling-floor between floors of a building by any known means, including the wire 16 shown.
As shown in FIG. 1, the holder 10 includes a generally rectangular base 18. Punched out and bent upwardly from the base 18 are a pair of securing lugs 20 which, adjacent their juncture with the base 18, have been slightly weakened by the fact that their cross-section is reduced at 22. This permits of ready bending of the same, as later described. Depending downwardly from each side of the base are a pair of flanges 24 which terminate in hooks 26. Also bent downwardly from the base 18 is a third flange 28 from which two projections extend still further downwardly in spaced relationship thereby defining an opening 32 between them. Each of the projections 30 terminates in a rounded portion 34.
As shown in FIGS. 2, 3 and 4, the supports 10 are elongated and arranged in spaced parallel relationship to each other. Each support 14 includes flanges 36 throughout the length thereof. Flanges 36 extend outwardly in opposite directions from each of the side walls 38 of the support 14. At selected intervals along each of the flanges 36, there are a plurality of slots or openings 40 for receipt of the lugs 20. It will be appreciated that the openings 40 are in pairs with opening in one flange 36 having a mating opening 40 in the other flange 36. As shown, the holder 10 is first applied to the support 14 by inserting the lugs 20 through the openings 40, at which time they are in dashed line positions shown in FIGS. 2 and 3. Thereafter, they are simply bent downwardly in the direction indicated by the arrows 42 until they assume the solid line position shown. In this position, the lugs 20 securely lock the holder 10 to the support 14. This bending over may usually be accomplished by using the fingers, although it may be aided with the use of a hammer or the like.
The ceiling panels 12 to be suspended from the holders 10, as illustrated herein, are generally elongated with two opposite relatively short edges and two opposite relatively longer edges. However, it will be understood that the relative dimensions of the panel are no way effected by or effect the holder or the features of this invention. The panels 12 can just as well be square. As shown in FIG. 3, each of the longer edges of the panels 12 has an upwardly bent flange 44, which flanges 44 are received in the opening 32 between the projections 30 of the holder 10.
One of the shorter edges of each panel 12 has an upwardly bent flange 46 which terminates in a downwardly curved hook-shape 48, which is engaged over the hook 26 on the flange 24 of the support 10. The opposite short edge of each of the panels 12 (i.e. opposite to the edge having flange 46) has an upwardly bent flange 50 terminating in a laterally extending flange 52 which, in assembled position, rests upon the hook portion 48 of a flange 46 for the next adjacent panel 12 whereby the laterally extending flange 52 is also supported from the hook 26. It will be appreciated that there will be a holder 10 positioned, as shown in FIG. 2, wherever the short edge flange 46 of one panel 12 faces a short edge flange 50 of an adjacent panel 12 as well as a holder 10 at the ends of the last panels in each row adjacent the wall.
As shown in FIG. 4, the elongated supports 14 are arranged in spaced parallel relationship but, in this figure, they are broken away in order to reveal the relationship of the holders 10 to the panels 12. In FIG. 4, portions of six panels 12 are shown, as indicated by the reference numerals 12a, 12b, 12c, 12d, 12e and 12f. There are also two holders 10 shown being separately marked 10a and 10b. The support 10a is so positioned that its projections 30 straddle the flanges 44 of the two adjacent panels 12a, 12c. The panel 12a has the hooked portion 48 of its upwardly extending flange 46 engaged over the hook 26a of the holder 10a. The flange 52 of the panel 12b is also supported by the hook 26a since it rests upon the hook terminus 48 of the flange 46 of the panel 12a. At its other end, the holder 10a has its hook 26b engaged beneath the hook terminus 48 of the flange 46 for the panel 12c and the flange 52 from the panel 12d rests thereupon. At their other ends, the flange 48 for the panel 12c and the flange 52 for the panel 12d are engaged with the hook 26c of the holder 10b. Thus, it will be seen that each holder 10 supports an adjacent corner of each of four panels, with the holder 10a supporting the adjacent corners of the panels 12a, 12b, 12c and 12d and the holder 10b, in like manner, supporting the adjacent corners of the panels 12c, 12d, 12e and 12f.
The flange 28 with its projections 30 serve on the one hand to support and to secure panels or mats of insulating material or the like which may, if desired, be placed within the panels 12. Also, the rounded ends 34 help in guiding the assembly or disassembly of the panels 12 with their flanges 44 positioned within space 32 between the projections 30. Also, the projections 30 serve to maintain the alignment of the flanges 44. If desired, a sealing material or an elastic material 54 may be inserted, as shown in FIG. 3, between the adjacent flanges 44 of adjacent panels 12 in order to cause them to bear firmly against the projections 30 and to avoid rattling.
FIG. 2 also shows a spacer element 56 positioned between the flange 52 and the base 18 of the holder 10. Still further, if desired, the spacer 56 may be held in place by a suitable connecter passing through aligned openings in the flange 36 of carrier 14, base 18 of the holder 10, the spacer 56, and an opening in the flange 52. Such aligned openings are generally indicated at 58 in FIG. 2. The opening in the base 18 is indicated at 60 in FIG. 1, there being three shown, any one of which may be used for the rivet, screw, bolt or other connecter passing through the aligned openings 58. The aligned openings 58, including the openings 60 in the holder, may be provided when the various parts are manufactured or may be provided on the site by drilling the same at that time. In most installations, particularly indoor installations, the spacer 56 is not necessary, although occasionally in large rooms the air currents may be such as to cause rattling which can be eliminated by the use of the spacer 56 with or without a connecter passing therethrough. Such rattling may also sometimes be caused in small air-tight rooms upon the sudden opening or closing of a door. When installed out-of-doors, such as on the ceiling of entry ways, overhangs, and the like, it is generally preferred to use some sort of spacer 56 with a connector since such a ceiling is subject to strong gusts of wind.
In FIG. 5, the holder 10 is shown with both of its projections 26 engaged beneath the same bent-over terminus 48 of the same flange 46 and with a single flange 52 of an adjacent panel resting thereupon. That is to say, that this figure shows the holder 10 positioned intermediate the ends of the short edges of a pair of adjacent panels 12. Such positioning will be necessary when the short edge of the panel is relatively long with large panels, in which case there may be a number of holders 10 for each panel 12, for example, intermediate the holders 10a and 10b of the panel 12c.
MODIFIED EMBODIMENT
FIG. 6 shows a modified embodiment 70 of the holder 10 having a rectangular base 72 with cut-out and upwardly bent lugs 74 similar to the lugs 20 of FIG. 1. In this embodiment, a downwardly bent flange 76 has at its opposite ends upwardly curved hook-like members 78 which serve essentially the same purpose as hooks 26 of the holder 10. Intermediate the hooks 78 and also extending from the flange 76 are a pair of projections 80, each terminating in an upwardly curved rounded portion 82. The projections 80 and the space 84 between them serve essentially the same functions as those served by the projections 30 and the space 32 in the first embodiment of the holder 10 shown in FIG. 1. | A suspended ceiling is disclosed having a plurality of spaced parallel elongated supports (14) suspended from permanent overhead structure. A plurality of panels (12) provide the ceiling face and are supported from the elongated supports (14) by means of holders (10). The holders (10) themselves are secured to the supports (14) by bent over lugs (20) passing through openings (40) in the support (14). Opposite edges of each panel (12) have support flanges (46,50) complementary to each other with one flange (46) being bent inwardly and downwardly (48) with respect to the panel (12) and the other flange (50) having a support portion (52) extending outwardly of the panel. The holders (10) have hook-like elements (26) which engage the inwardly and downwardly bent flanges (48) with the outwardly extending flanges (52) resting on top thereof. A pair of spaced downwardly extending projections (30) are provided which serve to engage in the space (32) therebetween upwardly bent side flanges (44) of adjacent panels (12). | 4 |
This is a continuation of application Ser. No. 07/788,157, filed Nov. 6, 1991, now abandoned, which is a continuation-in-part of application Ser. No. 07/715,722, filed Jun. 14, 1991, now abandoned, which is a continuation of application Ser. No. 07/377,062, filed on Jul. 10, 1989, now abandoned, which is a continuation-in-part of application Ser. No. 07/344,213, filed Apr. 27, 1989 now abandoned.
BACKGROUND OF THE INVENTION
This invention relates to methods and compositions for deactivating HIV (human immunodeficiency virus) infected blood and anticancer drugs which may have been accidentally spilled or which have leaked from a patient, thus constituting a possible hazard to attending personnel. In addition, some anticancer drugs are inherently colored and such leakages or spills may stain clothes. The invention is effective to eliminate such stains by decolorizing the drug.
Among the known antineoplastic or anticancer drugs which are used for treating cancers of various types, some are known or suspected to be in themselves carcinogenic. In addition, some of these anticancer drugs are also dyes capable of creating unsightly stains on clothes and other fabrics such as bedsheets. Accordingly, when solutions of anticancer drugs are spilled or leaked, a possible hazard to attending personnel, as well as an unsightly stain on clothing and the like, may be created.
BRIEF DESCRIPTION OF THE INVENTION
In accordance with the invention, spills or leaks of HIV infected blood and/or anticancer drugs are chemically deactivated by applying to the leak or spill an aqueous solution containing sodium or calcium hypochlorite as the active ingredient. In one embodiment, in order to thicken the aqueous solution and thus keep it from spreading beyond its intended area of application, the hypochlorite solution contains methylcellulose. In addition to chemically deactivating the active anticancer drug, the composition of the invention also effectively decolorizes it, thus preventing permanent stains on any surface or fabric with which the anticancer drug comes into contact.
In a second embodiment of the present invention, spills or leaks of HIV infected blood and/or anticancer drugs on stainless steel or ceramic work surfaces vulnerable to etching by the corrosive alkaline sodium or calcium hypochlorite solutions are inactivated with a two-step, towelette swabbing kit and process. A first absorbent, fibrous (preferably cotton and/or synthetic blend) towelette, impregnated with calcium hypochlorite or, preferably, sodium hypochlorite, is swabbed over the spilled HIV infected blood- or drug-containing work surface to deactivate the spilled compound. A second absorbent, fibrous (preferably cotton and/or synthetic blend) towelette, impregnated with sodium thiosulfate, is then swabbed over the spilled HIV infected blood- or drug-containing work surface to neutralize the alkaline calcium or sodium hypochlorite residue from the first towelette, so as to prevent the alkaline residue from corroding or etching the work surface.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
In accordance with the invention, HIV infected blood, or any of a number of active anticancer drugs, can be inactivated by applying thereto an aqueous solution containing 4-40% by weight of calcium or sodium hypochlorite. HIV infected blood, as well as any anticancer agent which can undergo oxidative or alkaline degradation can be deactivated in accordance with the method of the invention. Among the anticancer agents which can be effectively deactivated are the following:
anthracyclines, such as doxorubicin, daunorubicin, and epirubicin
anthracenes, such as mitoxantrone and bisantrene
alkylating agents, such as mitomycin-C, melphalan, cyclophosphamide, ifosphamide, thio-TEPA, decarbazine, carmustine, cisplatin, and carboplatin
antimetabolites, such as fluorouracil, cytarabine, methotrexate, and mercaptopurine
biologicals, such as α-interferon, interleukin 2, tumor necrosis factor, G-CSE, and GM-CSF
miscellaneous compounds, such as vincristine, vinblastins, actinomycin D, bleomycin, etoposide, L-asparaginase, mAMSA, vindesine, and teniposide
In addition to chemically deactivating the anti-cancer drugs, the method of the invention is also effective to decolorize those, e.g., the anthracyclines, doxorubicin and daunorubicin, which are naturally red in color, and the alkylating agent mitomycin C, which is naturally purple in color, which stain fabrics which they contact. The method of the invention renders the naturally colored anticancer drugs colorless, thus preventing permanent damage to clothes or other materials which come in contact with the drugs. It has been found that deactivation and colorization of the anticancer drug occur within approximately 30-60 seconds after a suitable solution of hypochlorite is applied in accordance with the invention.
The hypochlorite solution can be applied in any convenient manner, suitably by means of a manually operated spray bottle or other mechanical spray device. It is also within the contemplation of the invention to use, in addition to such mechanical devices, an aerosol dispenser activated by a conventional aerosol propellant.
If the HIV infected blood and/or the drugs are spilled on a ceramic or stainless steel work surface, which surfaces may be vulnerable to permanent etching or disfiguration by the alkaline deactivator compounds calcium hypochlorite and sodium hypochlorite, it is preferred to use a two step, towelette swabbing kit and procedure to deactivate the spilled material. A first absorbent, fibrous (preferably cotton and/or synthetic blend) towelette is impregnated with an aqueous solution containing 4-40%, but preferably less than 6%, of a deactivator compound such as calcium hypochlorite or, preferably, sodium hypochlorite by applying to the first towelette an excess of aqueous deactivator solution, beyond that amount necessary to completely saturate the first towelette. The ratio of deactivator volume to towelette weight should be in the range of about 1.8 to 15 ml deactivator per gram towelette (preferably 6.5 to 15 ml/gm); alternatively, the ratio of deactivator volume to towelette surface area should be in the range of about 0.01 to 0.2 ml deactivator per cm 2 of towelette. The deactivator-impregnated towelette is wiped or swabbed over the spilled HIV infected blood- or drug-containing work surface to deactivate the spilled compound; if the spilled compound is a drug which creates a stain, deactivation is indicated by disappearance of the stain after swabbing.
A second absorbent, fibrous (preferably cotton and/or synthetic blend) towelette, impregnated with an aqueous solution of 4-40%, but preferably less than 6%, of sodium thiosulfate, by applying to the second towelette an excess of the aqueous sodium thiosulfate solution, beyond that amount necessary to completely saturate the second towelette. The ratio of sodium thiosulfate volume to towelette weight should be in the range of about 1.8 to 15 ml deactivator per gram towelette (preferably 6.5 to 15 ml/gm); alternatively, the ratio of sodium thiosulfate volume to towelette surface area should be in the range of about 0.01 to 0.2 ml deactivator per cm 2 of towelette. The sodium thiosulfate-impregnated towelette is then wiped or swabbed over the spilled HIV infected blood- or drug-containing work surface to neutralize the alkaline calcium or sodium hypochlorite residue from the first towelette, so as to prevent the alkaline residue from corroding or etching the work surface. Furthermore, sodium thiosulfate itself is capable of deactivating several carcinogenic anticancer drugs, such as the alkylating agents nitrogen mustard and cisplatin.
Suitable towelettes include "Terri R Wipers", nylon-reinforced 4 ply, #34770, each measuring 17×23 cm and weighing approximately 2.6 gram, manufactured by Kimberly Clark, Neenah, Wis., in addition to the the following "Texwipe R " towelettes, manufactured by Texwipe Corporation, Upper Saddle River, N.J.: Technicon A, Absorbanal Applicators, and TX801 Applicators.
The compatability of the various "Texwipe R " towelettes with sodium hypochlorite was tested using this following procedure. Strips of the different Texwipe R fabrics were cut into 1×1 inch squares and weighed. The fabric strips were then placed in 15 ml plastic vials. 5 ml of an aqueous solution containing 5.25% by weight of sodium hypochlorite was added to each vial. The vials were capped and incubated at room temperature for 10 days. The strips were then removed from the vials, air dried, and weighed. To test the deactivation ability of the sodium hypochlorite solution remaining in each vial, 0.1 ml of a solution containing 1.0 mg/ml of the drug doxorubicin was applied to each of several "Terri R Wipers", nylon-reinforced 4 ply, #34770, each measuring 17×23 cm and weighing approximately 2.6 gram, manufactured by Kimberly Clark, Neenah, Wis. 0.1 ml samples of the sodium hypochlorite solution remaining in each vial were then added to a respective doxorubicin-containing Terri R Wiper. Deactivation was inferred by a color change from red to colorless.
The results of the "Texwipe R " tests are summarized in table A. Of the four "Texwipe R " towelettes tested, Technicon A yielded the best results, although the bleach was completely inactivated by the Technicon fabric after seven weeks. Two of the towelettes (Absorbanal Applicators and TX801 Applicators) exhibited significant weight gain after storage in the bleach, indicating possible covalent bonding of the hypochlorite directly to the fabric. The results for those three towelettes suggest that it may be preferable to add excess solution to the towelettes to assure adequate deactivating activity after storage. A fourth "Texwipe R " towelette (TX811) was completely dissolved by the bleach, and is thus not suitable for this application. Preferably, the sodium hypochlorite and sodium thiosulfate impregnated towelettes are prepared in advance and stored in separate sealed foil packages or the like until use.
TABLE A__________________________________________________________________________TEXWIPE SAMPLE TESTS: Compatibility With Sodium Hypochlorite Activity with Weights respect to Dry % DifferenceSample * No. (g) Quality Appearance Doxorubicin Weight In Weight__________________________________________________________________________Technicon 1) .0674 Paper-like texture; Clear Inactive .0619 +8A 2) .0462 Tears easily solution .0472 +2 3) .0501 .0460 -9/2 Average +0.6Absorbanal Applicator 1) .420 Thick, soft; Tears Yellow Highly active .1025 +144D 2) .511 with difficulty solution .1238 +142 3) .554 .1234 +123 Average +118TX811 Applicator 1) .0266 Paper-like quality; Clear Slowly active; NoneD 2) .0966 very thin solution Incomplete Available inactivation; 3) .0286 No wipes leftTX801 Applicator 1) .1128 Soft-life but sturdy Yellow Highly active .1901 +88D 2) .0966 solution .1582 +64 3) .1031 .1733 +68 Average +67__________________________________________________________________________ Bleach: National Sanitary Supply 5.25% w/v Sodium Hypochlorite * All white cloth, single thickness; Approximate sample size 1 × 1 inch.
It has also been determined that HIV infected blood and most anticancer drugs can be deactivated by application of a solution of calcium or sodium hypochlorite in water at a concentration of 4% by weight. A few of the anticancer drugs, notably mitoxantrone, may require the use of a solution having a substantially higher concentration of hypochlorite, up to 40% by weight, in order to achieve substantially complete deactivation of the anticancer drug.
In order to maintain the hypochlorite solution in contact with the drug, and to avoid displacement, it is desirable to increase the viscosity of the solution of hypochlorite. It has been found, however, that conventional thickeners tend to deactivate the solution of hypochlorite at different rates. Thus, gelatin causes an immediate violent endothermic reaction when added to a solution of calcium hypochlorite, while polyvinylpyrolidine and polyethylene glycol cause deactivation of the hypochlorite solution within one hour. Methyl cellulose deactivates the hypochlorite, but at relatively slow rates so that hypochlorite-methylcellulose solutions maintain a practical degree of effectiveness for a reasonable time (e.g., 8 hours) after mixing.
In addition to deactivating of the hypochlorite, addition of a thickener to a solution of hypochlorite causes an interaction between the hypochlorite and the thickener which reduces the ability of the thickener to increase the viscosity of the solution. Thus, for example, the viscosity of a typical solution of calcium hypochlorite and methylcellulose drops by more than two-thirds after a period of three days.
While the deactivating ability of the hypochlorite and the thickening ability of the thickeners decrease most rapidly in aqueous solution, similar effects occur when mixtures of the dry powders are stored. It has been found that mixtures of calcium hypochlorite and methylcellulose powders stored in a dry condition lose a significant proportion of deactivating ability within 5 days and became almost completely inactive after 30 days at room temperatures, such that complete inactivation can occur after 10 days at 50° C.
From the above, it is apparent that mixtures of hypochlorite and thickener, whether in solution or in dry form, have very limited shelf lives. The solutions of the invention should be prepared fresh immediately before use and should not be stored for any extended periods of time. Accordingly, the invention is suitably prepared and utilized as a two-package system including a first package containing an appropriate quantity of the hypochlorite, and a second package containing an appropriate quantity of the thickener, the contents of the packages to be dissolved in a predetermined volume of water immediately before use. In order to maintain the appropriate concentrations of hypochlorite and thickener in the finished solution, i.e., 4-40% by weight of hypochlorite and 1-5% by weight of thickener, the proportion by weight of hypochlorite in the first package to the weight of thickener in the second package is in the range of 1:1 to 40:1, and preferably 1.2:1 to 2.0:1.
Methylcellulose maintains its ability to thicken the deactivating solutions of the invention for relatively long periods of time with a relatively small effect on the deactivating ability of the hypochlorite. Accordingly, methylcellulose is the preferred thickener for use in the invention. Other common thickeners, such as agar, polyvinylpyrolidine, polyethylene glycol, and gelatin, either react violently when mixed with the hypochlorite or produce solutions having too short an effective life (minutes to hours) for practical use.
The effectiveness of the method and composition of the invention are demonstrated in the following examples.
EXAMPLE 1
Mutagenic Activity
Solutions of DNA intercalators (doxorubicin, daunorubicin and mitoxantrone) in concentrations of 10 ng/ml D5W were applied in 5 ml quantities to separate petri dishes. Two different concentrations of calcium hypochlorite, 40 g/l and 423 g/l, were applied in 1 ml. volumes separately to the anticancer drug solutions in each petri dish for a period of one minute. After thorough mixing and neutralization of the pH to 7.4 using HCl, 1 ml of each petri dish solution was applied to 35 mm petri dishes containing cultures of Salmonella Typhimurium TA 98 strain. The petri dishes containing bacteria plus overlaid mixtures of calcium hypochlorite/anticancer drug and control plates with bacteria alone were then incubated at 37° C. for 24 hours. The colonies of revertant organisms were counted and reported in Table 1.
TABLE 1______________________________________Mutagenic Activity from DNA Intercalators Treatedwith Calcium Hypochlorite No. Colonies of Revertant OrganismsDNA Intercalator Calcium Hypochlorite Concentration(10 ng/ml None 40 g/l 423 g/l______________________________________Doxorubicin 257 0 0Daunorubicin 365 0 0Mitoxantrone 164 44 0None (control) 20 0 0______________________________________
Table 1 reports the number of colonies of revertant (mutated) bacterial organisms resulting from calcium hypochlorite treatment at two different concentrations of three different anticancer drugs. The control bacterial plates (i.e., untreated with anticancer drug or calcium hypochlorite) contained only 20 bacterial colonies after 24 hours. On the other hand, the bacterial plates treated with the anticancer drug in the absence of calcium hypochlorite contained between 164 and 365 bacterial colonies per plate. At the higher concentration of calcium hypochlorite there were no colonies of revertant organisms in the bacterial plates and at the lower concentration of calcium hypochlorite only mitoxantrone was associated with bacterial revertant growth.
EXAMPLE 2
Anthracene or Anthracycline Chromophore Recovery by High Performance Liquid Chromatography
Treatment of the drugs with calcium hypochlorite was carried out as described in Example 1. One ml aliquots of doxorubicin, daunorubicin and mitoxantrone, separately, were taken from the petri dishes after calcium hypochlorite exposure at two different concentrations for a period of one minute. Ten (10) ng of each of the anticancer drug (based on the final concentration resulting from the addition of calcium hypochlorite to the separate petri dishes containing each anticancer agent) was added to a high performance liquid chromatography column and standard HPLC assays were carried out. A reverse phase C-18 bonded phase HPLC procedure was used. The mobile phase consisted of 30:70 CH 3 CN:ammonium acetate at a flow rate of 2 ml/min., using a Varian model 5020 HPLC unit. The anticancer drugs were detected using excitation at 480 nm and emission at 550 nm with a Schoeffel model FS 970 fluoroescence detector. At the higher concentration of calcium hypochlorite (423 g/l) the treatment resulted in complete chemical degradation of all three anticancer drugs. At the lower concentration, there was no chemical evidence of either doxorubicin or daunorubicin and approximately 60% degradation of mitoxantrone.
TABLE II______________________________________Anthracene or Anthracycline Chromophore Recoveryby High Performance Liquid Chromatography Concentration ng by Fluroescence*DNA Intercalator Calcium Hypochlorite Concentration(10 ng on Column) 0-(Control) 40 g/l 423 g/l______________________________________Doxorubicin 9.7 0 0Daunoxnycin 9.8 0 0Mitoxantrone 10.1 3.8 0______________________________________ *Reverse phase C18 bonded phase, mobile phase of 30:70 CH.sub.3 CN:ammonium acetate, flow rate 2 ml/min, (Varian Model 5020); detection using excitation at 480 nm and emission at 550 nm (Schoeffel Model FS 970
EXAMPLE 3
Compatibility of Hypochlorite and Methylcellulose in Aqueous Solution
The compatibility of calcium hypochlorite with methylcellulose in aqueous solution was investigated in a series of tests. Freshly made solutions containing 4% by weight of calcium hypochlorite and 2.5% by weight of methylcellulose were examined for viscosity, pH, and ability to deactivate anticancer drugs. Measurements of pH were made by a commercial pH meter while viscosity was measured by an instrument using the falling ball method. The ability to inactivate anticancer drugs was evaluated by titration of stock solutions of doxorubicin (2 mg/ml) and mitoxantrone (2 mg/ml). The tests were performed by titrating the inactivating solution onto absorbent paper containing measured amounts of each anticancer agent. The end point was the number of drops of inactivating solution required for complete neutralization of the red color of doxorubicin or the blue color of mitoxantrone.
The viscosity, pH, and neutralizing ability of the solutions were measured at intervals over a period of three to four days. The freshly made mixture had an initial viscosity of 32 cps, a pH of 11.0, and an assigned value of 100% inactivating activity. These values changed rapidly after the solution was prepared. The viscosity dropped by almost 40% in the first 12 hours, and by 68% within 72 hours, the pH value dropped to 7.0 in one day, and the inactivating activity dropped to 50% within a period of 12-48 hours, depending on how thoroughly the solid ingredients were dissolved in the mixture. Those compositions in which the components were not thoroughly dissolved retained inactivating activity for longer periods of time. By contrast, solutions in which the hypochlorite and methylcellulose were thoroughly dissolved became more inactive at a faster rate. In general, a loss of 10-20% of activity occurred within 8 hours after the aqueous solution was prepared. Accordingly, provided the solution was used within 8 hours of preparation, most of the inactivating ability of the solution was retained.
EXAMPLE 4
Stability of Dry Mixtures of Calcium Hypochlorite and Methylcellulose
The stability of mixtures of calcium hypochlorite and methylcellulose in dry form was tested by preparing individual mixtures of 4 grams of calcium hypochlorite and 2.5 grams of methylcellulose, and storing the mixtures in plastic bottles at room temperature (25° C.) and at elevated temperature (50° C.). At various times, water was added to the mixture of dry ingredients in an amount sufficient to produce 100 ml. of a solution containing 4 grams of calcium hypochlorite and 2.5 grams of methylcellulose. the solution was examined for pH, viscosity, and inactivating activity as described above. The results are given in Table III.
TABLE III______________________________________Stability of Calcium Hypochloriteand Methylcellulose Powders Properties of Solution**Days of Tempera- Viscosity InactivatingStorage ture (°C.) pH (cps) Activity*______________________________________1 25 11 30 1005 25 10.5 28 857 25 10 27 7110 25 8.5 18 6014 25 7.0 5.7 4521 25 6.4 4 2030 25 6.1 2.5 81 50 11 30 975 50 9 12 407 50 7.5 3 1010 50 6.0 1 0______________________________________ *Determined by titration to color neutralilty for stock solutions of doxorubicin and mitoxantrone (1 mg/ml each). Results standardized to initial activity. **100 ml of solution containing 4 g of calcium hypochlorite and 2.5 g of methylcellulose.
The data of Table III show that significant activity was lost after only five days of storage of the dry ingredients and that the mixture had become almost completely inactive after storage for 30 days at room temperature or 10 days at 50° C. It is apparent, therefore, that even when mixed as dry powders, the active ingredients of the mixture inactivate each other in a manner which is dependent on time and temperature.
EXAMPLE 5
Stability of Mixtures of Hypochlorite and Other Thickeners in Aqueous Solution
In addition to methylcellulose, four common viscosity enhancing agents were tested for suitability for increasing the viscosity of hypochlorite solutions. The results of these tests are reported in Table IV. It will be seen that, except for methlycellulose, the other thickeners were unsuitable for use in calcium hypochlorite solutions either because they became quickly deactivated (polyvinylpyrolidine and polyethylene glycol) or caused a violent reaction (agar, gelatin). Agar reacted violently and caused the solutions to thicken to a gel.
TABLE IV__________________________________________________________________________Tests of Pharmaceutical Thickeners in CalciumHypochlorite Solutions (4 g Ca(OCl).sub.2 per 100 mL) Time to Loss of Viscosity Inactivating AbilityStiffening Agent g/100 mL (cps)* Mitoxantrone Doxorubicin__________________________________________________________________________Polyvinylpyrolidine 14 17.8 30 min. 1 hr.40,000 Molecular WeightPolyethylene Glycol Mixture 3,350 Ave. Molec. Wt. 30 18 30 min. 1 hr. 400 Ave. Molec. Wt. 30Agar**(Vigorous exothermic 2.5 Too thick to 24 hr. 24 hr.reaction upon mixing, evaluateforming a gel) 5.0 Too thick to 48 hr. 48 hr. evaluate 10.0 Too thick to -- -- evaluateGelatin 1 Impossible to evaluate due to an 2.5 immediate violent endothermic 10 reaction.__________________________________________________________________________ *Measured immediately after mixing using the falling ball method. **The exothermic reaction precludes the use of agar in clinical settings because of potential explosive properties.
EXAMPLE 6
HIV Inactivation by Dilute Calcium Hypochlorite
The ability of dilute calcium hypochlorite to inactivate HIV was tested against an HIV-infected CD4+ human cell line (H9/IIIB). A saturated solution of dilute calcium hypochlorite completely inactivated infected human T-lymphocytes.
Procedure:
H9/IIIB cells (106 cells/ml of complete culture medium, RPMI in 10% fetal calf serum FCS!) were exposed to an aqueous solution containing 4% by weight of calcium hypochlorite for 15 minutes; the volumetric ratio of culture medium to calcium hypochlorite solution was 1:1, or a 50% dilution of a 4% dilute calcium hypochlorite solution in culture medium containing 10% serum. The cells were subsequently washed three times with 10% FCS RPMI and plated in fresh medium and allowed to incubate at 37° C. for three days, to allow any residual live virus and/or virus-infected cells to develop after the brief exposure to the dilute calcium hypochlorite solution. The cells were again pelleted and exposed to lytic CD4+ human cell line (MOT) as a target for any viable virus. The target MOT cells will lyse when infected with HIV. These cells were then allowed to incubate an additional four days. Next, the cells were incubated with human anti-HIV antibody (prepared in accordance the the procedures described in Lake D A, Sugano T, Matsumoto Y, et al: "A Hybridoma Producing Monoclonal Antibody Specific for Glycoprotein 120 kDa of Human Immunodeficiency Virus (HIV-1), Life Sciences 45:iii-x, 1989.) for one hour, and then washed and incubated with fluorescent labeled goat anti-human IgG for one hour. The method for HIV detection by formaldehyde fixation and flow cytometry was in accordance with the method described in Lifson J D, Sasaki D T, Engleman E G: "Utility of Formaldehyde Fixation for Flow Cytometry and Inactivation of the AIDS Associated Retrovirus", J Immunological Methods 86:143-149, 1986.
Controls:
As a positive control, the above procedure was followed with HIV-infected H9/IIIB cells exposed only to culture medium rather than to culture medium and calcium hypochlorite. As a negative control, the above procedure was followed with uninfected H9 cells exposed to an aqueous solution containing 4% by weight of calcium hypochlorite.
Results:
After a four day incubation period, the HIV positive control cultures exhibited large concentrations of swollen, HIV-infected MOT cells. The calcium hypochlorite solution (n=4 each) completely lysed non-infected as well as HIV infected MOT cells, and there were no viable HIV varions present.
HIV infected cells exposed to dilute calcium hypochlorite were also viewed under a fluorescent microscope following exposure to the fluorescent anti-HIV antibody. They showed no signs of HIV infection and were identical to the negative control.
Conclusion:
Dilute calcium hypochlorite completely inactivates human immunodeficiency virus when added to infected cell cultures in a 1:1 volumetric ratio. The cells are completely lysed by dilute calcium hypochlorite and no HIV antibody binding is detectable using a goat antibody specific to the 120 kDa viral glycoprotein.
EXAMPLE 7
HIV Inactivation by Dilute Calcium Hypochlorite Containing a Thickener
The materials and methods of Example 6 were repeated, except that the aqueous bleach solution applied to the infected and uninfected H9 cells included 2.5% by weight of the thickener methlycellulose in addition to 4% by weight of calcium hypochlorite. The results were the same as those obtained in Example 6. The MOT cells were lysed and the residual material was not infectious; however, the fluorescent entibody technique could not be completed because of the methlycellulose thickening effect.
EXAMPLE 8
Use of Towelette Swabs for Deactivating Anticancer Drug Materials
Experimental Materials
Test Swabs: 17×23 cm nylon-reinforced 4 ply, #34770, each weighing approximately 2.6 gram Terri R Wipers, manufactured by Kimberly Clark, Neenah, Wis.
Bleach: 5.25% by weight aqueous solution of household bleach, i.e., sodium hypochlorite (NaHC10 4 ), supplied by National Sanitary Supply, Los Angeles, Calif., having a pH of approximately 11.2.
Sodium thiosulfate: 5% by weight aqueous solution, supplied by Tarijian Labs, Inc., Queens Village, N.Y.
Doxorubicin: 1 mg/ml aqueous solution, supplied by Adria Labs, Columbus, Ohio.
Experimental Procedure
0.1 ml of the doxorubicin solution (1 mg/ml) was applied onto a fresh, dry towelette. The doxorubicin solution caused a red colored stain to appear on the surface of the towelette. One drop of the household bleach solution was then squeezed onto the red stained, doxorubicin contaminated towelette surface. Within 10-15 seconds the red color disappeared, indicating that the bleach solution had chemically inactivated the doxorubicin. The pH of the bleach solution on the surface of the towelette was found to be 11.2, as determined by a pH meter.
In a glass container, 10 ml of the 5% sodium thiosulfate solution was added to 10 ml of the 5.25% bleach solution; a slight exothermic reaction resulted from the addition of the sodium thiosulfate to the bleach solution. Between 10-20 drops of the resulting mixture was then added to a second doxorubicin stain on a towelette. The red doxorubicin stain remained on the towelette, indicating that the sodium thiosulfate neutralized the bleach solution so that the bleach could no longer inactivate the doxorubicin on the towelette. A pH meter was again used to determine the pH (1.3) of the combined sodium thiosulfate-bleach mixture on the surface of the towelette.
These results indicate that household bleach used in low volume can cause the chemical inactivation of doxorubicin droplet contamination on a paper towelette. Mixing together equal volumes of the 5% sodium thiosulfate solution and the 5.25% household bleach solution results in a mixture incapable of decolorizing the doxorubicin contamination on the dry towelette, indicating that the sodium thiosulfate neutralized the oxidizing action of the household bleach. The pH of the combination sodium thiosulfate/household bleach solution was 1.3.
Sodium thiosulfate increases the carcinogen inactivating capacity of the sodium hypochlorite solution due to the thiosulfate's ability to bind chemically to various alkylating type molecules such as nitrogen mustard and cisplatin. Furthermore, the addition of sodium thiosulfate to the sodium hypochlorite solution prevents permanent etching of stainless and ceramic surfaces caused by the alkaline sodium hypochlorite solution.
Various combinations and pHs of acid alcohol (a mixture of absolute ethanol and 0.1N hydrochloric acid), mixed with sodium hypochlorite and/or sodium thiosulfate, were evaluated as listed below.
In a series of experiments, between 1-10 ml acid alcohol, having pHs in the range of between 1-3.75, were added to between 5-10 ml household bleach. The acid alcohol was unable to inactivate the household bleach until the ratio of acid alcohol to bleach (having a pH of 1.0) was 2:1; at that high ratio of acid alcohol to bleach, a moderate exothermic reaction as well as noxious fumes occurred.
In another series of experiments, between 2.5-10 ml sodium thiosulfate, 5-10% were added to between 0-9 ml ethanol, together with 10 ml household bleach. The mixture of the three chemicals resulted in moderately severe exothermic reactions and inactivation of bleach's oxidizing activity only when equal ratios of 5% sodium thiosulfate were added to the bleach (in the presence of ethanol), and the resulting pH was below 2.
EXAMPLE 9
Use of Towelette Swabs for Deactivating Work Surfaces Contaminated by An Anticancer Drug Material
The Experimental Materials used are as described above in Example 8. A first fresh, dry test swab or towelette is impregnated with a 5.25% by weight aqueous solution of sodium hypochlorite by applying 5 (five) ml. of the sodium hypochlorite solution to the test swab. A second fresh, dry test swab or towelette is impregnated with a 5% by weight aqueous solution of sodium thiosulfate by applying 5 (five) ml. of the sodium thiosulfate solution to the test swab.
Doxorubicin is placed on a stainless steel work surface, which should cause a red stain to appear. The sodium hypochlorite impregnated towelette is then wiped or swabbed, over the doxorubicin spill, which should cause the red stain to disappear, indicating chemical inactivation of the doxorubicin by the sodium hypochlorite.
The sodium thiosulfate impregnated towelette is then wiped, or swabbed, over the work surface containing the chemically inactivated doxorubicin spill. The sodium thiosulfate should neutralize any residual sodium hypochlorite left on the work surface, thereby preventing the stainless steel surface from being etched by the residual alkaline sodium hypochlorite solution.
EXAMPLE 10
Use of Towelette Swabs for Deactivating Work Surfaces Contaminated by HIV Infected Cells
Experimental Materials
Test Swabs: 17×23 cm nylon-reinforced 4 ply, #34770, each weighing approximately 2.6 gram Terri R Wipers, manufactured by Kimberly Clark, Neenah, Wis.
Bleach: 4% by weight aqueous solution of calcium hypochlorite.
Sodium thiosulfate: 5% by weight aqueous solution, supplied by Tarijian Labs, Inc., Queens Village, N.Y.
HIV Infected Cells: H9/IIIB cells (106 cells/ml of complete culture medium, RPMI in 10% fetal calf serum FCS!), as described above in Example 6.
A first fresh, dry test swab or towelette is impregnated with a 4.0% by weight aqueous solution of calcium hypochlorite by applying 5 (five) ml. of the calcium hypochlorite solution to the test swab. A second fresh, dry test swab or towelette is impregnated with a 5% by weight aqueous solution of sodium thiosulfate by applying 5 (five) ml. of the sodium thiosulfate solution to the test swab.
A small amount of the HIV infected cells are placed on a stainless steel work surface. The sodium hypochlorite impregnated towelette is then wiped or swabbed, over the HIV infected cells, which should inactivate the virus.
The sodium thiosulfate impregnated towelette is then wiped, or swabbed, over the work surface containing the inactivated virus. The sodium thiosulfate should neutralize any residual calcium hypochlorite left on the work surface, thereby preventing the stainless steel surface from being etched by the residual alkaline calcium hypochlorite solution.
The foregoing description has been given for clearness of understanding only, and no unnecessary limitations should be understood therefrom, as modifications will be obvious to those skilled in the art. | Methods, compositions and a kit for deactivating spills or leaks of HIV infected blood or anticancer drugs by applying to the leak or spill an aqueous solution containing calcium hypochlorite or sodium hypochlorite as the active ingredient. In order to thicken the aqueous solution and thus keep it from spreading beyond its intended area of application, the solution of calcium hypochlorite contains methylcellulose. In addition to chemically deactivating the active anticancer drug, the solution of the invention also effectively decolorizes it, thus preventing permanent stains on any surface or fabric with which the anticancer drug comes into contact. | 8 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates in general to computer networks. In particular, the invention relates to a system and method for providing activity schedules, such as itineraries, of public persons over a network. More particularly, the invention relates to a system and method for providing a listing of the times, dates, and venues of scheduled media activities of public persons over a network, such as the Internet.
2. Description of the Related Art
Public persons, especially those which have achieved celebrity status, connote privilege, respect, and adulation from countless numbers of adoring fans throughout the world. However, along with such privilege exists a host of professional obligations which may include, for example, radio, magazine and newspaper interviews, television and public appearances (e.g., book signings, conventions, movie premieres, etc.), and recently, hosting chat room sessions on the world wide web. The general public's ability to track the numerous scheduled (and even non-scheduled) activities of public persons has become a daunting task in a fast-paced media society. A fan often learns to his/her consternation that a scheduled media activity or public event involving one of their favorite public persons has occurred without the fan having been made aware, informed and/or notified. For example, a fan may not have been aware that a favorite celebrity has appeared on a television broadcast or made an appearance at a mall or trade show. This is disconcerting to the fan. The fan could have only learned of the appearance of the public person through happenstance or by calling the public person's publicist; a task which is generally impractical or non-convenient.
Accordingly, there exists a need for a system and method for obtaining and coordinating the multitude of scheduled media activities for the countless number of public persons throughout the world and for providing network users of such information in an effortless, timely, and efficient manner.
SUMMARY OF THE INVENTION
A system and method are disclosed herein for providing timely and efficient scheduled media information of upcoming media activities of public persons to interested individuals over a network, such as the Internet. The present invention allows individuals to request upcoming media activities of public persons via a network and be provided with such information via a search engine having access to at least one media schedule database.
The system of the present invention includes a media schedule database storing scheduled media activities of a plurality of public persons. The media schedule database is preferably a relational database, i.e., the database relates scheduled media activities with respective public persons and vice versa. The system of the present invention further includes a database manager for creating and revising records of the media schedule database. The database manager is preferably a computer system having access to the media schedule database for revising, appending, deleting, etc. data stored within the media schedule database and for adding data within the media schedule database. The database manager also has access to a server of the system of the present invention for automatically receiving media schedule data via a network, such as the Internet. Further, the database manager is capable of directing the server to obtain information which is unavailable within the media schedule database via the Internet. The obtained information is routed to the database manager which is then automatically or manually processed and subsequently stored in the media schedule database.
It is contemplated, for example, that the database query search engine sends a query, e.g., via the server, to at least one network address, e.g., the network address of a celebrity's publicist, requesting updated schedule media activity information regarding one or more celebrities which is not stored within the media schedule database to be transmitted and stored within the media schedule database.
It is further contemplated that a celebrity's publicist or manager is provided with an access code for accessing the media schedule database for providing media activity information regarding one or more celebrities, and for revising, appending, deleting, etc. data stored within the media schedule database pertaining to the celebrity the publicist or manager is representing.
In operation, the database query search engine receives a query from a user, for example, by the user accessing a web site, via wired or wireless means over the Internet, where the web site is maintained or operated by the server of the system. The database query search engine, in response to the query, then searches the media schedule database for information satisfying the received query. The information satisfying the query is then transmitted via the Internet to a user's computer system where the information is displayed to the user. The information satisfying the received query generally contains at least the name of a public person and a venue, for example, a radio station, a book store, or an arena, where the public person is scheduled to appear. Preferably, the media schedule information satisfying the user query includes a listing of media categories where each media category includes one or more scheduled media events concerning the public person provided in the user query. The displayed listing of media categories may include, for example, listings of upcoming television and radio appearances, live appearances, and Internet chat time.
According to one aspect of the present invention, a supplemental media category is also included, where applicable, which lists recent print publications (e.g., books, magazines, etc.) mentioning the public person.
According to another aspect of the present invention, in response to a request for a public person, the displayed information further includes the names of public persons related in some manner to the public person requested in the user query. For example, if the user query requests the media scheduled activities of a specific cast member of a soap opera, then the media scheduled activities of other cast members of the same soap opera would be provided to the user. It is also contemplated for the user to request the media scheduled activities of a group of public persons having a common relationship. For example, the user query can request the media scheduled activities of all individuals affiliated with a specific soap opera, corporation, or sport. As a further example, the query could request the media scheduled activities of the justices of the Supreme Court of the United States.
According to another aspect of the present invention, the user may click on a particular listed media event provided to the user in response to the query, to retrieve, through a hyperlink, further information or even a service directly from a specific media venue's web site or mirror web site. For example, the user may purchase tickets to at least one displayed scheduled media activity by clicking an icon on the display and connecting via the Internet to the media venue's ticketing web site for entering the appropriate information required to purchase the tickets.
According to another aspect of the present invention, the user is notified via e-mail whenever information corresponding to a public person of which the user has an interest in is updated in the media schedule database. The e-mail could include the updated information and/or could include a hyperlink to the web site maintained or operated by the server of the system for viewing the updated information.
Traditional media information resources such as television guide, newspapers, magazines, and radio are too numerous and too dynamic to allow an individual to keep pace with the countless never-ending scheduled media events of public persons throughout the world. The present invention provides a system and method for centralizing, managing and providing schedule media information of public persons to a user in a manner which permits real-time access and timely up-to-date information. The system and method of the present invention enables the user to effectively search and retrieve the scheduled media activities of public persons throughout the world in a timely and efficient manner.
BRIEF DESCRIPTION OF THE DRAWINGS
The foregoing features of the present invention will become more readily apparent and may be understood by referring to the following detailed description, taken in conjunction with the accompanying drawings, where:
FIG. 1 illustrates a system for managing and providing schedule media information of public persons via a network to users in accordance with one embodiment of the present invention;
FIG. 2 illustrates a screen display of a home page of a web site maintained and operated by a server of the inventive system as shown by FIG. 1 ;
FIGS. 3 a - 3 c illustrate data entry screen displays provided by the server of the inventive system for determining a user's service provider(s) and geographic location; and
FIG. 4 is a listing of scheduled media events provided for a specific public person by the server of the inventive system in response to a user query.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The present invention is described in the context of the world wide web. However, the present invention may find application in any networked environment where one or more media schedule databases are accessible to a remote user. In such environments, a schedule information provider having access to at least one database can provide a user with scheduled media events of public persons or scheduled media events to occur in a particular venue, for example, a specific arena or radio station. In the following discussion, the primary context will be the Internet and the world wide web. It is also envisioned for the present invention to find use in providing a user with non-media scheduled events, such as cameo appearances, of public persons or other information.
In the following description for purposes of explanation, specific systems, interconnections, and processing steps are set forth in order to provide a thorough understanding of the present invention. However, it will be appreciated by one skilled in the art that the present invention may be practiced without the specific details disclosed herein.
Glossary of Terms and Acronyms
The following terms and acronyms are used throughout the detailed description:
Hyperlink: A navigational link from one document to another, or from one portion (or component) of a document to another. Typically, a hyperlink is displayed as a highlighted word or phrase that can be selected using a mouse for jumping or linking to the associated document or document portion.
World Wide Web (“Web”): Used herein to refer generally to both (i) a distributed collection of interlinked, user-viewable hypertext documents (commonly referred to as web documents or web pages) that are accessible via the Internet, and (ii) the client and server software components which provide user access to such documents using standardized Internet protocols. The primary standard protocol for allowing applications to locate and acquire web documents is HTTP, and the web pages are encoded using HTML. However, the terms “Web” and “World Wide Web” are intended to encompass markup languages and transport protocols which may be used in place of (or in addition to) HTML and HTTP.
Web Site System: A computer system that provides informational content over a network via a web site using the standard protocols of the World Wide Web. Typically, a web site corresponds to a particular Internet domain name, such as “yahoo.com,” and includes the content associated with a particular organization. As used herein, the term “Web Site System” is generally intended to encompass both (i) the hardware/software server components that provide the informational content over the network, and (ii) the “back end” hardware/software components, including any non-standard or specialized components, such as a database and search engines, that interact with the server components to perform services users accessing the web site.
URL (Uniform Resource Locator): A unique address which fully specifies the location of a file or other resource on the Internet. The general format of a URL is protocol://machine address:port/path/filename. The port specification is optional; if none is entered, the web browser defaults to the standard port for whatever service is specified as the protocol. For example, if HTTP is specified as the protocol, the browser will use the HTTP default port of 80 .
System of the Present Invention
FIG. 1 illustrates a system according to the present invention having web site system hardware 130 connected to a plurality of end user computers 110 via a network 120 , preferably, the Internet. The web site system hardware 130 includes functional components for allowing users to search for scheduled media activities associated with public persons throughout the world via the Internet 120 . Because the number of public persons (e.g., movie stars, celebrities, authors, politicians, athletes, singers, etc.) throughout the world can number in the millions, the web site system hardware 130 is an efficient system for providing users with scheduled media activities of public persons.
Preferably, the web site system hardware 130 is implemented using general purpose computer hardware. The general purpose hardware may advantageously be in the form of a Unix workstation or other suitable computer. The web site system hardware 130 is configured and customized by various software modules. The software modules include communications software of the type conventionally used for Internet communications and a database management system. Any number of commercially available database management systems may be utilized to implement the invention.
Referring to FIG. 1 , the web site system hardware 130 includes a database manager 131 for managing media data stored within a media schedule database 133 . For example, the database manager 131 is capable of finding relationships between the media data and creating look-up tables, such as mapping a particular public person to scheduled media events corresponding to that particular person. Preferably, the media data includes a plurality of records where each record includes at least a name of a public person and a description of at least one scheduled media activity of the public person. The description of the at least one scheduled media activity may include a time of the scheduled media activity, a venue of the scheduled media activity and a media category of the scheduled media activity.
The database manager 131 is preferably a personal computer system having data management software therein. The database manager 131 is also capable of communicating with a server 109 of the web site system hardware 130 for instructing the server to retrieve media schedule information concerning public persons via the Internet 120 , either through a wired connection or a wireless connection.
The web site system hardware 130 further includes a database query search engine 132 for processing queries received from end user computers 110 via the Internet 120 . The queries may be received via a wired connection or a wireless connection between the end user computers 110 and the Internet 120 . Computers 110 may be a conventional personal computer (PC) running a standard web browser for accessing the Internet 120 . In order to access the web site system hardware 130 , the web browser establishes a connection to the server 109 having a common gateway interface (CGI) as is known in the art.
Once a connection between a computer 110 and the server 109 is established via the Internet 120 , the server 109 transmits to the computer 110 an HTM document representing a web page, preferably, the home page, of a URL associated with the server 109 . FIG. 2 illustrates an exemplary home page 200 associated with the server 109 . The home page 200 includes search fields for entering information, including user queries for searching the media schedule database 133 for scheduled media activities of public persons. The home page 200 includes name and venue search fields 210 , 220 and associated control icons for allowing the user to initiate field-restricted searches of information contained within the media schedule database 133 from a remote location.
A search is preferably performed by typing desired information into one of the search fields 210 , 220 and performing a confirming action, such as clicking on one of two “SEARCH NOW” control icons 230 , 250 . The term or string of terms typed within the search fields 210 , 220 and which is transmitted to the database query search engine 132 for processing is referred to herein as the “query.”
It is contemplated that additional search fields can be provided on the home page 200 or another web page associated with the same URL as the home page 200 , such as a date field, where a date can be entered for retrieving media activities of public persons scheduled to occur on the particular date entered. It is also contemplated to provide a search field where two or more types of search data can be commingled, such as a search field where a date, a location, and a name of a public person can be entered.
The home page 200 as shown by FIG. 2 also includes on the left part of the screen a list of user-selectable categories 260 . If a category is selected from the list 260 , a user is provided with a list of public persons which fit the category and their corresponding scheduled media activities are obtained from the media schedule database 133 . For example, if a user selects the “politicians” category, the user is provided with a list of politicians and their corresponding scheduled media activities. It is contemplated that only the scheduled media activities scheduled to occur within a predetermined time in the future are displayed. For example, only the scheduled media activities scheduled to occur within the next month. It is further contemplated that upon a user selecting a category, sub-categories are provided for further refining the search. For example, sub-categories which could be provided include Alabama politicians, New York State politicians, and foreign politicians. A sub-category selected could then provide additional categories for further refining the search. For example, if the sub-category New York State politicians is selected, the following categories could then be provided: New York City Council Members, New York State Assemblymen, New York State Senators, and Suffolk County Legislature Members.
If a user sees a scheduled media activity of a particular public person and desires to be reminded of the particular scheduled media activity at a particular time in the future, e.g., one day before the media activity is scheduled to occur, the user can instruct the server 109 to send an e-mail or facsimile reminder letter. The user can accomplish this by clicking a “reminder” icon appearing in proximity to the particular scheduled media activity the user desires to be reminded of. If the user has registered with the web site, the server 109 is programmed to automatically acknowledge the identity and corresponding information for contacting the user, upon the user clicking the “reminder” icon. The server 109 is also programmed to appropriately send an e-mail or facsimile reminder letter to the user at the particular time in the future.
The home page 200 also includes an “Alert” display 270 for alerting users, once the users click on the display 270 , to scheduled media activities of public persons currently taking place or scheduled to occur in the immediate future, e.g., within 24-48 hours. It is contemplated that once the “Alert” display 270 is clicked, only events are provided which are currently taking place or scheduled to occur in a given location and/or include a public person of interest to the user. Accordingly, with the system of the present invention, the user provides the locations and/or names of public persons to the web site system hardware 130 of which the user desires to be alerted of by clicking the “Alert” display 270 . It is also contemplated for the location to be further defined by the user, e.g., within 50 miles of the user's address.
If there are any web casts currently taking place which feature a public person, the web site system hardware 130 provides a hyperlink for accessing the web site featuring the web cast once the “Alert” display 270 is clicked. It is contemplated that the web site system hardware 130 is programmed to automatically provide information regarding the user accessing the web cast to the web site system hardware operating the web cast once the user clicks the hyperlink, such that the user does not have to provide any identifying information once the user is connected to the web site featuring the web cast. Hence, the user is automatically provided with the web cast.
It is contemplated that the media schedule database 133 includes a library of web casts of lectures, speeches, etc. given by public persons which were previously telecast for users to access and view. Preferably, the users are charged a fee for accessing and viewing the web casts. The database manager 131 keeps track of web casts accessed and viewed by particular users, in order to allocate a percentage of the fee to the copyright owner of the web cast, e.g., a university or the public person, or other entity. The remaining percentage of the fee is allocated to the owner or operator of the web site system hardware 130 .
Additionally, the home page 200 also includes on the right part of the screen a list of user-selectable locations 275 . If a location is selected from the list 275 , a user is provided with a list of public persons which are to appear at that location and their corresponding scheduled media activities as obtained from the media schedule database 133 . For example, if a user selects “New York”, the user is provided with a list of public persons scheduled to appear in New York and their corresponding scheduled media activities. It is contemplated that only the scheduled media activities scheduled to occur within a predetermined time in the future are displayed. For example, only the scheduled media activities scheduled to occur within the next month.
If a user sees a scheduled media activity of a particular public person and desires to be reminded of the particular scheduled media activity at a particular time in the future, e.g., one day before the media activity is scheduled to occur, the user can instruct the server 109 to send an e-mail or facsimile reminder letter, as described above with the list of userselectable categories 260 .
It is contemplated that once a user clicks on a particular location, the location is further defined. For example, if the user clicks “New York”, the user is then provided with locations within New York, such as Buffalo, Syracuse, New York City, Hicksville, etc. The user can then click one of these locations to further refine the search. It is further contemplated that once one of these locations is clicked, the user is then provided with venues, such as universities, hospitals, malls, bookstores, office complex, etc. The user can then click one of these venues to further refine the search. Yet still, it is further contemplated that once one of these venues is clicked, the user is then provided with the name of the public person and/or the type of activity, such as book signing, movie premier, autograph session, etc.
In addition to the name and venue fields 210 , 220 , associated control icons 230 , 250 , user-selectable lists 260 , 275 , and “Alert” display 270 included in FIG. 2 , the home page 200 further includes at least one display field 280 . The display field 280 can advertise a particular media announcement or a promotion, such as a sweepstakes contest, a vacation package to attend a public event featuring a public person, etc. In a conventional manner, the user can select the display field 280 by performing a confirming action, such as clicking the display field 280 with a mouse button, to obtain additional information about the particular media announcement or promotion.
It is also contemplated to provide clickable icons within the display field 280 which can hyperlink the user to another URL. For, example by clicking an icon of a sale tag or ticket, the user is hyperlinked to a URL where the user can purchase merchandise, purchase tickets or register for a public event. The public event could be the public event advertised within the display field 280 or another public event.
It is further contemplated for the database manager 131 to keep track of users who hyperlinked to other URLs from the home page 200 or another web page associated with the same URL as the home page 200 . Further still, it is contemplated for the database manager 131 to store the type of actions a particular user undertook when he/she hyperlinked to another URL, such as the purchase of tickets, registration to a media event, etc. If the action involved a sales transaction or a commitment for a sales transaction in the immediate future, the database manager 131 is provided with such information, e.g., by e-mail, from the operator or owner of the URL where the sales transaction or commitment for a future sales transaction occurred. An operator of the web site system hardware 130 can then periodically invoice, e.g., by e-mail, the operator or the owner of the URL where the sales transaction or the commitment for a future sales transaction occurred following the sales transaction for a percentage of the sales transaction.
Additionally, the operator of the web site system hardware 130 could charge a flat fee to the advertiser or promoter of the contents displayed by the display field 280 based on various factors, such as the size of the display field 280 , the length of time the display field 280 is displayed, and the time-of-day the display field 280 is displayed. The operator of the web site system hardware 130 could charge a variable fee to the advertiser or promoter of the contents displayed by the display field 280 based on the number of hits the display field 280 receives and/or the number of sales transactions as a result of a user clicking on the display field 280 and linking to a sales transaction web page for purchasing tickets, merchandise, etc.
Preferably, the display field 280 also includes several icons, such as icon 285 , for learning about the media activities associated, for instance, with The Regis Show, which may include, for example, broadcast times of the television show, guests that will appear on the show, and public appearances of the host(s). This information could be provided by a pop-up window, by retrieving information stored within the media schedule database 133 , by hyperlinking to a URL associated with The Regis Show, etc.
Referring now to FIGS. 3 a - 3 c , when a search session is first established with a user, i.e., prior to a user entering a search query via one of the search fields 210 , 220 , the user is preferably shown a display screen as illustrated by FIG. 3 a . The user may be optionally or mandatorily required to enter a zip code to allow the web site system hardware 130 to provide information associated with geographic area represented by the zip code entered, e.g., television programming including name of shows and air times capable of being viewed by persons in the geographic area, appearances of public persons in the geographic area or vicinity thereof in the future, special events scheduled to take place in the geographic area or vicinity thereof, etc.
Subsequent to the display of the screen shown by FIG. 3 a , a user is then preferably shown the display screen of FIG. 3 b which requires the user to select a television service type used in the user's place of residence. FIG. 3 b illustrates three television service type options: cable 310 , satellite 312 , and broadcast 314 . Subsequent to making a selection using the screen shown by FIG. 3 a , the user is then preferably shown the screen of FIG. 3 c which requires the user to select a cable service provider. FIG. 3 c illustrates two exemplary cable service providers: Acme cable systems 316 , and Metro cable systems 318 . The data submitted by the user via the entries displayed in FIGS. 3 a - 3 c may be used, if the user so desires based upon confirmation, in all subsequent user queries, in order to return data appropriate to the user's desired geographic area and service provider.
The database query search engine 132 processes the user query, which is either a name query, a venue query, according to whether the query was entered in the name or venue search field, or a combination query as contemplated above, and accordingly searches the media schedule database 133 . The media schedule database 133 includes, for example, information including the time, place, venue (e.g., television, radio station, arenas, bookstores, etc.) and a media activity description for public persons throughout the world. The information for each item is arranged within fields (e.g., a “time” field and a “place” field), enabling the media schedule database 133 to be searched on a field-restricted basis. It is contemplated that other type of mapping of the data within the media schedule database 133 and query searching could be implemented using database management routines as known in the art.
Query search results are displayed by a display to the user, as shown in FIG. 4 , and designated generally by reference numeral 400 . If a query search term does not produce a query search result, the display will provide a message indicating that no search results were found based on the entered query. In an effort to appease the user by finding at least one query search result where no search results are evident, it is contemplated for the database manager 131 to refine the query and resubmit the refined query to the media schedule database 133 . For example, the query could be refined by using a geographic location within a predetermined distance of the originally entered geographic location in the venue field 220 .
With continued reference to FIG. 4 , query search results include one or more of elements 401 , 403 , 405 , 407 and 409 . Each query search result specifies a particular media category, e.g., television, magazines, Internet, radio and live appearances, including time and place information, as well as issue information in case of a publication.
In the particular example shown by FIG. 4 , the query search results 400 relate to media activities for actress Serena Roberts as indicated in a top heading 420 . Element 401 lists three scheduled television appearances by Serena Roberts: a first appearance 401 a which describes an appearance on The Regis Show including date, place and time information (i.e., Aug. 12, 2000, channel 7 at 9:00 am); a second appearance 401 b on Latenight With Lefty Letterman; and a third appearance 401 c on Good Morning New York. Element 403 lists current magazine issues featuring an article which mentions Serena Roberts. In the example, two magazines are listed: the August issue of Peek magazine 403 a and the September issue of Interview Now magazine 403 b.
Element 405 displays an Internet-related event. In this particular example as shown by FIG. 4 , element 405 displays an AOL live chat event which will feature Serena Roberts and which is scheduled to take place on Aug. 4, 2000 at 7:00 pm. Element 407 is a listing of a radio media event. In particular, element 407 provides a listing of a radio interview with Serena Roberts on the Herman Stem Show on August 10 where the time is to be announced. Finally, element 409 describes a live appearance that Serena Roberts will make at the Broadway Mall in Atlanta, Ga. on Aug. 8, 2000 from 8-9 am.
Query search results 400 may also provide a hyperlink connection upon selection of a particular icon, word or term. For example, by the term “Broadway Mall” may provide a hyperlink to a URL associated with the Broadway Mall of Atlanta, Ga., in order to provide further information about the mall and the appearance of Serena Roberts thereat. Further, the term “Broadway Mall” may provide a hyperlink to a LURL associated with selling tickets to the event, in order for a prospective attendee to purchase tickets to the event. It is contemplated that the operator or owner of the URL associated with the web site system hardware 130 is compensated for any sales transaction which occurs due to a hyperlink connection from the page featuring the query search results 400 ; similarly to being compensated for any sales transaction occurring via the display field 280 as discussed above.
It is contemplated that a celebrity's publicist or manager is provided with an access code for accessing the media schedule database 133 for providing media activity information regarding one or more celebrities, and for revising, appending, deleting, etc. data stored within the media schedule database 133 pertaining to the celebrity the publicist or manager is representing.
While the system has been described with reference to a preferred embodiment particularly suited for public persons. It is to be understood that the system according to the invention is suitable for other applications including the display of schedule information for any person or persons of interest to a community of users. For example, it is contemplated that the present invention may be employed on a company intranet to track the schedule of officers of a corporation. Another example include a college or university where the persons of interest may include faculty and administration. Access may be provided to all members of the college community or provided on a restricted basis. These examples are not meant to be restrictive of the intended applications, but rather as illustrative examples of the applicability of the present invention,
For example, one distinctive application is to allow users to be able to add or append the media schedule database 133 with information regarding media activities of public persons which may have inadvertently or purposely come to the attention of the users. This information can then be provided to subsequent users with the caveat that the information has not been verified with the public persons or their representatives.
It is also contemplated to notify a user via e-mail whenever information corresponding to a public person of which the user has an interest in is updated in the media schedule database 133 . The e-mail could include the updated information and/or could include a hyperlink to the web site maintained or operated by the server 109 of the web site system hardware 130 for viewing the updated information.
Accordingly, it is to be understood that various modifications may be made to the embodiments disclosed herein, and that the above descriptions should not be construed as limiting, but merely as exemplifications of preferred embodiments. Those skilled in the art will envision other modifications within the scope and spirit of the claims appended hereto. | A system and method are disclosed for providing timely and efficient scheduled media information of upcoming media activities of public persons to interested individuals over a network, such as the Internet. The present invention allows individuals to request upcoming media activities of public persons via a network and be provided with such information via a search engine having access to at least one media schedule database. The system includes a media schedule database storing scheduled media activities of a plurality of public persons and a database manager for creating and revising records of the media schedule database. The database manager is preferably a computer system having access to the media schedule database for revising, appending, deleting, etc. data stored within the media schedule database and for adding data within the media schedule database. The database manager also has access to a server of the system for automatically receiving media schedule data via a network, such as the Internet, and for routing via the server the media information to the interested individuals. | 8 |
FIELD OF THE INVENTION
The present invention relates generally to the field of software development and management, and more particularly to standardization of variable names in an integrated development environment.
BACKGROUND OF THE INVENTION
Within a software development team, standardization of the way code is written allows for easier reading and maintaining of the code because developers can become familiar with a new code component more quickly if it is written in a standardized style. Integrated Development Environments (“IDEs”) often enforce certain standards, for example, a Java® IDE will warn a developer that object types should have a name that begins with a capital letter. Development teams often have standards for variable naming as well, however, IDEs do not currently enforce these standards.
SUMMARY
Embodiments of the present invention disclose a method, computer program product, and computer system for providing for standardization of variable names in an integrated development environment. The method includes scanning, by one or more computer processors, a project source code for variable names, the project source code managed by a development team in an integrated development environment. The method includes determining, by the one or more computer processors, that the project source code contains a non-standard variable name, the distinction between a standard variable name, and the non-standard variable name defined by a set of standards and semantic rules. The method then includes identifying a location of the non-standard variable name in the project source code.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
FIG. 1 is a functional block diagram illustrating a development team environment, in accordance with an embodiment of the present invention.
FIG. 2 is a flowchart depicting operational steps of a standardization tool for allowing standardization of variable names in an IDE, in accordance with an embodiment of the present invention.
FIG. 3 depicts a block diagram of components of a data processing system, such as the developer computing device of FIG. 1 , in accordance with an embodiment of the present invention.
DETAILED DESCRIPTION
As will be appreciated by one skilled in the art, aspects of the present invention may be embodied as a system, method or computer program product. Accordingly, aspects of the present invention may take the form of an entirely hardware embodiment, an entirely software embodiment (including firmware, resident software, micro-code, etc.) or an embodiment combining software and hardware aspects that may all generally be referred to herein as a “circuit,” “module” or “system.” Furthermore, aspects of the present invention may take the form of a computer program product embodied in one or more computer-readable storage medium(s) having computer readable program code/instructions embodied thereon.
Any combination of computer-readable storage media may be utilized. A computer-readable storage medium may be, for example, but not limited to, an electronic, magnetic, optical, or semiconductor system, apparatus, or device, or any suitable combination of the foregoing. More specific examples (a non-exhaustive list) of a computer-readable storage medium would include the following: a portable computer diskette, a hard disk, a random access memory (RAM), a read-only memory (ROM), an erasable programmable read-only memory (EPROM or Flash memory), a portable compact disc read-only memory (CD-ROM), an optical storage device, a magnetic storage device, or any suitable combination of the foregoing. In the context of this document, a computer-readable storage medium may be any tangible medium that can contain, or store a program for use by or in connection with an instruction execution system, apparatus, or device.
Program code embodied may be transmitted using any appropriate medium, including but not limited to wireless, wireline, optical fiber cable, RF, etc., or any suitable combination of the foregoing.
Computer program code for carrying out operations for aspects of the present invention may be written in any combination of one or more programming languages, including an object oriented programming language such as Java®, Smalltalk, C++ or the like and conventional procedural programming languages, such as the “C” programming language or similar programming languages. The program code may execute entirely on a user's computer, partly on the user's computer, as a stand-alone software package, partly on the user's computer and partly on a remote computer, or entirely on the remote computer or server. In the latter scenario, the remote computer may be connected to the user's computer through any type of network, including a local area network (LAN) or a wide area network (WAN), or the connection may be made to an external computer (for example, through the Internet using an Internet Service Provider).
Aspects of the present invention are described below with reference to flowchart illustrations and/or block diagrams of methods, apparatus (systems) and computer program products according to embodiments of the invention. It will be understood that each block of the flowchart illustrations and/or block diagrams, and combinations of blocks in the flowchart illustrations and/or block diagrams, can be implemented by computer program instructions. These computer program instructions may be provided to a processor of a general purpose computer, special purpose computer, or other programmable data processing apparatus to produce a machine such that the instructions which execute via the processor of the computer or other programmable data processing apparatus, create means for implementing the functions/acts specified in the flowchart and/or block diagram block or blocks.
These computer program instructions may also be stored in a computer-readable storage medium that can direct a computer, other programmable data processing apparatus, or other devices to function in a particular manner such that the instructions stored in the computer-readable storage medium produce an article of manufacture including instructions which implement the function/act specified in the flowchart and/or block diagram block or blocks.
The computer program instructions may also be loaded onto a computer, other programmable data processing apparatus, or other devices to cause a series of operational steps to be performed on the computer, other programmable apparatus or other devices to produce a computer-implemented process such that the instructions which execute on the computer or other programmable apparatus provide processes for implementing the functions/acts specified in the flowchart and/or block diagram block or blocks.
The present invention will now be described in detail with reference to the Figures. FIG. 1 is a functional block diagram illustrating a development team environment, generally designated 100 , in accordance with one embodiment of the present invention.
Development team environment 100 includes developer computing device 120 and server computing device 130 , all interconnected over network 110 . Network 110 can be, for example, a local area network (LAN), a wide area network (WAN) such as the Internet, or a combination of the two, and can include wired, wireless, or fiber optic connections. In general, network 110 can be any combination of connections and protocols that will support communications between developer computing device 120 and server computing device 130 .
Developer computing device 120 includes IDE 122 and standardization tool 124 . In various embodiments of the present invention, developer computer device 120 can be a laptop computer, a notebook computer, a personal computer, a desktop computer, a tablet computer, a handheld computing device or smart phone, a thin client, a mainframe computer, a networked server computer, or any programmable electronic device capable of development of a software product, including computer programming, research, prototyping, modification, and maintenance, and capable of communicating with other computing devices within development team environment 100 . While developer computing device 120 is shown as a single device, within development team environment 100 there can be multiple developer computing devices communicating with each other and with server computing device 130 via network 110 . Developer computing device 120 may include internal and external components, as depicted and described with respect to FIG. 3 .
IDE 122 is a software application providing capabilities and facilities to developers and computer programmers for software development. IDEs present a single environment in which all development is done. An IDE normally consists of a source code editor, build automation tools and a debugger and typically provides many additional features for authoring, modifying, compiling, deploying and debugging software. Standardization tool 124 is a feature, add-on, or plugin in IDE 122 that scans a project's source code for standard variable names, according to standards and semantic rules defined by a development team, described in more detail below, and builds or adds to a database of the standard variable names, for example, variable name database 132 described below. Standardization tool 124 also generates a notification of non-standard variable names found in the project source code. A developer, programmer, or some other member of the development team can review the non-standard variable name and either correct the variable name, or add the variable name to the database. The database is editable by the development team, such as those operating on developer computing device 120 and similar such devices within development team environment 100 , and allows variable names to be defined appropriately and according to the standard of the team and for the problem domain in which IDE 122 is operating.
Server computing device 130 includes variable name database 132 . In various embodiments of the present invention, server computing device 130 can be a laptop computer, a notebook computer, a personal computer, a desktop computer, a tablet computer, a handheld computing device or smart phone, a thin client, a mainframe computer, a networked server computer, or any programmable electronic device capable of communicating with developer computing device 120 . Variable name database 132 stores standard or allowed variable names by object type, as determined and defined by the development team for the problem domain and according to the standards of the development team. While in FIG. 1 , variable name database 132 is located on server computer device 130 , one of skill in the art will appreciate that, in other embodiments, variable name database 132 can be located elsewhere within development team environment 100 and can be accessible to users of developer computing devices within development team environment 100 via network 110 .
FIG. 2 is a flowchart depicting operational steps of standardization tool 124 for allowing standardization of variable names in an IDE, such as IDE 122 , in accordance with an embodiment of the present invention.
Standardization tool 124 scans a project source code (step 202 ). In an IDE, such as IDE 122 on developer computing device 120 , standardization tool 124 scans a project's source code for standard names for variables based on object type. In various embodiments of the present invention, standardization tool 124 scans the source code using facilities available in IDE 122 for extracting object types and variable names based on an understanding of syntax of each particular programming language. For example, given “ItemTemplate itemTemplate=new ItemTemplate( )” and “ItemTemplate folderTemplate=TemplateFactory.getFolderTemplate( )” in the project source code, standardization tool 124 would recognize “itemTemplate” and “folderTemplate” as variable names for the object type “ItemTemplate.” In an alternate embodiment of the present invention, standardization tool 124 can scan the project source code for standard method names, such as “getFolderTemplate” in the example above.
Standardization tool 124 adds standard variable names to a database (step 204 ). Based on the scan of the project source code, standardization tool 124 builds a database of standard variable names, such as variable name database 132 . Variable names are stored in variable name database 132 on a per project, per development, team basis. In various embodiments of the present invention, standardization tool 124 can recognize inflections, or mutations, to a root word in the database based on context. For example, if a variable name for the object type “User” can be “user”, a list of users, “List<User>” would allow the variable name “users.” Additionally, standardization tool 124 can recognize inheritance relationships, for example, if object type “Cat” extends to object type “Animal”, an allowable variable name for an “Animal” would be “Cat”, since it is an allowable variable name for the object type “Cat.” In an exemplary embodiment of the present invention, a developer or programmer using IDE 122 can edit the database, for example, variable name database 132 , through an interface by removing, adding, or editing variable names based on standards defined by the development team operating within development team environment 100 .
In an alternate embodiment of the present invention, instead of storing variable names, the database can contain general rules for variable names. For example, a “regular expression (regex)” style rule could state “*Template”, which would allow the project source code to contain any variable name ending in “Template.”
Standardization tool 124 determines whether non-standard variable names are found in the scan (decision block 206 ). The distinction between standard and non-standard variable names is determined, or defined, according to standards and semantic rules defined by the development team. For example, “ItemTemplate it=getTemplate( )” is a non-standard variable name for the project source code because “it” is not a defined name for an “ItemTemplate” within development team environment 100 . If non-standard variable names are not found (decision block 206 , “no” branch), standardization tool 124 determines whether the scan reached the end of the available source code (decision block 216 ).
If non-standard variable names are found (decision block 206 , “yes” branch), standardization tool 124 locates the non-standard variable names in the source code (step 208 ). For example, standardization tool 124 may locate “ItemTemplate flderTemplate=getTemplateQ” because the variable name contains a spelling error.
Standardization tool 124 displays a notification indicating the location of a non-standard variable name (step 210 ). A notification, or other alert or warning, is generated indicating the location of the non-standard variable name in the source code, which calls the non-standard variable name to the developer or programmer's attention. The notification may include, for example, highlighting the location of the non-standard variable name in the source, displaying a window containing a message indicating the location of the non-standard variable name, or any other manner to indicate to the developer or programmer the location of the non-standard variable name.
Standardization tool 124 determines whether the non-standard variable name is added to the database (decision block 212 ). If the developer or programmer approves the non-standard variable name, either because, for example, it is an appropriate name or it is for a new object type, the developer or programmer, can choose to add the non-standard variable name to the database as a new variable name. In an exemplary embodiment of the present invention, only a developer, programmer, or some other member of the development team with a level of permission corresponding to permission to add, remove, or edit variable names in the database, as designated by the development team, may do so. In various embodiments of the present invention, a developer, programmer, or some other member of the development team with certain levels of permission, as designated by the development team, may choose to suppress the notification upon a determination that the non-standard variable name is appropriate, without adding the variable name to the database.
If the non-standard variable name is not added to the database (decision block 212 , “no” branch), standardization tool 124 determines whether the non-standard variable name is corrected in the source code (decision block 214 ). For example, the developer or programmer may correct a misspelling or incorrect variable name in the project source code. If the non-standard variable name is not corrected (decision block 214 , “no” branch), standardization tool 124 continues to display a notification locating the non-standard variable name in the source code (step 210 ).
If the non-standard variable name is added to the database (decision block 212 , “yes” branch), or if the non-standard variable name is corrected in the source code (decision block 214 , “yes” branch), standardization tool 124 determines whether the scan reached the end of the source code (decision block 216 ). If the scan is not at the end of the source code (decision block 216 , “no” branch), standardization tool 124 continues to scan the source code (step 202 ). If the scan is at the end of the source code (decision block 216 , “yes” branch), standardization tool 124 no longer scans the source code for variable names and standardization tool 124 ends.
In an embodiment of the present invention, the created database, variable name database 132 in development team environment 100 , can be used to standardize new source code by auto-completion of variable names while writing the new source code.
FIG. 3 depicts a block diagram of components of developer computer device 120 , in accordance with an illustrative embodiment of the present invention. It should be appreciated that FIG. 3 provides only an illustration of one implementation and does not imply any limitations with regard to the environments in which different embodiments may be implemented. Many modifications to the depicted environment may be made.
Developer computer device 120 includes communications fabric 302 , which provides communications between computer processor(s) 304 , memory 306 , persistent storage 308 , communications unit 310 , and input/output (I/O) interface(s) 312 . Communications fabric 302 can be implemented with any architecture designed for passing data and/or control information between processors (such as microprocessors, communications and network processors, etc.), system memory, peripheral devices, and any other hardware components within a system. For example, communications fabric 302 can be implemented with one or more buses.
Memory 306 and persistent storage 308 are computer-readable storage media. In this embodiment, memory 306 includes random access memory (RAM) 314 and cache memory 316 . In general, memory 306 can include any suitable volatile or non-volatile computer-readable storage media.
IDE 122 and standardization tool 124 are stored in persistent storage 308 for execution by one or more of the respective computer processors 304 via one or more memories of memory 306 . In this embodiment, persistent storage 308 includes a magnetic hard disk drive. Alternatively, or in addition to a magnetic hard disk drive, persistent storage 308 can include a solid state hard drive, a semiconductor storage device, read-only memory (ROM), erasable programmable read-only memory (EPROM), flash memory, or any other computer-readable storage media that is capable of storing program instructions or digital information.
The media used by persistent storage 308 may also be removable. For example, a removable hard drive may be used for persistent storage 308 . Other examples include optical and magnetic disks, thumb drives, and smart cards that are inserted into a drive for transfer onto another computer-readable storage medium that is also part of persistent storage 308 .
Communications unit 310 , in these examples, provides for communications with other data processing systems or devices, including server computing device 130 . In these examples, communications unit 310 includes one or more network interface cards. Communications unit 310 may provide communications through the use of either or both physical and wireless communications links. IDE 122 and standardization tool 124 may be downloaded to persistent storage 308 through communications unit 310 .
I/O interface(s) 312 allows for input and output of data with other devices that may be connected to developer computing device 120 . For example, I/O interface 312 may provide a connection to external devices 318 such as a keyboard, keypad, a touch screen, and/or some other suitable input device. External devices 318 can also include portable computer-readable storage media such as, for example, thumb drives, portable optical or magnetic disks, and memory cards. Software and data used to practice embodiments of the present invention, e.g., IDE 122 and standardization tool 124 , can be stored on such portable computer-readable storage media and can be loaded onto persistent storage 308 via I/O interface(s) 312 . I/O interface(s) 312 also connect to a display 320 . Display 320 provides a mechanism to display data to a user and may be, for example, a computer monitor or an incorporated display screen, such as is used in tablet computers and smart phones.
The programs described herein are identified based upon the application for which they are implemented in a specific embodiment of the invention. However, it should be appreciated that any particular program nomenclature herein is used merely for convenience, and thus the invention should not be limited to use solely in any specific application identified and/or implied by such nomenclature.
The flowchart and block diagrams in the Figures illustrate the architecture, functionality, and operation of possible implementations of systems, methods and computer program products according to various embodiments of the present invention. In this regard, each block in the flowchart or block diagrams may represent a module, segment, or portion of code, which comprises one or more executable instructions for implementing the specified logical function(s). It should also be noted that, in some alternative implementations, the functions noted in the block may occur out of the order noted in the figures. For example, two blocks shown in succession may, in fact, be executed substantially concurrently, or the blocks may sometimes be executed in the reverse order, depending upon the functionality involved. It will also be noted that each block of the block diagrams and/or flowchart illustration, and combinations of blocks in the block diagrams and/or flowchart illustration, can be implemented by special purpose hardware-based systems that perform the specified functions or acts, or combinations of special purpose hardware and computer instructions. | A method for providing for standardization of variable names in an integrated development environment is provided. The method includes scanning a project source code for variable names, where the project source code is managed by a development team in an integrated development environment. The method includes determining that the project source code contains a non-standard variable name, where the distinction between a standard variable name and the non-standard variable name is defined by a set of standards and semantic rules. The method then includes identifying a location of the non-standard variable name in the project source code. | 6 |
This application claims the priority under 35 USC 119(e)(1) of copending U.S. provisional application No. 60/227,093 filed on Aug. 22, 2000.
FIELD OF THE INVENTION
The invention relates generally to digital communications and, more particularly, to coding and modulation in digital communications.
BACKGROUND OF THE INVENTION
Each of the documents listed below is referred to herein by the corresponding number enclosed in square brackets to the left of the document. Each of these documents is also incorporated herein by reference.
[1] E. Biglieri, D. Divsalar, P. J. McLane, and M. K. Simon, Introduction to Trellis Coded Modulation with Applications . MacMillan, 1991.
[2] C. Berrou, A. Glavieux, and P. Thitimajshima, “Near Shannon limit error-correcting coding: Turbo codes,” Proc. 1993 IEEE International Conference on Communications ICC , pp. 1064–1070, 1993.
[3] S. L. Goff, A. Glavieux, and C. Berrou, “Turbo-codes and high spectral efficiency modulation,” Proc. 1994 IEEE International Conference on Communications ICC , pp. 645–649, 1993.
[4] A. J. Viterbi, E. Zehavi, R. Padovani, and J. K. Wolf, “A pragmatic approach to trellis-coded modulation,” IEEE Commun. Mag. , pp. 11–19, July 1989.
[5] P. Robertson and T. Worz, “A novel bandwidth efficient coding scheme employing turbo codes,” Proc. 1996 IEEE International Conference on Communications ICC , pp. 962–967, 1996.
[6] P. Robertson and T. Worz, “Bandwidth-efficient turbo trellis-coded modulation using punctured component codes,” IEEE JSAC , pp. 206–218, February 1998.
[7] S. Benedetto, D. Divsalar, G. Montorsi, and F. Pollara, “Parallel concatenated trellis coded modulation,” Proc. 1996 IEEE International Conference on Communications ICC , pp. 974–978, 1996.
[8] S. Benedetto and G. Montorsi, “Design of parallel concatenated convolutional codes,” IEEE Trans. Commun. , pp. 591–600, May 1996.
[9] O. Y. Takeshita, O. M. Collins, P. C. Massey, and D. J. Costello, “On the frame error rate of turbo-codes,” Proceedings of ITW 1998, pp. 118–119, June 1998.
[10] O. Y. Takeshita, O. M. Collins, P. C. Massey, and D. J. Costello, “A note on asymmetric turbo-codes,” IEEE Communications Letters , vol. 3, pp. 69–71, March 1999.
[11] S. Benedetto, D. Divsalar, G. Montorsi, and F. Pollara, “A soft-input soft-output APP module for interative decoding of concatenated codes,” IEEE Commun. Lett. , pp. 22–24, January 1997.
Trellis-Coded Modulation (TCM) has been demonstrated in [1] to offer a substantial coding gain without requiring bandwidth expansion. This is achieved by appropriate joint design of coding and modulation. Turbo codes, also known as parallel concatenated convolutional codes (PCCC), were initially proposed in [2], and have been known to attain very low error rates within the signal-to-noise ratio (SNR) range close to the Shannon limit. Attempts have therefore been made to combine TCM and turbo codes to obtain a class of powerful bandwidth-efficient coded modulation schemes. One such attempt was reported in [3]. The arrangement described in [3] uses the structure of the pragmatic TCM proposed in [4]. Schemes with improved performance were later proposed in [5], [6] and [7].
The original turbo code proposed in [2] utilizes two identical recursive systematic component codes (RSCCs) in parallel concatenation with an interleaver. This turbo code attains excellent bit-error rate (BER) for low SNR values. As the SNR increases, the BER drops very quickly. However, after a certain SNR value, there is a sudden reduction in the rate at which the BER drops. This phenomenon, referred to in [8], [9] and [10] is known as the “error floor”.
It is demonstrated in [9] and [10] that the error floor for the original turbo code of [2] occurs at 10 −5 for a length-16384 interleaver. Such an error floor is not desirable for high quality data communication applications such as, for example video communications for a wireless personal area network (WPAN). Such applications can require a BER of, for example, 10 −8 . Although the error floor for the original turbo code can be lowered, for example, by choosing a larger interleaver size, such an adjustment disadvantageously increases system complexity and latency.
Several attempts have been made to lower the error floor without increasing the interleaver size. For example, it is shown in [8] that the error floor can be lowered by choosing the feedback polynomial of the component codes to be primitive. This essentially increases the effective Hamming distance of the turbo code (which is known from [8] to be a good measure of code performance). However, as the error floor goes down, the BER in the low SNR region (referred to herein as the waterfall region) increases (see [9] and [10]).
The authors of [9] and [10] attempted to provide for a trade-off between a low error floor and good performance in the waterfall region. In this regard, they suggested an asymmetric turbo coding structure wherein one component code has a non-primitive feedback polynomial (as in the original turbo code of [2]), and the other component code has a primitive feedback polynomial. An example of this coding structure, referred to in [9] and [10] as an asymmetric PCCC, is illustrated in FIG. 1 . In the example of FIG. 1 , the upper component code (RSCC 1 ) is a rate ½ RSCC with a primitive feedback polynomial, and the lower component code (RSCC 2 ) is a rate ½ RSCC with a non-primitive feedback polynomial. The systematic of the lower code is punctured, so the asymmetric PCCC produces coded bit outputs C 1 and C 2 from the upper branch and C 3 from the lower branch.
FIG. 2 illustrates a conventional example of a parallel concatenated trellis-coded modulation (PCTCM) structure. In the example of FIG. 2 , the RSCC 25 and mapping 26 for the upper and lower branches are identical. This type of structure is referred to herein as symmetric mapping PCTCM. In conventional structures such as shown in FIG. 2 , the PCTCM is typically designed using the conventional approach of searching for a component code that has good properties for a given mapping (see [6] and [7]). Typical examples of conventional mappings that are used in arrangements like FIG. 2 include natural (set partitioning) mapping and Gray mapping. The coded bits from each component RSCC are mapped into signals S 1 and S 2 that take values within a constellation. For PCTCM, the search criterion is to maximize the effective Euclidean distance of the trellis code (see [7]). Like PCCC, PCTCM does not always provide a low enough error floor for some applications (such as the aforementioned video communication applications for WPAN). This can occur in PCTCM even when a component code that results in maximum effective Euclidean distance of the trellis code has been identified for a given mapping. This is especially true when an interleaver of moderate size is utilized.
FIG. 3 illustrates a specific example of the PCTCM structure shown in FIG. 2 . The example of FIG. 3 is a 2 bps/Hz PCTCM system for 16-QAM. U 1 and U 2 represent uncoded bits from a communication application. The upper (X 2 and X 1 ) and lower (Y 2 and Y 1 ) coded bits are mapped onto a 4-PAM constellation to form in-phase (I) and quadrature (Q) components, which are combined (e.g. summed) at 31 to produce the 16-QAM signal. Two different length K-bit interleavers π 1 (for LSB U 1 ) and π 2 (for LSB U 2 ) are used in FIG. 3 to implement the interleaver section 27 of FIG. 2 . As an example, K=4096. The rate-1 RSCC G(D) with maximum effective Euclidean distance for Gray mapping (see FIG. 5 ) is used. FIG. 4 illustrates an example of the G(D) of FIG. 3 . In particular, the G(D) shown in FIG. 4 is the “best” 8 state RSCC G(D) for Gray mapping, and is disclosed in [7]. (The FIG. 4 G(D) was used for both transmitter branches in all simulations described herein.)
Another possibility for the mapping in FIG. 3 is conventional 0231 mapping, as illustrated in FIG. 6 . Again, a search could be conducted for a RSCC G(D) with good properties for the 0231 mapping.
FIG. 3A illustrates another example of the structure of FIG. 2 . FIG. 3A uses identical QPSK (or 8PSK) mappings at 26 , and the results of the mappings are applied to a parallel-to-serial converter before transmission.
In each of the examples of FIGS. 3 and 3A , the G(D) for one branch can differ from the G(D) for the other branch.
With respect to the example of FIG. 3 , FIGS. 7 and 8 illustrate exemplary simulation results using Gray mapping and 0231 mapping, respectively, for h 0 =13, h 1 =17, h 2 =15 and K=4096, and assuming an additive white Gaussian noise (AWGN) channel with a power spectral density of N 0 . The simulations of FIGS. 7 and 8 plot the BER as a function of the uncoded SNR per bit, or E b /N 0 . The simulations of FIGS. 7 and 8 use the iterative MAP decoding algorithm for PCTCM found in [11], and results for 2, 4, 6 and 8 iterations are shown. In FIG. 7 (Gray mapping), the error floor occurs at around BER=10 −7 . Thus, and although the Gray mapping system provides excellent performance in the waterfall region, nevertheless it does not meet the aforementioned requirement of BER=10 −8 . In FIG. 8 (0231 mapping), the error floor is greatly reduced and is clearly below the aforementioned target of BER=10 −8 . However, the BER in the waterfall region is significantly higher than in FIG. 7 .
It is desirable in view of the foregoing to provide for a PCTCM system that can achieve acceptable performance in the waterfall region while also achieving an error floor that is acceptable for high quality data communication applications.
According to the invention, an error floor suitable for high quality data applications can be advantageously achieved in combination with acceptable performance in the waterfall region by providing an asymmetric PCTCM system including two component trellis code branches which utilize different coded bits-to-signal mappings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 diagrammatically illustrates a conventional PCCC system.
FIG. 2 diagrammatically illustrates a conventional PCTCM system.
FIG. 3 diagrammatically illustrates a specific example of the conventional system of FIG. 2 .
FIG. 3A illustrates another example of the system of FIG. 2 .
FIG. 4 illustrates a portion of the conventional system of FIG. 3 in more detail.
FIGS. 5 and 6 illustrate conventional examples of coded bit-to-signal mapping which can be utilized in the conventional systems of FIGS. 2 and 3 .
FIG. 7 illustrates exemplary simulation results for the system of FIG. 3 using the mapping of FIG. 5 .
FIG. 8 illustrates exemplary simulation results for the system of FIG. 3 using the mapping of FIG. 6 .
FIG. 9 diagrammatically illustrates exemplary embodiments of a PCTCM system according to the invention.
FIGS. 9A and 9B diagrammatically illustrate specific examples of the FIG. 9 system.
FIG. 10 illustrates exemplary simulation results for the system of FIG. 9 .
FIG. 11 graphically compares selected simulation results from FIGS. 7 , 8 and 10 .
FIG. 12 diagrammatically illustrates further exemplary embodiments of a PCTCM system according to the invention.
FIG. 13 illustrates exemplary operations which can be performed by the PCTCM system of FIG. 12 .
DETAILED DESCRIPTION
FIG. 9 diagrammatically illustrates exemplary embodiments of a PCTCM system according to the invention. In some embodiments, the coded bits of FIG. 9 can be produced in the same conventional fashion as illustrated in FIG. 2 or FIG. 3 . However, in the system of FIG. 9 , one branch uses a first coded bits-to-signal mapping (mapping 1 ) and the other branch uses a second coded bits-to-signal mapping (mapping 2 ) which is different than the first mapping. In some embodiments, mapping 1 is the 4-PAM Gray mapping described above which respect to FIGS. 3 and 5 , and mapping 2 is the 4-PAM 0231 mapping described above with respect to FIGS. 3 and 6 . As other examples, 6-PAM Gray mapping and 6-PAM 0231 mapping can be used. In other exemplary embodiments, first and second QPSK mappings (which differ from one another) can be used, or first and second 8PSK mappings (which differ from one another) can be used. By using different mappings for the different branches, the desired performance in the waterfall region can be advantageously balanced with the desired error floor.
The system of FIG. 9 can be used in any desired communication transmission apparatus, for example a wireless communication apparatus or a wireline communication apparatus. The system of FIG. 9 receives the uncoded bits from a communication application (for example a video application for WPAN) associated with the transmission apparatus. In embodiments that use 4-PAM or 6-PAM mappings (see FIG. 9A ), the output signals S 11 and S 22 can be combined (as in FIG. 3 ) to produce a 16-QAM signal for output to a communication channel interface which interfaces the 16-QAM signal to a communication channel. Any desired mappings other than 4-PAM (or 6-PAM) Gray and 4-PAM (or 6-PAM) 0231 mappings can be used for mapping 1 and mapping 2 in FIG. 9A . For example, 4-PAM (or 6-PAM) 0213 mapping can be combined with 4-PAM (or 6-PAM) Gray or 0231 mapping. In embodiments that use first and second QPSK or 8PSK mappings (see FIG. 9B ), a parallel-to-serial converter can be used (as in FIG. 3A ) to format the signals S 11 and S 22 for a suitable communication channel interface.
Referring again to FIG. 9 , as shown by broken line, the architecture can be extended to any desired number (N) of branches and mappers. In some embodiments, the transmission apparatus can be a wireless transmission apparatus such as provided in wireless telephones, laptop computers, personal digital assistants, etc.
In each of the examples shown in FIGS. 9 , 9 A and 9 B, the RSCC G(D) for one branch can be the same as or different from the RSCC G(D) for the other branch. For example, a code that is optimal for one of the mappings could be chosen for both mappings, or the optimal code for each mapping can be used with its associated mapping, or a single code for both mappings could be chosen arbitrarily, or one or two codes could be chosen empirically based on experimentation.
A suitable wireless or wireline communication receiver for receiving the signals transmitted by the transmission apparatus embodiments of FIGS. 9 , 9 A and 9 B can be readily implemented, for example, by modifying conventional receivers associated with the transmitters of FIGS. 2–3A to account for the fact that the PCTCM structure of FIGS. 9 , 9 A and 9 B utilizes different coded bits-to-signal mappings in the respective branches thereof.
FIG. 10 illustrates simulation results associated with one example of the system of FIG. 9 . FIG. 10 illustrates the relationship between BER and SNR for a 2 bps/Hz PCTCM system for 16-QAM. As discussed above with respect to FIGS. 7 and 8 , the iterative MAP decoding algorithm for PCTCM found in [11] is used, and results for 2, 4, 6 and 8 decoding iterations are illustrated. Also as in the simulations of FIGS. 7 and 8 above, h 0 =13, h 1 =17, h 2 =15 and the interleaver length K=4096.
Comparing FIG. 10 with FIG. 7 , it can be seen that the asymmetric mapping system of FIG. 9 lowers the error floor from 10 −7 to below 10 −8 as compared to the symmetric Gray mapping system results of FIG. 7 . Comparison of FIG. 10 with FIG. 8 indicates that the asymmetric mapping system of FIG. 9 realizes only a marginal performance loss of approximately 0.2 dB in the waterfall region as compared to the symmetric 0231 mapping results illustrated in FIG. 8 .
FIG. 11 provides a graphical comparison of the 4 th iteration results from the symmetric Gray mapping of FIG. 7 , the symmetric 0231 mapping of FIG. 8 and the asymmetric mapping of FIG. 10 . As shown in FIG. 11 , the asymmetric mapping of the present invention outperforms the symmetric Gray mapping with respect to error floor, while experiencing only a marginal performance loss in the waterfall region with respect to the symmetric 0231 mapping of FIG. 8 .
In the examples of FIGS. 9 , 9 A and 9 B, mapping 1 and mapping 2 are essentially used in the same frequency. However, as illustrated in the exemplary embodiments of FIG. 12 , mapping 1 and mapping 2 need not be used in the same frequency. Moreover, as shown in FIG. 12 , both mapping 1 and mapping 2 can be used to produce the signal S 11 , and both mapping 1 and mapping 2 can be used to produce the signal S 22 .
In the example of FIG. 12 , the coded bits at 21 and the interleaved version of the coded bits at 22 are input to respective selectors 121 and 122 . These selectors are responsive to control signals received from a controller 123 for routing their associated coded bits to either a mapper that performs mapping 1 or a mapper that performs mapping 2 . Thus, signal S 11 can be produced using both mapping 1 and mapping 2 , and signal S 22 can similarly be produced using both mapping 1 and mapping 2 . The controller 123 receives relative frequency information and controls the selectors 121 and 122 appropriately in response to this information, so that the signals S 11 and S 22 reflect the desired relative frequency combination of mapping 1 and mapping 2 . The relative frequency information can, in some embodiments, include a relative frequency parameter ρ. This relative frequency parameter can be used to control a trade-off between waterfall performance and error floor performance. Different values of ρ that respectively correspond to different combinations of waterfall/error floor performance can be determined, for example, from simulations and/or experimental observations, and the values of ρ can then be stored, for example, in a look-up table, indexed against the corresponding combinations of waterfall/error floor performance.
FIG. 13 illustrates exemplary operations which can be performed by the system of FIG. 12 to produce the signals S 11 and S 22 . At 131 , the value of ρ is determined. If ρ=∞, then at 132 only mapping 1 is used for both S 11 and S 22 (conventional symmetric mapping for mapping 1 ), until a new value of ρ is provided at 134 . If ρ=0, then at 133 only mapping 2 is used for both S 11 and S 22 (conventional symmetric mapping for mapping 2 ), until a new value of ρ is provided at 134 . If ρ is neither 0 nor ∞, then at 136 , mapping 1 is used ρ times as frequently as is mapping 2 , until a new value of ρ is provided at 134 . For example, if ρ=3, then mapping 1 can be used exclusively to produce S 11 in FIG. 12 , while controller 123 controls selector 122 such that mapping 1 and mapping 2 can be used alternately to produce alternate symbols of S 22 . If ρ=⅓, then, for example, mapping 2 can be used exclusively for S 22 while mapping 1 and mapping 2 are used alternately to produce alternate symbols of S 11 .
Note, for example, that when each mapping is to be used in the same frequency (ρ=1), this can be realized, for example, by using only mapping 1 to produce S 11 and using only mapping 2 to produce S 22 . However, in some embodiments, the controller 123 can control the selectors such that each of the signals S 11 and S 22 is produced using both mapping 1 and mapping 2 . In such embodiments, each mapping can be used in the same frequency (ρ=1), for example, by using mapping 1 and mapping 2 alternately to produce alternate symbols in S 11 , and correspondingly using mapping 2 and mapping 1 alternately to produce alternate symbols in S 22 . That is, the symbol mapping sequence for S 11 , would be mapping 1 , mapping 2 , mapping 1 , mapping 2 , etc., while the timewise corresponding sequence for S 22 would be mapping 2 , mapping 1 , mapping 2 , mapping 1 , etc. In general, a “both switch” signal can be activated at an input of the controller 123 to indicate that both mapping 1 and mapping 2 are to be used to produce each of the signals S 11 , and S 22 . The controller 123 then controls the selectors 121 and 122 such that both mappings are used to produce both signals S 11 , and S 22 , while still complying with the relative frequency parameter ρ. Any desired symbol mapping sequences can be used for S 11 , and S 22 , provided that they comply with the selected value of ρ.
It will be apparent to workers in the art that the invention described above can be readily implemented by suitable modifications in software, hardware or a combination of software and hardware in conventional communication transmission and receiver stations.
Although exemplary embodiments of the invention are described above in detail, this does not limit the scope of the invention, which can be practiced in a variety of embodiments. | Parallel concatenated trellis-coding modulation is accomplished by producing coded bits ( 21 ) from uncoded bits and also producing an interleaved version ( 22 ) of the coded bits from the uncoded bits. A first coded bits-to-signal mapping (mapping 1 ) is applied to the coded bits to produce a first output signal (S 11 ), and a second coded bits-to-signal mapping (mapping 2 ) is applied to the interleaved version of the coded bits to produce a second output signal (S 22 ), wherein the second coded bits-to-signal mapping differs from the first coded bits-to-signal mapping. | 7 |
FIELD OF THE INVENTION
The present invention relates to securing a hinged door from the inside.
BACKGROUND OF THE INVENTION
It is a common practice to provide a lock for a hinged door. Certain type locks provide a securely locked door which is tamper proof from the outside. These locks thwart entry by the use of duplicate keys or jimmying devices. The present inventor patented such a door lock device in U.S. Pat. No. 4,629,229. There a flexible cable secured the inside door knob against the inside wall.
Dead bolt type door locks are also known. These devices teach the use of a straight bolt mounted across the door jam and the swinging side of the door. It is known in the art to mount such a dead bolt inside the door. The dead bolt is moved into the lock position by turning the handle on the inside of the door. A gear mechanism is required to convert the turning motion of the handle into the sliding motion of the dead bolt.
SUMMARY OF THE INVENTION
It is the object of the present invention to provide a quick throw latch key mechanism for closing a dead bolt.
Another object of the present invention is to provide a complete locking mechanism having a quick throw dead bolt.
Another object of the present invention is to provide a complete locking mechanism having a quick throw dead bolt which is universally mounted on variable width doors.
Another object of the present invention is to provide a complete locking mechanism having a quick throw latch key which further includes a safety catch to avoid accidental unlocking.
Other objects of this invention will appear from the following description and appended claims, reference being had to the accompanying drawings forming a part of this specification wherein like reference characters designate corresponding parts in the several views.
DESCRIPTION OF THE DRAWINGS
FIG. 1 is a front elevational view of the universal dead bolt installed on a wall. The view is from the inside of the room.
FIGS. 2a-2f are plan views of component elements of the preferred embodiment of the universal dead bolt.
FIG. 3 is a longitudinal sectional view taken along line A--A of FIG. one.
FIG. 4 is a longitudinal sectional view taken along line B--B of FIG. one.
FIG. 5 is an elevation of a cut-away portion of the door and wall of FIG. 1 showing an embodiment with the mounting plate removed, having multiple dead bolts.
Before explaining the disclosed embodiment of the present invention in detail, it is to be understood that the invention is not limited in its application 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.
DETAILED DESCRIPTION
Referring first to FIG. 1, the universal dead bolt assembly 1 is mounted in wall 2. The universal dead bolt assembly 1 could alternatively be mounted inside door 3 (not shown).
A dead bolt 4 slides in sleeves 5 and 5'. When the door 3 is closed and the dead bolt 4 is moved into sleeve 5', the door 3 becomes securely locked. Sleeves 5 and 5' are mounted inside the door jam 6 and door 3 respectively.
A latch key 7 is bolted to one end of dead bolt 4 by bolts 8 and 8'. This latch key end of dead bolt 4 has threads 9 for bolts 8 and 8'. Latch key 7 slides through cutout 10 in wall 2 as shown in FIG. 4. Latch key 7 also slides through groove 11 of mounting plate 12 which is affixed to wall 2 by screws 13.
Latch key 7 is shown in the open position resting in safety catch 15. In order to move dead bolt 4 to the locked position, it is necessary to lift latch key 7 out of safety catch 15, then slide latch key 7 to the locked position, then drop latch key 7 into safety catch 14. Safety catch 14 ensures that dead bolt 4 will not be accidentally brushed open.
The basic principal of operation of universal dead bolt 1 relies on the center mounted sleeves 5 and 5'. An approximate ratio of three to one between the dead bolt 4 length and the length of groove 11 and sleeve 5' ensures a powerful dead bolt across door 3. The center mounted sleeves 5 and 5' remove any reliance on surface mounted screws 13 for strength. Only sleeves 5 and 5' and their respective mounting supports, door jam 6 and door 3, receive pressure during an attempted forced entry. Mounting plate 12 merely serves to hold latch key 7 in either the open or locked position.
FIGS. 2a-2f shows all the parts of the preferred embodiment of the universal dead bolt assembly 1 shown in FIG. 1. The installation procedure is as follows.
First, mounting holes for sleeves 5 and 5' are drilled into door 3 and door jam 6 respectively. Next, a cutout 10 is chiseled into wall 2 in order to allow latch key 7 to slide (about two inches in the preferred embodiment). Cutout 10 must also be large enough to allow the mounting of nuts 8 and 8' onto threads 9 of dead bolt 4. Next, sleeves 5 and 5' are pushed into their respective holes. Then dead bolt 4 is inserted into sleeve 5 threads 9 first. Dead bolt 4 is inserted through hole 22 in latch key 7. Nuts 8 and 8' are tightened to allow adequate penetration of dead bolt 4 into sleeve 5' in the locked position. Plate 12 is affixed to wall 2 by screws 13 fitting into holes 21 and, if necessary, plugs 20.
A unique design feature of latch key 7 is the shank 23. The relatively narrow shank 23 in relation to the handle 24 and mounting end 25 allows this latch key 7 to be universally mountable in various width doors. Many installations mount the universal dead bolt assembly 1 of FIG. 1 in the door 3 rather than the wall 2 as shown.
FIG. 3 simply shows sleeve 5' mounted inside a hole 31 which has been drilled in door 3 as noted above. Sleeve 5' has a hollow center 30 into which dead bolt 4 slides in the locked position.
FIG. 4 shows how cutout 10 accommodates nut 8 and the mounting end 25 and shank 23 of latch key 7. the handle 24 of latch key 7 is readily available to quickly slide latch key 7 in groove 11 thereby locking door 3.
FIG. 5 shows an alternate embodiment of the universal dead bolt which has more than one dead bolt. Dead bolts 50 and 51 are affixed to latch key mounting end 52 by nuts 8 and 8'. Cutout 101 accommodates an optional mounting box 102. Screws 110 affix the mounting box 102 to wall 2. Latch key 7' operates in a similar fashion to FIGS. 1, 2, 3 and 4. Optional front plates 106 and 107 are used to reduce wear and tear on sleeves 104, 104', 105 and 105'. This embodiment makes the door 3 more resistant to a forced entry. | A simple dead bolt is mounted inside sleeves which are aligned between a door and its door jam. One end of the dead bolt has a latch key projecting inside the room. The latch key can be mounted either on the door or in the wall. Sliding the latch key closed securely and rapidly locks the door from the inside. | 4 |
This application is a continuation of application Ser. No. 08/204,189 filed on Mar. 4, 1994, now abandoned, which is a 371 PCT/AT92/00113 filed Aug. 17, 1992.
BACKGROUND OF THE INVENTION
The invention relates to a process, a device, and an installation using this device for the separation of gaseous components from pourable media, in particular suspensions of solids.
Processes and devices for the separation of gases from liquids, suspensions and solids-gas-mixtures known so far operate on the principle of a centrifuge. Here the medium to be separated from the gas must be set in rotation, the heavier components being enriched at longer radii because of stronger centrifugal forces and the gases and more volatile components mainly at shorter radii and at the center of rotation, respectively. The gas accumulated at shorter radii is then evacuated from the system via an appropriate conduit. In most cases underpressure is applied to the evacuating system for the removal of gas.
A disadvantage of such processes is that energy has to be introduced into the medium for generating swirl, which energy is completely or partly lost in the further course of the process.
A further disadvantage resides in the fact that complicated control is often necessary in order to avoid that a large amount of gas, in particular air, but no other components are separated. This applies in particular when varying amounts of gas occur in the medium to be degassed during operation.
Conventional processes are furthermore disadvantageous in that additional devices aiming at a stabilization of the spout-like gas separation are necessary for efficient operation.
With media and liquid-solids-gas-mixtures, respectively, as for instance the suspensions of fibrous material occurring in paper and pulp industry, the gaseous components (mostly air) adhere well to the fiber network, thus making the segregation of gaseous and non-gaseous components (water, fibers, etc.) more difficult. In these cases it is of major importance to keep the distance the gas has to travel inside the medium in order to reach the zone from where it may be evacuated as short as possible. The result thereof is that with known processes long dwelling times of the medium in the region of the centrifuge are necessary because of the long travel distances, and thus the throughput of the medium is strongly limited or the centrifuge becomes very long.
A further disadvantage of known processes and devices resides in the fact that, in order to prevent the concomitant separation of non-gaseous components, provision has to be made for devices functioning as a sieve. Especially with media likely to form clots, as for instance the fiber suspensions dominating the paper and pulp industry, the components carried along with the evacuated gas may result in clogging. Rinsing means are necessary in order to prevent this.
SUMMARY OF THE INVENTION
The present invention avoids the above disadvantages. For this purpose it proposes a process which is characterised in that underpressure zones are formed by relative movement between the media and a body, in particular a rotary body, arranged within these media, as a result of the shape thereof and in that the gas accumulating in the underpressure zones is evacuated via the interior of the body.
The effect of centrifugal force is employed for separating gaseous components from the medium. Advantageously according to the invention the medium enriched with gas, entering the interior of the body together with accumulated gas, is subject to further degassing by centrifugal force inside the body.
Conveniently the medium degassed inside the body is recycled to the medium surrounding the body.
The relative movement between the body and the medium may be achieved by moving the body or the medium, but also by simultaneously moving the body and the medium.
Advantageously according to the invention the relative movement is achieved by preferably continuous rotation of the body.
Conveniently according to the invention the relative movement is achieved by preferably continuous rotation of the body and movement, preferably for conveyance of the medium.
In industrial processes quite frequently media of varying composition, for instance due to changing pressure and temperature conditions, are to be subjected to a treatment. In order to optimize the separation of gas from medium of varying composition, according to the invention the relative speed is adjusted by changing the speed of movement of the body and/or the medium, in particular in dependance on the state parameters of the medium to be degassed.
Conveniently according to the invention the direction of flow of gas inside the body is changed by deviating it.
Underpressure is applied in order to promote the separation of gas from the medium. Advantageously according to the invention the gas separated from the medium is removed from the interior of the body under application of underpressure.
Conveniently according to the invention the underpressure applied is adjusted in dependance on the state parameters of the medium to be degassed.
The invention also relates to a device for separating gaseous components from pourable media, in particular for carrying out the process according to the present application.
The invention is characterised primarily in that the device for generating relative movement is disposed between the media and a body arranged within these media, which body is in particular provided rotatably and has a shape generating underpressure on the surface of the body in the course of this relative movement, and in that the body has at least one inlet in the region of the underpressure zones, which inlet communicates with a gas discharge for transporting off separated gas.
According to an advantageous embodiment of the invention the body takes the form of a rotary body and the gas discharge has at least one through-channel in the body and opening in the region of the radially outer circumference.
Conveniently according to the invention the channel opening in the region of the radially outer circumference discharges into an enlarged cavity, preferably in the region of the radially outer circumference.
Advantageously according to the invention the channel open in the region of the radially outer circumference communicates with a further channel, optionally via an enlarged cavity.
Conveniently according to the invention the body has several arms. Advantageously according to the invention several arms are arranged in one plane.
According to the present invention it may also be convenient for the arms to be arranged in at least two planes with respect to the rotational axis, preferably above each other.
Conveniently according to the invention the gas discharge opens into a collecting channel.
According to an advantageous embodiment of the invention the gas discharge communicates with a gas evacuation device, in particular a suction device, preferably via the collecting channel.
In order to promote the evacuation of gas from the medium the body of appropriate shape is moved. According to an advantageous embodiment of the invention the body and the arms, respectively, is/are connected to a drive device, in particular to a drive shaft.
Conveniently according to the invention the collecting channel is arranged in the drive shaft. Preferably according to the invention the collecting channel is arranged between hub and shaft.
The configuration of the entrance opening on the body exerts a major influence on the efficiency of the separation of gas from the medium. Conveniently according to the invention at least one inlet is of circular cross section. Preferably at least one such inlet is formed as a bore.
Conveniently according to the present invention several such bores are, at least substantially in a radial direction, arranged adjacent to each other on the body.
According to the present invention it is also advantageous for several such bores to be arranged adjacent to each other on the body, at least substantially in parallel to the rotational axis.
According to a preferable embodiment of the invention at least one inlet takes the form of a slot. Conveniently at least one slot-like inlet is oriented in the radial direction.
Preferably according to the invention at least one inlet has a cross section widening in the direction towards the interior of the body, preferably in a continuous fashion.
According to an advantageous embodiment of the invention at least one additional profile being oriented at least substantially in parallel to the rotational axis is provided in the region of the radially outer circumference.
The invention also relates to an installation using the device for separating gaseous components from pourable media, in particular solid suspensions, described above. Conveniently according to the invention the device is arranged within a housing. According to another advantageous embodiment of the invention the device is arranged in a channel, in particular a pipe, a bent and a curved pipe, respectively.
Conveniently according to the invention the device is arranged in an oblique position in the housing and channel, respectively.
Advantageously according to the invention the device is arranged in an eccentric position in the housing and channel, respectively.
According to an advantageous embodiment of the invention the device is arranged downstream of a container and protrudes at least partly from the housing and channel, respectively, into the container.
Conveniently according to the invention the device is arranged upstream of a pump.
Advantageously according to the present invention the device is directly connected to the shaft of the pump. According to a preferred embodiment of the invention the device takes the form of a pump rotor vane.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be described by way of the exemplary embodiments in the drawings, wherein
FIG. 1 shows a side view of a device according to the invention,
FIG. 2 shows a plan view in direction B according to FIG. 1,
FIG. 2a shows a plan view of a further device according to the invention,
FIG. 3 shows section A--A according to FIG. 1 as well as flow lines of the medium,
FIGS. 3a and 4a show a plan view of a device according to the invention with flow lines shown,
FIGS. 4b to 11 show side views of diverse variants of the type and place of positioning of suction openings,
FIG. 12 shows a side view of a variant of the invention having additional elements for generating a centrifugal effect,
FIGS. 13 to 15 show side views of variants of the assemblage of the device in an installation,
FIGS. 16 and 17 show vertical sections of variants of the device directly connected to a pump shaft,
FIGS. 18 and 19 show side views of variants for arranging the device upstream of a pump,
FIG. 20 shows a side view of a variant for discontinuous use of the device,
FIG. 21 shows a side view illustrating the incorporation of the device in a pump rotor vane, and
FIG. 22 shows section C--C according to FIG. 21.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 shows a side view of a device according to the invention which essentially consists of a body 1 having arms 2 extending radially outwards, each of which is provided with channels 3 and 4, an inlet 5 and a cavity 6 opening outwardly, so that there is a connection to space 13 where the medium to be degassed is located. The suction opening or inlet 5 connects space 13 to channel 4, which is in turn connected to cavity 6. Channel 3 connects cavity 6 to the suction conduit or collecting channel 7. Body 1 is connected to a drive shaft 9, so that the whole device rotates in direction 20 in a housing 12 into which feed medium may enter through an opening 10 and from which the medium processed according to the invention may exit through an opening 11.
FIG. 2 shows a plan view of the device, similar parts being indicated with the corresponding reference numerals according to FIG. 1. An embodiment having three arms 2 is shown in plan view in FIG. 2a.
Section A--A according to FIG. 1 is shown in FIG. 3. FIG. 3a shows a plan view of a device according to the invention, this figure giving, on the one hand, media flows and, on the other hand, important operation and device parameters. With reference to these figures the process is to be explained in more detail now. Rotation of the device generates a relative speed R between the medium to be degassed and the arms 2. The medium now flows around the upper and lower external surfaces of arms 2 in direction 19, generating underpressure zones 8 having a pressure p 3 in certain locations of the arms 2 and in its surroundings, where the gas or gas-enriched medium accumulates because of its low specific density. The relative speed R is chosen so that it results in a sufficient pressure difference (p 1 -p 3 ) to cause the separation of gas. Here the relative speed R is determined by the number of revolutions n as well as the radial dimensions (r 1 ,r 2 ,r 3 ,l 3 ,l 4 ), the number of revolutions being higher than a minimum value of about 200-300 rpm. The gas or gas mixture accumulated in the underpressure zones 8 subsequently, via suction inlet 5, enters channel 4 and furthermore cavity 6. Pressure p 2 prevailing in collecting channel 7 is set so that it is lower than pressure p 3 of underpressure zones 8. In this cavity 6, due to the higher centrifugal force prevailing there, the gas in the gas-enriched medium is effectively completely separated from non-gaseous components possibly present. The separated components are again recycled to the medium flow through the outer open end of cavity 6 remote from the zone 8. The purified gas enters the collecting channel 7 via channel 3. With appropriate design of the device and choice of operation parameters (e.g. number of revolutions, underpressure) no control is necessary during operation. This results in high safety of operation even with highly varying operating conditions and markedly different compositions of the liquid-solids-gas-mixture.
Advantageously inlet 5 is formed so that it results in the evacuation of gas over a certain area by a large radial extension and thus keeps the distance the gas has to cover in the medium in order to reach the zone of suction short. With media which are difficult to degas the distance may be kept correspondingly short by increasing the number of revolutions n in order to achieve effective degassing anyhow.
The separation of non-gaseous components from the gas by differing centrifugal forces of the components caused by the differences in density takes place in cavity 6. Separation is effected at a distance l 4 from the center of rotation. The forced dislocation of the process of separation to a relatively large distance l 4 from the center of rotation as compared to known processes with the formation of spouts near the center of rotation results in extremely good separation of the components. The (solid and liquid) components separated from the gas are recycled to the medium via the cavity 6 open towards the radially outer periphery of the rotary body. The gas is redirected at least 90° relative to the direction of entry of the medium into cavity 6 and evacuated from the device via channel 3 and collecting channel 7. For the functioning of the device wherein the gas is redirected there is a lower limit of dimension r 2 -l 3 of cavity 6. This is, on the one hand, determined by the fact that the medium enters the cavity 6 because of the pressure difference p 1 -p 2 (external pressure of the medium minus pressure in collecting channel 7). Due to the rotation a counterpressure is generated by the centrifugal forces until a penetration depth of the medium of r 1 -l 4 has been reached, where a pressure equilibrium comes about. On the other hand, the cross sectional area of the cavity 6 between l 4 and l 3 is to be kept so large that the gas may unrestrictedly pass from channel 4 to channel 3.
The pressure drop from outer space 13 via cavity 6 into channel 3 or 7 may be promoted by appropriately forming the outer contour 14 of body 1 and arms 2, respectively, if, for instance, the outer contour 14 takes such a form that the radial extension of arms 2 decreases in the direction opposite the direction of rotation, thus creating an underpressure zone 8 in this region. Because of the underpressure zone 8 the medium cannot penetrate into the cavity 6 as deeply as would be the case with a cylindrical outer contour 14.
Thus with this process, even in cases of varying operating conditions, no control activities are necessary; instead, effective degassing of the medium at high operating reliability takes place because of the practically delay-free procedure even in cases of highly unsteady operating conditions. Even in the extreme case of the medium being completely free of gas no non-gaseous components may get out of the system if the dimensions and operative parameters are chosen appropriately. In this case the medium flows into channel 4 via inlet 5 and returns to the outer space 13 via cavity 6.
The medium is conveyed by appropriately shaping the arms 2 and angles α and β, respectively, with respect to the rotational axis. The angles α and β, respectively, are chosen in dependance on the amount of throughput of medium to be degassed, the number of revolutions, and the desired conveyance behaviour, and with one embodiment of the rotor vane type may differ as to the radius. Ordinarily angle α≧β.
Thus, it may be seen by inspection of FIGS. 1-3, that the body has a radially inner portion mounted for rotation about a central axis, a radially outer portion defining a radial periphery, and a continuous internal space extending from the inner portion to the outer portion of the body. In the illustrated embodiment, the inner space includes a cavity 6 at the outer portion of the body, defining a media discharge opening at the radial periphery 14. Discharge channel 3 extends in fluid communication between the cavity 6 and a gas discharge opening at the radially inner portion of the body, in fluid communication at the discharge opening with the collecting channel 7. The inlet opening 5 is in fluid communication with the internal space, which may include an inlet channel 4 extending in fluid communication between the inlet 5 and the cavity 6. The discharge channel 3 extends radially and the inlet channel 4 extends in parallel to the discharge channel. As shown in FIG. 1, the inlet channel 4 can be situated at a different elevation from the discharge channel 3, when the body is viewed in cross section.
The cross section of inlet 5 and its course, respectively, may be different. Thus FIG. 4a in plan view and FIG. 4b in side view, respectively, show a slot-like inlet 5, extending over the total length of arm 2. FIG. 4a again shows the individual media flows (liquid-solids-gas-mixture, gas, non-gaseous components). In this embodiment, the interior space consists of a cavity 6, 3, 4 extending radially along a straight path between the gas discharge opening and the media discharge opening. By way of example FIG. 5 shows diverse configurations of inlet 5, these being employable alone as well as in combination. It illustrates bores 5' arranged near shaft 9 and ending, on the one hand, in a channel 4 and, on the other hand, in a cavity 6. Furthermore slot-like openings 5" are shown, the direction of which is tangential to the direction of movement and in any oblique arrangement thereto, respectively, this choice depending on the material parameters of the medium and the other operating conditions. If the non-gaseous components may be separated easily, channels 3 and 4 may be short as shown in FIG. 5 or a single cavity may perform the function of channels 3,4 and of cavity 6 (FIG. 6). The cross section of inlets 5, having the form of bores in FIG. 6, increases in the direction of cavity 3,4,6, and this is how clogging by non-gaseous components carried along is prevented.
In the case of minor amounts of gas to be separated the cavity 6 may also be very small (FIG. 7). Also, as shown in FIG. 8, channels 3 and 4 may be directly connected via opening 3'. FIG. 8 furthermore shows a variant of how to form the collecting channel 7, which in this case surrounds shaft 9 as an annular gap.
FIG. 9 and the plan view thereof in FIG. 10 show an embodiment with media that are difficult to degas or large amounts of gas to be evacuated. Here body 1 is provided with additional wing portions 2' or 2" which extend from the arm portion 2 in a direction substantially parallel to the central axis, and define the external surfaces which generate the under pressure zones. The wing portions have openings 5' and 5", respectively, (shown as bores here, but also possible in slot-like configuration), which communicate with cavity 6 via channels 4' and 4", respectively, or optionally via a channel 4. These inlet openings 5', 5" are oriented to draw gaseous components with media, in a direction which is substantially mutually perpendicular to the central axis and a radius passing from the axis through the arm. In this embodiment, the discharge channel 3 extends radially, and the inlet channels 4', 4", enter the cavity 6 (either directly or indirectly via channel 4), along a path which is substantially parallel to the central axis.
FIG. 11 shows a further embodiment of the device having an additional portion 2"' and a channel 4"', suction from the underpressure zone 8 taking place via inlets 5.
FIG. 12 illustrates a variant of the device according to the invention, combining the process according to the invention with the known processes employing centrifugal effect. Elements 15 are provided here, which are able to degas the medium in the outer peripheral region up to about r 1 according to the principle of a centrifuge. Appropriate portions 16 may be provided for stiffening purposes. The advantage of this embodiment resides in the fact that the length of the construction is considerably shortened as compared to known devices and that no gas separation has to take place within the area of r 1 . Thus the distance to be covered by the gas to be separated is considerably reduced. The elements for stabilizing the spout as well as the necessity for elaborate control may be dispensed with as well. The individual gas velocity components are illustrated here as well, namely in axial direction the same speed as medium c 1 , in radial direction component c 2 depending on the medium to be degassed and the operative parameters, and the velocity component c 3 resulting therefrom in the direction of the center of rotation. Because of the evacuation of gas over a certain area inside radius r 1 the otherwise necessary length of a centrifuge of l 2 is reduced to l 1 . As no spout-like gas separation near the center of rotation has to be done, no elements for the stabilisation thereof are necessary either. Because of the efficient separating function, the sieves or the like used so far may be dispensed with as well.
FIGS. 13 to 15 show various arrangements of the device according to the invention in a housing 12 which is ordinarily disposed below a container to be evacuated. FIG. 13 differs from FIG. 14 in that in FIG. 13 the device is completely contained in the housing 12, while the device of FIG. 14 protrudes at least partly into the container arranged thereabove.
FIG. 15 shows the arrangement of the device in housing 12 with an oblique shaft 9.
In FIGS. 16 und 17 the device is directly connected with the shaft 9 of a pump arranged downstream thereof, the collecting channel 7 in FIG. 16 being provided centrally in the shaft 9 and sucked off via an annular chamber 17. By contrast, in FIG. 17 suction takes place via an annular gap 7'. In particular, the gap is defined by a collar or sleeve annularly disposed in spaced relation from the device drive shaft and the pump drive shaft, such that an annular gap extends from the gas discharge opening in the body, to a collection chamber surrounding the pump drive shaft. As shown in FIGS. 16 and 17, the collection chambers 17, are provided downstream of the pump rotors.
FIGS. 18 and 19 show arrangements of the device in a housing 12 to which pump 18 is directly connected.
If a liquid-solids-gas-mixture is to be degassed discontinuously, an arrangement according to FIG. 20 is used.
FIG. 21 shows an embodiment wherein the device is directly integrated into the pump rotor vane. FIG. 22 shows a section C--C according to FIG. 21. Preferably, the body of the separating device, forms the upstream end of the rotor vane. The pump drive shaft 9 includes a gas collection channel which extends along the pump drive shaft to a gas collection chamber downstream of the rotor vane. The gas discharge opening from the discharge channel 3 in the body, is in fluid communication with the gas collection channel 7. The inlet 5 and inlet channel 4 are situated upstream relative to the discharge channel 3, when viewed along the direction of media flow through the pump.
Basically body 1 of the device may also take a form so as to achieve a conveying effect on the medium.
The illustrated embodiments of the invention only serve as examples and may be modified by one skilled in the art within the scope of the claims. | The invention relates to a process and apparatus for separating gaseous components from pourable media. The main feature of the invention is that regions of under pressure are formed by relative movement between the media and a substantially vane-shaped external surface on a body arranged therein. The gas collecting in the under pressure regions is evacuated through the interior of the body. The body is preferably arranged to rotate, such that at least one inlet on the body at the under pressure region communicates with a gas outlet inside the body to remove the separated gas. | 3 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention herein pertains to resilient fiber masses and methods for producing the same from fiber battings treated with polyurethane foam.
2. Description of the Prior Art and Objectives of the Invention
It is well-known in the art that the characteristics of a fiber batting or web can be changed and improved by impregnating the web with a resinous material to change the physical properties. U.S. Pat. No. 4,496,624 describes various polymeric compositions used for these purposes. Also, various fabrics are described in U.S. Pat. No. 4,448,922 which are used with polyurethane dispersions to improve the surface characteristics of the end product. Fiber batt coating techniques are described in U.S. Pat. Nos. 4,367,148, 4,511,605, 4,332,710 and 4,171,391, certain of which utilize polyurethane resins such as U.S. Pat. Nos. 4,511,605 and 4,332,710. U.S. Pat. Nos. 4,902,542 and 4,944,992 provide a cushion formed from fibers with a polyurethane resin binding the fibers at the intersection. U.S. Pat. Nos. 5,021,286 and 5,149,567 demonstrate methods of impregnating intertwined fibers with urethane polymer emulsions to maintain the fibers in place by binding the intersections thereof. Nevertheless, these patents do not provide the advantages and benefits of the present invention for forming a highly resilient mass which may be used as padding in the production of arms, backs and cushions in automotive interiors and furniture.
It is understood in the industry that polyester fiber batting can be used as a padding material, however, such batting exhibits very poor shape retention and low resiliency. Consequently very large amounts of batting are generally compressed into upholstering envelopes in order to obtain a sufficient degree of padding. Attempts have been made at enhancing the physical properties of polyester fiber batting by introducing low melt fibers onto the batting and then heating it, to thus obtain a bonded network of fibers. While some improvement in the shape retention properties may be noticeable, the product so produced is generally "boardy" in feel and its properties are still not adequate to fulfill the comfort and aesthetic appeal required by most furniture and bedding manufacturers.
It is therefore one objective of the present invention to provide a method for producing a fiber mass having reduced deformability and increased resiliency by the process of treating a fiber batting with a foamable prepolymer in a hydrocarbon solvent-free continuous process.
It is still another objective of the present invention to provide a method to improve the resiliency of fiber batting by spraying a foamable polyurethane prepolymer onto garnetted needle punched, or similarly prepared, fiber batting and then polymerizing and foaming the prepolymer with steam to provide a fiber mass with the fiber separated by foamed polymer.
It is a further objective of the present invention to provide a process for forming a furniture seat or other article by molding a coated fiber batting with steam having small amounts of a tertiary amine therein and with traces of dimethylsiloxane in the prepolymer to enhance the foaming properties.
It is yet another objective of the present invention to provide an economical method of producing a highly resilient furniture cushion or other article by first spraying a fiber batting with a foamable polyurethane prepolymer, folding and shaping the sprayed batting to conform to the interior dimensions of a mold, compressing the fiber batting within the mold, subjecting the mold contents to steam to crosslink or polymerize the foamable prepolymer, and thereafter removing the finished article from the mold.
Various other objectives and advantages of the present invention will become apparent to those skilled in the art as a more detailed description is set forth below.
SUMMARY OF THE INVENTION
The aforesaid and other objectives are realized by providing a resilient fiber mass as used in a chair seat comforter, cushioning, furniture, bed padding or otherwise, which will not easily deform and which is highly durable. The resilient fiber mass is manufactured by the process of coating a conventional fiber batting which may be, for example formed from air laid polyester fibers which are sprayed with a foamable polyurethane prepolymer. The treated (sprayed) fiber batting is then pressed together by means of a mechanical conveyor or mold to the desired density and load-bearing properties and is subjected to steam for polymerization for a few minutes. The fibers separate at the intersections as the prepolymer foams to form resilient intersections. The resilient mass thus produced may be cut, slit or otherwise portioned as needed for use in subsequent upholstering or quilting operations.
The foamable polyurethane prepolymer is conventionally formed by reacting a 3,000 molecular weight polyether polyol with toluene diisocyanate whereby the reaction yields a 20% free N═C═O radicals liquid prepolymer having a viscosity in the range of 3,000-5,000 cps suitable for spraying purposes. The prepolymer liquid is then modified by adding less than 2% but more than 0.1% of a silicone surfactant such as L-520 (supplied by Union Carbide). The foamable prepolymer liquid blend thus produced is then placed in a conventional spraying apparatus. After spraying, the fiber batting is then processed either by a continuous method consisting of compressing the fiber batting and subjecting it to steam, which may contain less than 5% but more than 0.1% of a tertiary amine catalyst, or a batch method which consists of placing the prepolymer sprayed fiber batting in a mold, subjecting it to steam for foaming (polymerization) and cutting suitable portions from the resilient fiber mass formed, or placing sheets cut from the sprayed batting into a suitably shaped mold for polymerization to obtain specific shaped articles such as cushions. During polymerization foaming occurs which separates the fibers, forming highly resilient fiber intersections.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 demonstrates one method of the invention with a conventional fiber batting being coated with a modified foamable prepolymer, compression of the sprayed batting by a conveyor and steam treatment for foaming and polymerization and slitting the resulting thin fiber mass to desired lengths;
FIG. 2 illustrates the preferred method of the invention in which a fiber batting is sprayed with a modified foamable prepolymer, the sprayed batting rolled into a coil which is then placed into a mold for shaping and polymerizing, and subsequent slitting of the foamed polymerized resilient mass to desired size portions;
FIG. 3 shows another method of spraying a conventional fiber batting with a modified, foamable prepolymer, slitting the sprayed batting to desired lengths and molding the slit sections to a specific resilient mass shape; and
FIG. 4 depicts an enlarged schematic view of a few of the fibers of the fiber mass to illustrate the separated fibers and resilient intersections with the polyurethane foam.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The preferred method of the invention is shown in FIG. 2 which schematically demonstrates an opened and blended polyester fiber mixture delivered to a web or batt forming machine such as a garnet or other type of air-laid web forming machine. In this method, the thickness of the fiber batting formed will be approximately 1/2 to 3/4 of one inch (1.3-1.9 cm) thick, with a square foot (0.09 m 2 ) of the fiber batting weighing approximately 1/4 of an ounce (8.5 gm). However, an air laying machine, such as a Rando webber, can be used to form a thicker, single layer batting if desired. The fiber batting is sprayed on both sides with a hydrocarbon solvent-free foamable polyurethane prepolymer and is rolled into a cylindrically-shaped mass. The mass is then placed in a mold having a rectangular cavity, where it is compressed to the desired density, preferably 1.1 to 2.5 pcf. Steaming for one minute causes foaming and polymerization to occur. The polymerized, preferred resilient fiber mass so formed is then removed and cut to desired portions, which can be used for cushions, furniture padding or the like as the intersections of the fibers separate upon foaming to provide high resiliency of the fiber mass.
In the most preferred method, a standard needle punched fiber batting having a thickness of approximately six millimeters, a width of 1 meter and a length of 3 meters is continuously formed from polyester fibers having a denier of 2-6 with an average length of 75 mm. The fiber batting is driven on a conventional motorized conveyor at an appropriate speed past spray heads which are in fluid communication with a liquid-containing tank holding a cross-linkable, foamable liquid polyurethane prepolymer. The prepolymer in the preferred embodiment, consists of a liquid polyurethane as is conventional in the art formed by reacting a 3,000 molecular weight polyether polyol with toluene diisocyanate to yield a 20% N═C═O free radicals liquid prepolymer having a viscosity of 3,000-5,000 centipoises (cps) at 70° F. The prepolymer is modified by the addition of 0.1-2% silicone surfactant. The liquid modified foamable prepolymer is sprayed onto the fiber batting in a weight ratio of fiber to prepolymer of 1:1. The resulting density of the batting with prepolymer is most preferably 1.8 pounds per cubic foot. Next, after the sprayed fiber batting is removed from the conveyor it is placed on a table where it is manually rolled into a properly sized coiled cylinder. The cylinder is next placed in a mold and steam at 220° F. is used to polymerize and foam the polyurethane prepolymer. The resultant resilient fiber mass so formed is removed from the mold and can then be cut into selected size portions for use as cushions, paddings or otherwise.
The chemistry of the foamable prepolymer will also determine the end physical properties of the desired resilient mass, with higher molecular weight polyols yielding fiber masses with lower load-bearing properties, and while toluene diisocyanate is the preferred isocyanate because of its reactivity, it is also possible to use other commercially available aromatic and aliphatic isocyanates and mixtures thereof. Additionally, co-spraying a reactive mixture of a polyether polyol formulated to polymerize the reactive isocyanate portion of the formulation yields a desirable, resilient mass. While utilizing this method it is possible to enhance the formation of cellular structures within the fiber mass rather than the development of an elastomeric coating typical of the method that utilizes only the prepolymer and steam. The foaming prepolymer mixture during polymerization causes the fibers to separate at the intersections, thus forming a more resilient fiber mass than by usual methods of merely adhering the fibers together.
DETAILED DESCRIPTION OF THE DRAWINGS AND OPERATION OF THE INVENTION
For a better understanding of the invention, turning now to the drawings, three distinct manufacturing techniques are described:
In FIG. 1 fiber batting 11 from standard garnet machine 10 continues along conveyor 12 after being sprayed with a modified foamable prepolymer 13 where it is compressed to obtain a desired density, preferably 1.2 to 2.0 pcf by means of adjustable tension conveyor 17 having manual pressure handles 18, 18'. Fiber batting 11 is also subjected to steam 14 during compression for a period of approximately one minute. After exiting from the steaming (polymerizing) process resilient fiber mass 15 is then slit into desired lengths 20 by means of standard slitter 19, which may be a saw, laser beam, hot wire cutter or the like. Lengths 20 can be used for cushions and padding as usual in the furniture and related industries. An enlarged view of a portion of resilient fiber mass 15 is seen in FIG. 4 with fibers 51 separated by resilient polyurethane foam 52. While all fibers 51 may not be spaced apart by foam 52, a sufficient number are which greatly increases the resiliency of fiber mass 15.
In FIG. 2, the preferred method of the invention is shown whereby garnet machine 10 is loaded with polyester fibers 30 to produce fiber batting 31. Fiber batting 31 is sprayed on both sides with a modified foamable polyurethane prepolymer 13 as hereinbefore described from tank 32. The modified foamable prepolymer sprayed fiber batting is then manually rolled into coiled cylinder 33. Cylinder 33 is then placed in mold 34. Mold 34 includes an upper half and a lower half which are hingedly joined and latched during injection of steam 14. As would be understood, cylinder 33 is compressed and deforms to the shape of the internal rectangular cavity 35 of mold 34. As seen, mold 34 includes a substantially rectangular cavity 35 although other shapes and configurations may be used. The resultant resilient fiber mass 36 (similar ro fiber mass 15 as seen in FIG. 4) formed is then removed and a standard slitter 19 can be used to cut desired size portions such as portion 37 seen therein. Once cut, portion 37 can be used as a furniture cushion, padding or otherwise and as needed.
In another embodiment of the invention, as seen in FIG. 3, garnet machine 10 forms fiber batting 41 which is sprayed with a modified foamable prepolymer mixture 13, as described in FIG. 2, and passes along conveyor 12 to slitter 19. Slitter 19 cuts sprayed fiber batting 41 into desired lengths 42 which are then placed within mold 22 which has a specific shaped cavity, as seen in FIG. 3, for a particular article. Mold 22 consists of an upper mold portion 43 and a lower mold portion 44 with hinge 45 and latch 46. Once the mold has been loaded with sprayed fiber batting sections 42, it is then closed and latched as shown in the schematic cross-sectional view. Next, a conventional steam source (schematically shown at 47) delivers steam at 220° F. which is mixed with trace amounts of a standard tertiary diamine catalyst 48 (approximately 1% of prepolymer 13 weight contained in mold 22). Steam 14 is directed to mold 22 for approximately three minutes. The resilient fiber mass 49 thus produced is thereafter removed and has a resiliency comparable to polyurethane foam having the same approximate density thereof.
Other specific examples of the methods are as follows:
EXAMPLE 1
A randomly arranged mixture of polyester fibers having an average denier of 15 and average length of 12 inches and containing 10% by weight of low melt polyethylene fibers having an average denier of 9 to 75 mm in length was sprayed with a modified foamable polyether urethane prepolymer. The foamable prepolymer is prepared by reacting a 6500 MW triol with toluene diisocyanate to obtain 10% free N═C═O radicals. The resulting mass consisted of 80% fibers and 20% polyurethane by weight. The mass is placed in a perforated metal cavity and compressed to a density of 1.4 pcf. The mass was then subjected to steam vapors for a period of two minutes for foaming and polymerization. After drying for a period of 24 hours, the mass was tested for resiliency and height retention after conventional cycle pounding to 30% of its original height. The results of the test indicate that the product exhibited physical properties slightly below the expectations of virgin polyurethane foam but far superior to the characteristics of conventional polyester batting.
EXAMPLE 2
An air laid polyester fiber batting having a thickness of 10 mm, an average denier size of 5 and fiber length of 75 mm, was sprayed with a foamable polyether urethane prepolymer consisting of a 4000 MW triol reacted with MDI to obtain 18% free N═C═O radicals and 0.5% of a conventional silicone surfactant as used in the urethane foam industry to enhance foaming and control cell formation. The fiber mass was folded onto itself and placed in a perforated metal cavity mold to a density of 1.8 pcf. The mass was then subjected to steam which had 1.0% by weight of a tertiary diamine catalyst, for a period of three minutes. Upon removal, very small foamed cell formations having dimensions from 0.5 to 2.0 mm in diameter were noticed throughout the fiber network. The resilient mass appears to have a resiliency similar to comparable polyurethane foam.
EXAMPLE 3
A 0.5 inches thick garnetted polyester fiber batting was sprayed with the same prepolymer as described in the method of FIG. 2 above at a ratio of 60% fiber and 40% foamable urethane prepolymer. The fiber mass was placed on a perforated metal tool that had the shape of a back cushion and compressed by the mold lid to a density of 1.2 pcf. It was then subjected to steam for a period of one minute for foaming and polymerization. The article was demolded and allowed to dry for a period of two hours. It showed desirable characteristics of shape retention and was adequate for use as a chair back.
Those skilled in the art will recognize several modifications to the above-described process, foamable prepolymers and fibers which may enhance the properties or change the characteristics of the resilient mass which is so formed combinations of polypropylene and polyester fibers, recycled fibers and others may be utilized as desired. Thus, the examples presented are merely for explanatory purposes and are not intended to limit the scope of the appended claims. | A resilient fiber mass and method of forming the same is provided whereby a conventional batting is sprayed with a polyurethane prepolymer and is then in one embodiment rolled into a tight cylindrical shape for subsequent molding. A steam catalyst is introduced into a mold having a specific shape which causes the prepolymer to foam and polymerize. The foaming action separates the fibers at the intersections to provide resiliency to the fiber mass. The molded mass is then removed and can, for example, be attached to a chair seat and covered with decorative fabric as is standard in furniture manufacturing. The chair cushion so formed is highly resilient and durable. | 3 |
CROSS-REFERENCE TO RELATED APPLICATION(S)
[0001] This application is a divisional of application Ser. No. 11/033,605 filed Jan. 11, 2005, the disclosure of which is incorporated fully herein by reference.
SUMMARY OF THE INVENTION
[0002] Birding, that is the recreational activity of observing birds, is an increasingly popular pastime around the world. An important component of birding is the identification of the species of an observed bird. At least as important to the birder is the identification of the genus or family, of an observed bird, especially if the species is unknown. Of special importance to serious birders is aiding their accomplishment of learning to identify observed birds in the field.
[0003] To date, birders have had only field guides and recordings as personal aids for identifying and learning to identify birds. However, in no case do these aids actually determine an identification, they only provide comparative references and the judgment of whether a match is made or not is left entirely to the birder. Further, in no case is any feedback given on the quality or reliability of the match they have just made, Additionally, in the case of learning bird songs and calls, there is currently no practical way to precisely indicate to the learner which aspects of a particular bird's song are most relevant to the identification. In consequence, making progress in learning identification is slow at best.
[0004] More recently, there have been electronic versions of field guides created (sometimes including audio recordings) that speed the process of searching for a particular comparative reference. However, even with these more sophisticated approaches, the ultimate judgment about a match is left entirely to the birder and no feedback on the quality of their match is provided, or even possible.
[0005] For other birders, such as people who set out bird feeders in their backyard, the joy of knowing what birds have visited their yard is foremost and learning the skill of identifying the birds is not as important. For these birders, field guides and recordings, electronic or not, have another significant liability. This liability is that the birder must be actively engaged in birding at the time a bird shows up in their yard in order to make the identification. Every backyard birder will surely identify with the experience of noticing an interesting bird, perhaps by hearing its unusual song, and running to get a field guide only to discover that the bird has left by the time they get back to make the identification.
[0006] The current invention teaches how to overcome all the deficiencies noted above with an apparatus that automatically identifies birds by way of their vocalizations (calls and songs) and employs a novel method for doing so. Previous methods for attempting to identify birds by their vocalizations such as neural network, hidden Markov model, dynamic time warping, and other techniques, attempt to match an incoming bird vocalization against a library of exemplars using an overall similarity standard to determine a match. These techniques have not achieved notable success in resolving any of the deficiencies noted above.
[0007] The current invention takes a different approach. Instead of an overall similarity standard, the current invention, as described in detail below, employs a hierarchical method that largely parallels the neuro-physiological hierarchy of bird vocalizations. When this method is embodied in a very portable computing device, such as a personal digital assistant augmented with appropriate software and audio capture capability, this method allows the device to determine that a bird is singing, even if nothing else about the bird can be determined. Further, it allows the family of a bird to be determined, even if the species cannot be determined. Finally, it allows the species to be determined. Additionally, it provides for the time-based annotation of the bird song so that that the relative importance of each part of the song for the purpose of identification can be relayed to the birder to aid in their learning.
[0008] The current invention teaches how to embody such functionality in a hand-held computational device together with a microphone, an audio capture card or other means, a user application that runs on the device, and a library of vocalization characteristics that, because it resides on the audio capture card, is accessible to the application but generally inaccessible to the user. This last characteristic allows for new libraries of characteristics to be sold as hardware additions, lessening the problem of unauthorized distribution.
[0009] The intended use of this invention is two-fold. When a birder carrying the device hears a bird of interest while observing birds in the field, they point the microphone of the device toward the calling bird and activate the identification function of the device. The device processes the sound and presents the results of the analysis to the birder. The possible results include that no bird was detected; that a bird was detected but the family could not be determined; that a bird was detected and the family was identified (and was so and so), but the species could not be determined; that a bird was detected, the family was determined (and was so and so) and the species was determined to be so and so.
[0010] Alternatively, the device can be used in backyard mode in which all incoming sounds are analyzed and when a bird is detected the device automatically proceeds with the identification process and records the results for the birder to review immediately or at a later time.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] These and other aspects of the invention will be better understood by reference to the drawings herein.
[0012] FIG. 1A is a pictorial elevation view of an embodiment of the invention.
[0013] FIG. 1B is a side view of the embodiment of FIG. 1 .
[0014] FIG. 1C is a pictorial elevation view of an alternate embodiment of the invention.
[0015] FIG. 1D is a side view of another alternate embodiment of the invention.
[0016] FIGS. 2A and 2B are elevation and side views of another alternate embodiment of the invention.
[0017] FIG. 3 is a block diagram of a preferred embodiment of the invention.
[0018] FIG. 4 is a diagram comparing the hierarchy of the components of the invention with physiological/neurological hierarchy of bird vocalization.
[0019] FIG. 5 is a waveform diagram and graph of a segment of a particular species of bird.
[0020] FIG. 6 is a functional block diagram of the software employed in the computational device according to the present invention.
[0021] FIG. 7 is an additional block diagram of a subset of the software used in the present invention.
[0022] FIG. 8 is a diagram of dataflow through the components of the present invention.
[0023] FIG. 9 is an illustration of a display provided by the computational device for a specific species of bird.
DETAILED DESCRIPTION OF THE INVENTION
[0024] FIG. 1A is a front view of the embodiment of the current invention in which the system is to be used inside a residence or other building to keep track of birds that come near the window. For example, if a birder has a bird feeder or other attractive feature outside their kitchen window, they may use this system to identify birds that come into their yard.
[0025] In this embodiment, holding cradle 130 is attached to the interior side of windowpane 120 of window 110 by suction cups 150 or other attachment mechanism. The purpose of the cradle 130 is to hold the handheld computational device 160 on the window so that it can be operated while looking out the window and yet be easily removed for maintenance including battery charging or using wired means of communication with other devices to, for example, exchange recorded bird identifications. Accordingly, there is a connector 170 that provides for a connection between the handheld computational device 160 including an audio capture means (not illustrated in this figure) and a contact microphone 190 through a microphone cable 180 . The contact microphone 190 employs the entire windowpane 120 as a diaphragm, as is well known in the art, enhancing the sensitivity of the bird detection system. The connector 170 allows for the handheld computational device to be physically removed from the window location without also displacing the contact microphone.
[0026] FIG. 1B illustrates a side view of the embodiment of the current invention in which the system is to be used inside a residence or other building to keep track of birds that come near the window. In particular, it illustrates the manner in which the contact microphone 190 is attached to the interior surface of the windowpane 120 and requires that the connector 170 be removed in order to remove the handheld computational device 160 from the cradle 130 .
[0027] FIG. 1C illustrates an alternate embodiment of the current invention in which instead of being a contact microphone attached to the interior side of windowpane 120 of window 110 , the sound receiver is an open air microphone 195 attached to a remote location such as a bird feeder 185 or the external side of windowpane 120 through an extended cable 180 .
[0028] FIG. 1D illustrates another view of the embodiment of the current invention in which instead of employing a contact microphone attached to the interior side of windowpane, the sound receiver is instead an open air microphone 195 attached to a remote location such as a bird feeder 185 or the external side of windowpane 120 through an extended cable 180 . In this embodiment the cable 180 is of the flattened type that can pass between the windowpane and the frame without damage.
[0029] FIG. 2 illustrates the embodiment of the current invention that provides for use of the invention in field conditions such as walking through a forest. It includes a hand-holdable cradle 230 that is used to secure both the handheld computational device 160 and a directional open-air microphone 290 . The cradle includes attachment means 235 to hold the microphone in place and a connector 170 that allows the microphone cable 280 to be removed from the handheld computational device 160 including an audio capture means (not illustrated in this figure) to make it possible to remove the handheld device so that it may be used in other contexts such as charging its battery or connecting to other devices.
[0030] FIG. 3 illustrates the system block diagram of the preferred embodiment of the current invention. It shows a microphone subsystem 303 comprising microphone 390 with a cable terminating in a connector 170 . The audio capture subsystem 302 is contained in a compact flash or secure digital input/output or other suitable case that allows it to be plugged into the extension slot of hand-held computational device 301 . The audio capture subsystem 302 comprises a connector 385 that mates with microphone connector 170 , an analog to digital converter 380 , a random access memory buffer 380 wherein the result of the signal digitization are temporarily stored, non-volatile storage 375 such as flash memory in which is stored the data necessary for the family and species characterizations. These are connected to a card interface that includes control logic and power, data, and control signal connections in the usual way. Access to the non-volatile storage, and hence the data contained therein, should be through a proprietary control sequence rather than standard bus logic so users cannot readily copy the contents and distribute it to others.
[0031] The audio capture subsystem mates with a hand-held computational device 301 comprising an extension card interface 360 , a system data bus 340 , non-volatile storage 355 accessible to the user, a central processing unit 310 , system random access memory 350 , a user display 345 , communication port 315 , key input 335 , (optional) touch screen input 330 , and a power supply 320 .
[0032] FIG. 4 illustrates the parallelism between the neuro-physiological hierarchy of bird vocalization and the hierarchy of detection means employed in the current invention. The lowest levels of the hierarchy correspond to aspects of bird vocalizations that change slowly even on evolutionary time scales. These map to the bird detection means, 410 . One such aspect, and the one employed in the preferred embodiment, is the fact that birds have dual, substantially identical but independent, vibrating membranes in their syrinx. The corresponding audio characteristic of such a feature is used to establish that a bird was vocalizing at a particular time and providing fiduciary points for the next level of the hierarchy of analysis.
[0033] The next levels of the hierarchy correspond to aspects of bird vocalizations that change more rapidly on evolutionary time scales but are largely independent of the neural activity of the bird. These map to the family detection means, 420 . One such aspect, and the one employed in the preferred embodiment, is the set of dynamical modes achievable by a bird's vocal tract. Just as a duck call (or, for that matter, a flute) has only a limited number of dynamical modes no matter how you play it, so too do bird vocal tracts, as evidenced by experiments in which the syrinx is excised as played independently of the bird. The corresponding audio characteristics of the dynamical modes are used to index potential bird families vocalizing at various time regions and to focus analysis at the next level on familialy coherent regions of the vocalization.
[0034] The next levels of the hierarchy correspond to aspects of bird vocalizations that are neurologically controlled, but at lower levels of the neurological control hierarchy. These stereotypical aspects evolve over many generations. These map to the species detection means 430 . One such aspect, and one employed in the preferred embodiment, is the patterned sequence of shifts between dynamical modes. The corresponding audio characteristics, combined with the results of the other levels of analysis, allow for the rapid and sure identification of the family and species of a particular bird vocalization.
[0035] The next levels of the hierarchy correspond to aspects of bird vocalizations that are neurologically controlled and can change over the course of a bird's life
[0036] FIG. 5 illustrates in schematic form the signal annotation process of the current invention. In this figure is shown a graph 610 of a segment of recorded vocalization of a screech owl. Highlighted in the graph are four regions 601 , 602 , 603 , and 604 whose significance will be explained below. The illustration element 620 represents a region of memory containing the digitized signal as time-ordered samples.
[0037] The illustration element 630 represents the region of memory logically parallel to that represented in 620 but which contains the results of the bird detection means according to the current invention. Although one skilled in the art will realize that there are many ways to encode this information (for example, recording the start and stop times of positive results) for the purposes of illustration we will assume that the signal is represented by a copy of the original signal with the audio sample values replaced by detection result values. In this case, the highlighted signal region 601 is one in which the bird is apparently switching from vocalizing with one side of its syrinx to the other side. Hence in this region both sides of the syrinx will be in operation and the bird detection means will give a positive result as shown by the shaded is-bird region of 630 .
[0038] The illustration element 640 represents a region of memory logically parallel to those represented in 620 and 630 but which contains the results of the family identification means according to the current invention. For purposes of illustration as above, we will assume here that the family signal is represented by a copy of the original signal with the audio sample replaced by family or dynamical mode index values. In the preferred implementation, the family identification means is preferentially applied to the region of the digitized signal around which the bird detection means has returned a positive result. In this way, the possibility of inappropriately applying the means to non-bird sounds is lessened. The bird detection signal thus provides time anchoring for the family, and eventually species, determinations. In this illustration there are three regions of the signal (highlighted in 602 , 603 , and 604 ) surrounding the positive bird identification region in which the family identification means has returned meaningful values. In region 602 , the family identification means has found a dynamical mode, A, which is highly characteristic of the owl family. In regions 603 and 604 , it has found a mode, B, which while not as characteristic, is consistent with the owl family.
[0039] The illustration element 650 represents a region of memory logically parallel to those represented in 620 , 630 , and 640 but which contains the results of the species identification means according to the current invention. For purposes of illustration as above, we will assume here that the species signal is represented by a copy of the original signal with the audio sample replaced by species values. In the preferred implementation, the species identification means examines broader characteristics of the signal in a region including and surrounding regions consistent with a single family to determine the identity of the species in question. In the illustrated case it has determined that the entire region corresponds to a vocalization of a screech owl.
[0040] FIG. 6 illustrates functional blocks of the software application to be employed on the handheld device in the current invention for field use. Upon user initiation of the application, represented by block 710 in FIG. 6 , the application moves to process block 720 in which the user is presented with the current status of the time, date, and location and the user is enabled to confirm the current settings or revise them.
[0041] For the location data, the user may be presented with a scrollable map with the last known position marked and allowed to select, graphically, a new location. Alternatively, the user may enter geographic coordinates (or import them from a GPS or other positioning system), or select from a list of known places. The date, time, and location information is used in the system in two ways. First, it is used to annotate any recorded bird events so that the time, date, and location will be available along with other information about the event. Second, it is used to prioritize the list of candidate bird families and species to be considered as candidates in an identification attempt. To prioritize the list of candidates, a probability function for each family and species, constructed in the usual way from report densities and stored with the software, is evaluated on the time, date, and location data. The value of that probability serves as the ranking index of the family and species. This ranking is used to sequence the process of identification with the more probable candidates being examined first, although no candidates are ruled out on the basis of the time, date, and location data.
[0042] The application then proceeds to choose block 730 in which the user can select among modes of operation. In particular, the user may choose to enter a mode in which they can manage the list of identifications they have accumulated, exchange data with another device, and so on. This is represented by process block 760 and is described in more detail in another figure. Alternatively, the user may review and revise their location, time and date (process block 720 ,) enter field identification mode (process block 770 ) or exit the application (exit block 740 .)
[0043] Actual bird identification is enabled when the user enters field identification mode (process block 770 .) When this mode is entered, the application activates the audio digitization means (see FIG. 3 ) including an analog to digital converter and associated buffer. In field identification mode, the audio digitization means is then continuously recording (and, eventually, discarding) incoming sound and must therefore be draining power from the system, which can pose a problem for field use if unmanaged. It is thus important that the recording means be deactivated when exiting field identification mode either to choose another mode (process block 730 ) or to exit the application (exit block 740 .)
[0044] After entering field identification mode, the application proceeds to process block 772 in which it waits for the user to indicate that they are hearing, or just have heard, a bird they wish to have identified, that they wish to change mode, or that they wish to exit the application. In case they wish to identify a bird, the application proceeds to process block 774 in which the currently recorded (that is, already digitized and present in the buffer 370 of FIG. 3 ) signal is transferred out of the continuous recording buffer and into system memory where it can be examined without interfering with the operation of the recording means. It also queues up the process of transferring later blocks of recorded sound to system memory as they are required by the identification process and become available from the recording means. The application then proceeds to the decision block 776 . In this block, the application calls on the bird detection means to examine the currently recorded sound to establish whether or not a bird's vocal production is apparent in the recording.
[0045] In the preferred embodiment of this invention, this detection means looks in the signal for a pair of an harmonically related spectra that are shaped by the same resonant cavity. If no bird is detected, the application proceeds to process block 784 in which the recording in system ram can be saved or discarded (in this case discarded), any pending transfer queues are cancelled, and the user is informed of the result (negative in this case.) The purpose of aborting the search as early as possible under these conditions is three-fold. First, it gives immediate feedback to the user that the current conditions are unlikely to yield valuable results and thus train them more quickly to choose favorable over unfavorable conditions as best they can. Second, it allows the user to attempt another identification as soon as possible, without waiting for the (possibly lengthy and likely unsuccessful) repeated attempts at comparing with less and less likely family and species candidates. Third, in the case where bird characteristics are not present anywhere in the sample, the search for a family and species, if successful, is more likely to return spurious results than would be desirable.
[0046] If, on the contrary, a bird's vocal production is apparent in the recording, the application proceeds to decision block 778 . In this block, the application calls on the family identification means to examine the currently recorded sound near the time points at which the bird detection means has indicated that a bird's vocal production is apparent. This use of the bird detection means helps insure that the family identification means does not waste resources in trying to determine the bird family corresponding to a sound that was not produced by a bird. In the preferred embodiment, the family identification means employs a dynamical synchronization method to suggest to which family, if any, among the families whose representation is available to the application, this bird belongs. The dynamical synchronization method, most widely used in the field of communications through chaotic systems, couples the output signal of an unknown dynamical system to one or more models of dynamical systems and determines by the degree of synchronization of each model to the signal which model best represents the unknown system. For example, in the communication method known as chaos-shift keying, at any given time the message transmitter selects the output of one of two predetermined chaotic dynamical systems to be transmitted. The receiver couples the incoming signal to two model dynamical systems and determines which synchronizes to the incoming signal. In the current application to bird families, there will be one or more dynamical models for each family corresponding to the modes of oscillation that family employs.
[0047] In the case that the family is not successfully identified, the application proceeds to process block 782 in which the failure is reported to the user along with such additional information as may be desirable to the user. This information would include, for example, which families were considered and the degree of evidence discovered for each. The application then proceeds to process block 784 in which the user chooses whether to save the recorded sound in more permanent data storage for later analysis or, instead, to discard it.
[0048] In the case in which the family has been successfully identified, the application proceeds to process block 780 in which the species identification means is employed on the part of the recording around that in which the family was identified. This successive scoping aids in the identification process by focusing attention on the most relevant, and coherent, parts of the recording thus lessening the problems due to overlapping songs from other birds, or other interfering background noise. The candidate species to consider are determined by the family identified and prioritized for consideration by their likelihood of occurrence correlated to the time, date, and location. In the preferred embodiment, the species is identified by matching larger-scale characteristics of the sound against those characteristics of the candidate species. These characteristics include the time-base of the sound (characteristic frequency and duration of a phoneme or indecomposable unit) and which dynamical mode switches occur in what order. Whatever the results of these comparisons, the application then continues to process block 782 in which the results of the process are reported to the user. The application then continues to process block 784 described above and then back to block 772 to await another event.
[0049] FIG. 7 illustrates additional detail of functional blocks of the software application to be employed on the handheld device in the current invention for field use. In particular, it illustrates the functional blocks associated with mode in which the user can review and manage the collection of captured identification results they have saved and exchange data with another, suitably arranged, computing device such as a laptop or desktop computer or remote server. In process block 760 , the user chooses whether they would like to exchange data, review their list, or choose another mode. In the final case, the application continues to process block 730 , previously described. In the first case, the application continues to process block 810 in which the well-known desktop or remote server synchronization process is undertaken. In this specific case, the recordings and related information the user has accumulated on their handheld device through the use of this invention but not yet archived is transmitted in the usual way to the desktop or other device and archived there. Similarly, data for use with the family and species identification means, or updates to the application, which is present on the desktop or other device but not presently installed on the handheld are transmitted to the handheld and incorporated into the system. Once the user's data has been transmitted for archive, this fact is noted with the data so that the user can more easily decide which items they can delete on the handheld without losing them completely.
[0050] In the case that the user indicates that they would like to review their list, the application proceeds to process block 815 in which a scrolling or otherwise paginated list of items with short identifying information is presented to the user. In addition to scrolling or paging through the list, the user can either leave this mode, in which case the application proceeds to process block 760 , or select an item from the list represented here by process block 820 . Once an item has been selected, the user can either discard an item (process block 825 ) and return to review list process block 720 , or view details of that item (process block 830 .) In process block 830 all the saved information about the identification attempt is presented to the user including the time and date, the location, the bird family (if successfully identified,) the bird species (if successfully identified,) the recorded sound (if the user chose to save it,) and whether this item has been archived. From here the user can choose ( 835 ) to add or delete a photo or other image file to this item (so that if they also took a photo of this bird when they identified it, they can add this to their record of the event). Similarly, they can choose ( 840 ) to add or edit a text annotation to this item (so if they made other observations of interest such as the surrounding in which the event occurred, they can record this as well). If in addition, the user's device is appropriately configured to allow for playback of sound recordings and if the user chose to save the recorded data, they may choose ( 845 ) to play back the recorded sound. If, in addition, the user has other sound recording installed on their device in the usual way they can choose ( 850 ) to play one or more of those for comparison.
[0051] In an extension of this invention, the application here described can be integrated with a more typical electronic field guide containing descriptions, identification marks, photos or drawings, and sample sound recordings. In particular, the species or family information can be used as in index into the electronic field guide so that all the addition information available from the field guide can be viewed here as well.
[0052] FIG. 8 illustrates the dataflow aspects of the current invention when deployed for unattended operation, for example for use inside a residence as illustrated in FIGS. 1A-1D . This embodiment does not require the user to indicate to the system that the user is hearing, or has just heard, the song of a bird of interest. It must, therefore, make the determination of the presence of a bird of interest on an ongoing basis. Accordingly, all the processes shown in FIG. 8 operate concurrently to form a processing pipeline, as illustrated.
[0053] Those skilled in the art will recognize that such effective concurrency is often achieved through multiple threads of programmatic control that time-share a single central processing unit rather than employing multiple processing units actually operating in parallel.
[0054] In operation, sound, including bird-produced sound, enters microphone 910 and is converted to a continuous electrical sound signal that passes to analog-digital converter (ADC) 915 . Here, the signal is converted, in the usual way, to a digitized signal by sampling the signal periodically and recording each sample as a digital quantity in successive locations in a RAM buffer 920 . In the preferred embodiment, the ADC is a separate processor that operates independently of the central processing unit and takes samples approximately 44,000 times per second, and records each sample as a 16 bit quantity. In the preferred embodiment, the RAM buffer 920 is separate from system RAM, is directly addressable by the ADC 915 , is capable of storing approximately 6 seconds of recorded audio, and is operated as a circular buffer. That is, after the ADC 915 records a sample at the last available 16-bit block in the buffer, it continues recording at the first available location, overwriting the sample already in that location.
[0055] The purpose of the buffer is to allow ADC 915 to continue to record sound uninterrupted even while the central processing unit is occupied with one or another of the other processes described here.
[0056] From the buffer 920 , the digitized signal flows to the bird detector process 925 . In the preferred embodiment, the bird detector process 925 is carried out by the central processing unit and employs the bird detection means. In the bird detector process, the digitized signal is transferred out of the buffer 920 and analyzed with a sliding window methodology. That is to say, the incoming signal is treated as a sequence of overlapping blocks (windows into the signal data,) each approximately one half second in duration. The bird detection means is applied to a block and the result is recorded, keyed to that block. The next block to be analyzed is formed by adding one or more subsequent later samples to the block and removing the same number of earlier samples from the block. Both the digitized signal and the results of the bird detection process keyed to the signal are stored by the bird detector process into a known region of system RAM 930 for additional processing.
[0057] In the preferred embodiment, the bird detector process discards, before saving into system RAM 930 any parts of the digitized signal that are not within approximately 3 seconds of a window in which a bird was detected. This approach solves the problem that, in typical unattended conditions, there may be hours that go by without any bird vocalizations and without this mechanism, system RAM would fill up with useless data. With the current invention, after any number of hours of operation without bird vocalizations, at most 3 seconds of data would be accumulated into system RAM.
[0058] From the region of system RAM 930 in which the bird detector process stored the relevant parts of the digitized signal along with the results of the bird detection analysis, the data flow to the family detector process 935 . In this process, family identification data are generated from the family identification means applied to the digitized signal and bird detection data. The resulting family index data are keyed to the digitized signal and both are written to a known region of system RAM 940 to enable further processing. In the preferred embodiment, the family detector process 935 is carried out by the central processing unit and employs the family identification means. In this embodiment, the family detector process locates family-associated dynamical modes in the signal surrounding the time windows in which a bird vocalization has been detected. It does so by determining which of the dynamical models available to the application will synchronize with the time regions of the signal. The time sequence of these synchronizing models constitutes the family index of the signal over time.
[0059] From the region of RAM 940 in which the family detector process stored the relevant parts of the digitized signal along with the result of the family identification analysis, the data flow to the species detector process 945 . In this process, species identification data are generated from the species identification means applied to the digitized signal and family index data. The resulting species identification data are keyed to the digitized signal and both are written to a known region of system RAM 950 .
[0060] FIG. 9 illustrates the salient features of the bird song replay aspect of the software application in accordance with the current invention. An important element of the utility of the current invention is to assist birders in their ability to learn bird songs themselves. Because both the family index data and the species identification data are stored with, and keyed to, the digitized recorded signal, an abstract of this information can be displayed to the user in synchrony with the audio replay of the song itself. This allows the user to learn for themselves which elements of the bird's vocalization were most important for the identification of the family and species and therefore, to learn which elements to listen for to improve their capacity to identify birds for themselves. Although there have long been bird illustrations in field guides that include arrows or other methods to highlight visual characteristics most relevant to the identification of a species, prior to this invention there was no effective method to emphasize the elements of a bird's vocalization that are relevant to the identification, and certainly no method that enabled those elements to be emphasized in a just-made recording in the field.
[0061] FIG. 9 represents a possible screen shot of the display 1210 of the personal computational device on which the software application is running and the user has selected a recording for replay. The recording information 1215 is shown typically including the time, date, and location of the recording, and the family and species determination (if any) that was made in accordance with the current invention. Also shown are typical replay controls including a volume control 1225 and a play bar 1220 that allows the user to start, stop, rewind, and select a time in the recording. In addition to these typical elements, there are indicators 1230 and 1235 of the relevance of the time block of the recording immediately surrounding the current time point of the playback to the identification of the family and the species, respectively. Thus, at any time around which a dynamical mode characteristic of the family has been identified, the family relevance bar will be high. If this is not the case, the bar will be low. At any point near a mode transition characteristic of the species or in a time region in which the song is undergoing a smoother parameter change (an upward sweep of frequency, for example) that is characteristic of the species, the species relevance bar will be high and otherwise it will be low. In an alternate implementation in accordance with the current invention, the two types of information can be merged (say, summed) into a single display of relevance. In a further elaboration, this same relevance signal can be used to alter the volume control during the replay so that those parts of the song most relevant to identification are played at a higher volume level, while those less relevant are played at a lower volume level. | An apparatus for detecting and identifying birds based upon electronic analysis of their bird calls and songs and method for doing so by utilizing a step-by-step hierarchical method of breaking down bird vocalizations according to order, family, and species of the specific bird. Several embodiments of the apparatus are disclosed particularly a hand held computational device, microphone, audio capture card, user application software and a collection of prerecorded audio data. | 0 |
BACKGROUND
[0001] The present technology relates to a display control apparatus, a display control method, and a computer program product, and more particularly to a display control apparatus, a display control method, and a computer program product that display related information related to items such as icons such that they can be easily recognized by a user.
[0002] For example, with electronic devices such as personal computers (PCs), digital cameras, mobile terminals, TVs (television receivers), and car navigation apparatus, icons may be implemented as a user interface whereby a user supplies input to an electronic device.
[0003] In a user interface implementing icons, there are display methods that display explanatory messages explaining what an icon represents. For example, there is a method that displays a static explanatory message, and a method that displays an explanatory message for an icon in the case where a cursor that moves according to operations of directional keys or other cursor keys is positioned over that icon.
[0004] Meanwhile, as a user interface implementing icons, there is for example a user interface using a touchscreen, wherein a display panel such as a liquid crystal panel that displays icons, etc. and a touch panel that detects touches by the user's finger, etc. are integrated together.
[0005] In a user interface that uses a touchscreen, a function assigned to an icon displayed on the touchscreen is executed when that icon is touched.
[0006] As above, in a user interface that uses a touchscreen, since a function assigned to an icon is executed when triggered by that icon being touched, it may be difficult to use the touching of an icon as a trigger for displaying an explanatory message for that icon.
[0007] For this reason, in a user interface that uses a touchscreen, a guide icon (button) for guidance is provided, for example, and an explanatory message for a desired icon is displayed when the desired icon is touched after touching the guide icon.
[0008] In contrast, in recent years there have been proposed display methods that use a display panel which detects the proximity of a user's finger, etc., and display a menu when the user's finger, etc. comes into proximity with the display panel (see Japanese Unexamined Patent Application Publication No. 2007-108841, for example).
SUMMARY
[0009] As discussed above, with a method that displays an explanatory message for an icon that is touched after touching a guide icon, a user first touches the guide icon and then also touches the desired icon, which is inconvenient.
[0010] Also, with a method that displays an explanatory message for an icon that is touched after touching a guide icon, it is difficult to display an explanatory message for the guide icon. Furthermore, it is difficult for a user who does not know how to use the guide icon to view explanatory messages.
[0011] Meanwhile, in electronic devices, there is increasing adoption of a user interface that displays icons or items such as text strings arrayed in a list format, and conducts given processing in the case where a user touches an item.
[0012] Consequently, proposals are being demanded for technology that enables a user to easily recognize related information related to items, such as an explanatory message which explains what an item displayed on a display panel represents.
[0013] The present technology, being devised in light of such circumstances, is configured to enable a user to easily recognize related information related to an item such as an icon, for example.
[0014] In one embodiment, a display control apparatus includes
[0015] a processing circuit that
[0016] detects when an object is in a proximity position relative to a display and changes a display state of a displayed item when the object is detected as being in the proximity position, and
[0017] causes a relation item to be displayed at a position adjacent to the proximity position, the relation item being related to the displayed item.
[0018] One aspect of the apparatus is that
[0019] the processing circuit changes a size of the displayed item in response to the object being detected in the proximity position.
[0020] Another aspect of the apparatus is that
[0021] the processing circuit changes the display state by moving the displayed item to a different display location.
[0022] Another aspect of the apparatus is that
[0023] the processing circuit includes a detector that detects when the object is in the proximity position.
[0024] Another aspect of the apparatus is that
[0025] the relation item includes at least one of a function name of a function and an explanation of the function.
[0026] Another aspect of the apparatus is that
[0027] the displayed item is part of a matrix of displayed icons.
[0028] Another aspect of the apparatus is that
[0029] the relation item is displayed in a popup form.
[0030] Another aspect of the apparatus is that
[0031] the processing circuit also detects a touch of the object to the display, and processes the touch differently than when the object is in the proximity position.
[0032] Another aspect of the apparatus is that
[0033] the processing circuit subsequent removes the relation item from the display when the processing circuit detects that the object has been moved away from the display.
[0034] Another aspect of the apparatus is that
[0035] the processing circuit deletes related information for other icons in the matrix of display icons that are not adjacent to the proximity position.
[0036] Another aspect of the apparatus is that
[0037] the processing circuit also displays a relation item for another displayed item when the object is detected as also being proximate to the another displayed item.
[0038] Another aspect of the apparatus is that
[0039] the processing circuit changes a display state for a plurality of displayed items when the object is detected in the proximity position.
[0040] Another aspect of the apparatus is that
[0041] the relation item is displayed as text strings arrayed in a list format.
[0042] Another aspect of the apparatus is that
[0043] the text strings are displayed as user-actuatable buttons.
[0044] Another aspect of the apparatus is that
[0045] the processing circuit changes at least one of a color and a brightness of the displayed item in response to the object being detected in the proximity position.
[0046] According to an exemplary display control method, the method includes
[0047] detecting with a proximity detector when an object is in a proximity position relative to a display;
[0048] changing a display state of a displayed item in response to the detecting, and
[0049] causing with a processing circuit a relation item to be displayed at a position adjacent to the proximity position, the relation item being related to the displayed item.
[0050] According to an aspect of the method,
[0051] the causing includes changing a size of the displayed item in response to the object being detected in the proximity position.
[0052] According to another aspect of the method,
[0053] the causing includes changing the display state by moving the displayed item to a different display location.
[0054] According to another aspect of the method,
[0055] the relation item includes at least one of a function name of a function and an explanation of the function.
[0056] According to an exemplary non-transitory computer readable storage device embodiment, the device has instructions that when executed by a processing circuit implement a method, the method includes
[0057] detecting with a proximity detector when an object is in a proximity position relative to a display;
[0058] changing a display state of a displayed item in response to the detecting, and
[0059] causing with the processing circuit a relation item to be displayed at a position adjacent to the proximity position, the relation item being related to the displayed item.
[0060] According to an embodiment of the present technology, a user is able to easily recognize related information related to an item displayed by a display apparatus.
BRIEF DESCRIPTION OF THE DRAWINGS
[0061] FIG. 1 is a block diagram illustrating an exemplary configuration of an embodiment of a digital camera to which the present technology has been applied;
[0062] FIGS. 2A and 2B are perspective diagrams illustrating an exemplary exterior configuration of a digital camera;
[0063] FIG. 3 is a block diagram illustrating an exemplary functional configuration of a display control apparatus;
[0064] FIGS. 4A to 4D illustrate a first exemplary display of a display screen on an input/output panel 18 ;
[0065] FIGS. 5A to 5C illustrate a second exemplary display of a display screen on an input/output panel 18 ;
[0066] FIG. 6 is a flowchart explaining a display control process conducted by a display control apparatus; and
[0067] FIGS. 7A to 7C illustrate a third exemplary display of a display screen on an input/output panel 18 .
DETAILED DESCRIPTION OF EMBODIMENTS
[0068] [Embodiment of Digital Camera to which the Present Technology has been Applied]
[0069] FIG. 1 is a block diagram illustrating an exemplary configuration of an embodiment of a digital camera (digital still camera) to which the present technology has been applied.
[0070] A lens unit 11 includes an imaging lens, diaphragm, focus lens, eta. Light entering the lens unit 11 irradiates an imaging element 12 .
[0071] The imaging element 12 includes for example a charge-coupled device (CCD) or a complementary metal-oxide-semiconductor (CMOS) imager, etc. The imaging element 12 photoelectrically converts light from the lens unit 11 , and supplies an analog image signal obtained as a result to an analog signal processor 13 .
[0072] The analog signal processor 13 performs analog signal processing such as correlated double sampling or automatic gain adjustment on the image signal from the imaging element 12 , and supplies the result to an analog/digital (A/D) converter 14 .
[0073] The analog/digital (A/D) converter 14 A/D converts the image signal from the analog signal processor 13 , and supplies digital image data obtained as a result to a digital signal processor 15 .
[0074] The digital signal processor 15 performs digital signal processing such as white balance adjustment, noise removal, and appropriate compression coding (such as Joint Photographic Experts Group (JPEG) coding, for example) on the image data from the A/D converter 14 , and supplies the result to (the display unit 17 of) an input/output panel 18 and a recording device 19 .
[0075] The input/output panel 18 includes an input unit 16 and a display unit 17 .
[0076] The input unit 16 is a device that includes functions for receiving (detecting) external input. Namely, the input unit 16 includes, for example, a capacitive or other touch panel, or a set combining a light source that radiates light and a sensor that receives a reflection of that light off an object.
[0077] When the input unit 16 is put in proximity to or touched by an external object, or in other words the user's finger or a touch pen wielded by the user, for example, the input unit 16 supplies the CPU 23 with a signal expressing the position where that proximity or touch occurred.
[0078] The display unit 17 is a device that displays an image (a display apparatus). Namely, the display unit 17 includes a liquid crystal panel, for example, and displays an image according to image data, etc. supplied from the digital signal processor 15 .
[0079] The input/output panel 18 is an integration of an input unit 16 and a display unit 17 like the above. The input/output panel 18 is able to display an image with the display unit 17 , and receive external operational input (herein being both touch and proximity) with respect to an image displayed by the display unit 17 with the input unit 16 .
[0080] A disc such as a Digital Versatile Disc (DVD), semiconductor memory such as a memory card, or other removable recording medium (not illustrated) can be loaded into or removed from the recording device 19 , for example. The recording device 19 conducts recording and playback control of image data with respect to a loaded recording medium.
[0081] In other words, the recording device 19 records image data from the digital signal processor 15 onto a recording medium, or alternatively, reads out image data recorded onto a recording medium and supplies it to the digital signal processor 15 .
[0082] The actuator 20 is a motor that adjusts the focus lens and diaphragm of the lens unit 11 , and is driven by the motor drive 21 .
[0083] The motor drive 21 drives the actuator 20 following control by the central processing unit (CPU) 23 .
[0084] The timing generator (TG) 22 , following control by the CPU 23 , supplies the imaging element 12 with a timing signal for adjusting the exposure time, etc.
[0085] The CPU 23 controls the respective blocks constituting the digital camera by executing a program stored in the program read-only memory (ROM) 26 , and as appropriate, a program stored in the electrically erasable programmable ROM (EEPROM) 25 .
[0086] The operable unit 24 includes physical buttons, etc. operated by the user, and supplies the CPU 23 with a signal corresponding to the user's operation.
[0087] The EEPROM 25 stores data and programs which should be saved even when the digital camera is powered off, such as imaging parameters, etc. set by the user operating the operable unit 24 , for example.
[0088] The program ROM 26 stores programs executed by the CPU 23 , etc.
[0089] the RAM 27 temporarily stores data and programs involved in operations by the CPU 23 .
[0090] In a digital camera configured as above, the CPU 23 controls the respective units of the digital camera by executing a program stored in the program ROM 26 , etc.
[0091] Meanwhile, light entering the lens unit 11 is photoelectrically converted by the imaging element 12 , and the image signal obtained as a result is supplied to the analog signal processor 13 . In the analog signal processor 13 , analog signal processing is performed on the image signal from the imaging element 12 , and the result is supplied to the A/D converter 14 .
[0092] In the A/D converter 14 , the image signal from the analog signal processor 13 is A/D converted, and the digital image data obtained as a result it supplied to the digital signal processor 15 .
[0093] In the digital signal processor 15 , digital signal processing is performed on the image data from the A/D converter 14 , the result is supplied to the (display unit 17 of) the input/output panel 18 , and a corresponding image, or in other words a through-the-lens image, is displayed.
[0094] Also, the CPU 23 executes given processing following signals from the (input unit 16 of) the input/output panel 18 and the operable unit 24 .
[0095] In other words, if the input/output panel 18 or operable unit 24 are operated so as to conduct imaging, for example, the CPU 23 conducts processing for imaging a still image as a photograph, causes the digital signal processor 15 to perform compression coding on image data from the A/D converter 14 , and causes the result to be recorded onto a recording medium via the recording device 19 .
[0096] Also, if the input/output panel 18 or the operable unit 24 is operated so as to conduct playback, for example, the CPU 23 causes image data to be read out from a recording medium via the recording device 19 by controlling the digital signal processor 15 .
[0097] Additionally, the CPU 23 causes the digital signal processor 15 to decompress the image data read out from the recording medium and supply it to the input/output panel 18 for display.
[0098] Also, the CPU 23 causes (images of) items such as icons or text strings arrayed in a list format to be supplied to the input/output panel 18 and displayed via the digital signal processor 15 as a user interface.
[0099] Additionally, the CPU 23 causes related information related to an item to be supplied to the input/output panel 18 and displayed via the digital signal processor 15 in response to a signal from (the input unit 16 of) the input/output panel 18 .
[0100] Herein, (image) data for items and related information is stored in the EEPROM 25 or the program ROM 26 , for example.
[0101] Besides the above, the CPU 23 generates an image of a focus frame (AF frame) used for focus control and supplies it to the input/output panel 18 via the digital signal processor 15 for display, for example.
[0102] Herein, the digital camera includes, for example, AF (Auto focus) functions, AE (Auto Exposure) functions, AWB (Auto White Balance) functions, etc. These functions are realized by the CPU 23 executing a program.
[0103] For example, display of an AF frame on the input/output panel 18 is conducted by AF functions. The position of an AF frame displayed on (the display screen of the display unit 17 of) the input/output panel 18 can be moved by operations that move the position of the AF frame with respect to the input/output panel 18 . Also, the size of an AF frame display on (the display screen of the display unit 17 of) the input/output panel 18 can be modified by operations that modify the size of the AF frame with respect to the input/output panel 18 .
[0104] Herein, a program executed by the CPU 23 may be installed onto the digital camera from a removable recording medium, or downloaded via a network and installed onto the digital camera, for example.
[0105] FIGS. 2A and 2B are perspective diagrams illustrating an exemplary exterior configuration of a digital camera.
[0106] Namely, FIG. 2A is a perspective view of the front side (the side facing a subject during imaging) of the digital camera, while FIG. 2B is a perspective view of the rear side of the digital camera.
[0107] A lens cover 31 is provided so as to cover the front of the digital camera, and is movable up and down.
[0108] When the lens cover 31 is positioned upwards, the lens unit 11 , etc. enters a covered state. Also, when the lens cover 31 is positioned downwards, the lens unit 11 , etc. are exposed, and the digital camera enters a state where imaging is possible.
[0109] In FIG. 2A , the lens cover 31 is positioned downward, and the lens unit 11 is exposed.
[0110] On the left side of the lens unit 11 , an AF illuminator 32 is provided. The AF illuminator 32 emits light (assist light) for illuminating a subject in cases where the subject is dark and it is difficult to focus using AF functions, for example.
[0111] Herein, in the case of imaging using a self-timer, the AF illuminator 32 also functions as a self-timer lamp that emits light for informing the user of the imaging timing by the self-timer.
[0112] On the top of the digital camera are provided a power button 33 , a play button 34 , a shutter button (release button) 35 , and a zoom lever 36 , which constitute the operable unit 24 in FIG. 1 .
[0113] The power button 33 is operated when switching the digital camera power on and off. The play button 34 is operated when playing back image data recorded onto a recording medium loaded into the recording device 19 ( FIG. 1 ).
[0114] The shutter button (release button) 35 is operated when recording image data onto a recording medium loaded into the recording device 19 ( FIG. 1 ) (taking a photograph (still image)). The zoom lever 36 is operated when adjusting the zoom.
[0115] On the back of the digital camera, the input/output panel 18 is provided. A through-the-lens image is displayed on the input/output panel 18 . Also, (images of) items such as icons or text strings arrayed in a list format, and related information related to items, etc., are displayed on the input/output panel 18 .
[0116] The user is able to supply various (operational) input to the digital camera by causing a finger or touch pen, etc. to come into proximity to or touch the input/output panel 18 .
[Exemplary Configuration of Display Control Apparatus]
[0117] FIG. 3 is a block diagram illustrating an exemplary functional configuration of a display control apparatus, given as the CPU 23 in FIG. 1 , which conducts display control.
[0118] In the digital camera in FIG. 1 herein, the CPU 23 conducts display control, which displays items such as icons or text strings arrayed in a list format and related information for the items on the input/output panel 18 .
[0119] FIG. 3 illustrates an exemplary functional configuration of a display control apparatus, given as the CPU 23 , which conducts such display control.
[0120] The display control apparatus includes an input detector 51 and a display controller 52 .
[0121] The input detector 51 is supplied with a signal from (the input unit 16 of) the input/output panel 18 . The signal (hereinafter also called a stimulus signal) is in response to external stimulus (input) imparted to (the input unit 16 of) the input/output panel 18 .
[0122] The input detector 51 , on the basis of a stimulus signal from (the input unit 16 of) the input/output panel 18 , detects-external input with respect to (the input unit 16 of) the input/output panel 18 . In other words, the input detector 51 detects that the user's finger or a touch pen, etc. wielded by the user has been put in proximity to or made to touch, and the position, etc. (on the input/output panel 18 ) of that proximity or touch, for example. The input detector 51 supplies the result to the display controller 52 as operation information expressing the operation conducted on the input/output panel 18 by the user.
[0123] The display controller 52 conducts display control as appropriate, which displays items such as icons on (the display unit 17 of) the input/output panel 18 . Data for such items is stored in the EEPROM 25 or program ROM 26 .
[0124] Also, in the case where operation information from the input detector 51 expresses proximity of an object with respect to the display screen of the input/output panel 18 , the display controller 52 takes the item being displayed near the proximity position in proximity to the object to be a target item to be targeted, changes the display state of that target item, and conducts a display control that displays related information for the target item on the input/output panel 18 . Data for such related information is stored in the EEPROM 25 or the program ROM 26 .
[Exemplary Display on Input/Output Panel 18 ]
[0125] FIGS. 4A to 4D illustrate a first exemplary display on the display screen of (the display unit 17 of) the input/output panel 18 .
[0126] FIG. 4A illustrates an exemplary display on the display screen of the input/output panel 18 in a state where not object is in proximity or touching, for the case where the digital camera is in an imaging standby state.
[0127] Herein, an imaging standby state means a state in which imaging of a photograph (still image) will be conducted if the shutter button 35 ( FIG. 2 ) is operated (a state in which an image will be imaged and recorded onto a recording medium loaded into the recording device 19 ( FIG. 1 )).
[0128] In FIG. 4A , a through-the-lens image is displayed on the input/output panel 18 except in the left and right portions of the display screen, while icons assigned with given functions are displayed at a predetermined default size at predetermined default positions on the left and right of the display screen (the icons are displayed in a predetermined default display state).
[0129] Herein, a function assigned to an icon may be a function whereby given processing is executed by touching that icon, such as auto imaging which automatically configures the digital camera with imaging parameters, etc. or switching a smile shutter on and off which conducts imaging when a smile is detected, for example. An assigned function may also be a function that displays the state of the digital camera, such as the remaining battery charge or the number of photographs (still images) which can be imaged.
[0130] FIG. 4B displays an exemplary display on the display screen of the input/output panel 18 in the case where the user has put his or her finger (or a touch pen or other object) in proximity to an icon displayed uppermost on the left side from among the icons displayed on the display screen in FIG. 4A , for example.
[0131] In FIG. 4B , the display state of the icon put in proximity to the finger by the user has been changed. Namely, the icon put in proximity to the finger by the user is displayed at an enlarged size that has been enlarged from the default size.
[0132] Furthermore, in FIG. 4B , the function name “Smile shutter” of the function assigned to the icon put in proximity to the finger by the user is displayed near that icon.
[0133] Since the function name of the function assigned to the icon put in proximity to the finger by the user is displayed as above, the user is easily able to recognize the function assigned to that icon given by related information related to the icon, by merely putting his or her finger in proximity to the icon and without performing a complicated operation.
[0134] Also, since the icon whose function name is displayed is displayed at an enlarged size, the user is easily able to recognize which icon's function name is being displayed.
[0135] Herein, the function assigned to the icon with the function name “Smile shutter” (hereinafter also called the smile icon) is a function whereby processing for switching auto imaging on and off is executed by touching that icon.
[0136] Consequently, if the user puts his or her finger in proximity to the smile icon, the smile icon is displayed at an enlarged size, while the function name “Smile shutter” is also displayed as related information for that smile icon. Then, if the user touches the smile icon with his or her finger, auto imaging is switched on or off.
[0137] The user is able to view the function name displayed by putting his or her finger in proximity to the smile icon. Thus, the user is able to touch the smile icon with assurance, so to speak, after having ascertained (to some degree) the function assigned to that smile icon.
[0138] FIG. 4C illustrates another exemplary display on the display screen of the input/output panel 18 in the case where the user has put his or her finger in proximity to the smile icon displayed uppermost on the left side of the display screen in FIG. 4A .
[0139] In FIG. 4C , the function name “Smile shutter” of the function assigned to the smile icon put in proximity to the finger by the user is displayed, similarly to the case in FIG. 4B .
[0140] However, FIG. 4C differs from the case in FIG. 4B in that the smile icon put in proximity to the finger by the user is not displayed at an enlarged size, but is displayed at a displaced position displaced from the default position (in FIG. 4C , a position displaced from the default position towards the center of the display screen).
[0141] Since the function name of the function assigned to the icon put in proximity to the finger by the user is also displayed in the case of FIG. 4C similarly to the case in FIG. 4B , the user is easily able to recognize the function assigned to an icon simply by putting his or her finger in proximity.
[0142] Also, in FIG. 4C , since the icon put in proximity to the finger by the user is displayed displaced from the default position, the user is easily able to recognize which icon's function name is being displayed, similarly to the case of FIG. 4B wherein an icon is displayed at an enlarged size. Moreover, an icon can be prevented from becoming difficult to see as a result of the finger put in proximity to that icon by the user.
[0143] Furthermore, it is possible to display an icon put in proximity to the finger by the user at an enlarged size and displaced from its default position.
[0144] FIG. 4D illustrates another exemplary display on the display screen of the input/output panel 18 in the case where the user has put his or her finger in proximity to the smile icon displayed uppermost on the left side of the display screen in FIG. 4A .
[0145] In FIG. 4C , the function name “Smile shutter” of the function assigned to the smile icon put in proximity to the finger by the user is displayed, similarly to the case in FIG. 4B .
[0146] However, in FIG. 4D , the function name “Smile shutter” of the function assigned to the smile icon put in proximity to the finger by the user and a function explanation explaining that function are displayed.
[0147] As above, in the case where an explanatory text for an icon put in proximity to the finger by the user is displayed, the user is able to recognize the function assigned to the icon in more detail.
[0148] Furthermore, although both a function name and a function explanation are displayed in FIG. 4D , it is possible to display just the function explanation.
[0149] Herein, one or both of a function message and a function explanation will be called a function message.
[0150] FIGS. 5A to 5C illustrate a second exemplary display of a display screen on the input/output panel 18 .
[0151] FIG. 5A illustrates an exemplary display on the display screen of the input/output panel 18 in a state where a menu is displayed but an object is not in proximity or touching.
[0152] In FIG. 5A , a menu wherein icons are disposed in a matrix is being displayed on the input/output panel 18 .
[0153] FIG. 5B illustrates an exemplary screen on the display screen of the input/output panel 18 in the case where the finger has put his or her finger in proximity to the icon disposed in the upper-left of the display screen in FIG. 5A .
[0154] In FIG. 5B , the icon put in proximity to the finger by the user is being displayed at an enlarged size enlarged from its default size.
[0155] Furthermore, in FIG. 5B , the function name “Easy mode” of the function assigned to the icon put in proximity to the finger by the user is being displayed in popup form near that icon.
[0156] FIG. 5C illustrates another exemplary display on the display screen of the input/output panel 18 in the case where the user has put his or her finger in proximity to the icon disposed in the upper-left of the display screen in FIG. 5A .
[0157] In FIG. 5C , the icon put in proximity to the finger by the user is displayed at an enlarged size and the function name “Easy mode” of the function assigned to that icon is displayed in popup form, similarly to the case in FIG. 5B . Moreover, a function explanation explaining that function is being displayed.
[0158] In the case in FIG. 5 , by simply put his or her finger in proximity, the user is easily able to recognize the function assigned to an icon, and is easily able to recognize which icon's function message (function name, function explanation) is being displayed, similarly to the case in FIGS. 4A to 4D .
[Display Control Processing in Fullscreen Mode]
[0159] FIG. 6 is a flowchart explaining a display control process conducted by the display control apparatus in FIG. 3 .
[0160] In an operation S 10 , the display controller 52 displays given items such as icons in a default display state on (the display screen of) the input/output panel 18 , as illustrated in FIGS. 4A to 4D or 5 A to 5 C, for example. The process proceeds to an operation S 11 .
[0161] Herein, the default display state is predetermined, and displaying icons in a default display state means displaying items such as icons at default positions and at default sizes, for example.
[0162] In operation S 11 , the display controller 52 , on the basis of operation information supplied from the input detector 51 , determines whether or not proximity or touch has been detected with respect to the display screen of the input/output panel 18 .
[0163] In the case where it is determined in operation S 11 that touch has been detected with respect to the display screen of the input/output panel 18 , or in other words, in the case where the user has touched the input/output panel 18 with his or her finger, etc., the process proceeds to an operation S 12 , and the display controller 52 conducts a tap process according to the touched position on the input/output panel 18 . The tap process is a predetermined process.
[0164] In contrast, in the case where it is determined in operation S 11 that neither touch nor proximity has been detected with respect to the display screen of the input/output panel 18 , the process proceeds to an operation S 13 , and if there is an item from among the items displayed by the input/output panel 18 whose display state has been modified in an operation S 17 later discussed, the display controller 52 displays that item in its default display state (re-display). Furthermore, in the case where related information such as function message is being displayed by the input/output panel 18 in operation S 17 later discussed, that related information is deleted, and the process returns to operation S 11 .
[0165] Also, in the case where it is determined in operation S 11 that proximity has been detected with respect to the display screen of the input/output panel 18 , or in other words, in the case where the user has put his or her finger, etc. in proximity to the input/output panel 18 , the process proceeds to an operation S 14 , and the display controller 52 acquires the coordinates of the position on the input/output panel 18 where the finger, etc. was put in proximity to the input/output panel 18 (proximity position) from operation information supplied from the input detector 51 . The process proceeds to an operation S 15 .
[0166] In operation S 15 , the display controller 52 determines whether or not the coordinates of the proximity position (proximity coordinates) are coordinates within an item area, which is a given area defining an item's display position on the input/output panel 18 .
[0167] In other words, the item area for an item such as an icon displayed on the input/output panel 18 , for example, is a predetermined area (region on the display screen) defining the display position (default position) on the display screen where that icon is displayed.
[0168] Herein, the item area for an icon is a rectangular, circular, or other area enclosing that icon, for example. In the case where a position subjected to touch or proximity is within (above) the icon's item area, the display controller 52 recognizes (determines) that that icon has been subjected to touch or proximity.
[0169] For example, if it is assumed that icons for N items are currently being displayed on the input/output panel 18 , in operation S 15 it is determined whether or not the proximity coordinates are coordinates within the item area of one of the respective item areas # 1 to #N of the N items.
[0170] In the case where it is determined in operation S 15 that the proximity coordinates are not coordinates within the item area of one of the N item areas # 1 to #N, or in other words, in the case where although the user's finger, etc. came into proximity to the input/output panel 18 , no icon exists around the proximity position subjected to that proximity (including the proximity position), and thus the user's finger, etc. came into proximity to a position not of one of the icons given as the N items, the process proceeds to operation S 13 and a process similar to the case discussed above is conducted.
[0171] Then, the process returns from operation S 13 to operation S 11 , and thereafter a similar process is repeated.
[0172] Also, in the case where it is determined in operation S 15 that the proximity coordinates are coordinates within the item area of one of the N item areas # 1 to #N, or in other words, in the case where the user's finger, etc. has come into proximity with one of the icons given as the N items displayed on the input/output panel 18 , the process proceeds to an operation S 16 , and the display controller 52 takes the item corresponding to the item area #n that includes the proximity coordinates from among the item areas # 1 to #N, or in other words, the item put in proximity with the user's finger, etc. (the item surrounding the proximity position put in proximity with the user's finger, etc.), as the target item.
[0173] Then, in operation S 16 , if there is an item from among the items displayed on the input/output panel 18 , excepting the target item, whose display state has been modified in operation S 17 , the display controller 52 displays (re-displays) that item in its default display state. Furthermore, in the case where related information such as a function message for an item other than the target item is being displayed by the input/output panel 18 , that related information is deleted, and the process proceeds to operation S 17 .
[0174] In operation S 17 , the display controller 52 displays related information for the target item on the input/output panel 18 . In other words, the display controller 52 displays a function message for the icon put in proximity to the user's finger, etc. as related information for the target item, as illustrated in FIGS. 4A to 4D or 5 A to 5 C, for example.
[0175] Furthermore, in operation S 17 , the display controller 52 modifies the display state of the target item. In other words, the display controller 52 displays the icon put in proximity to the user's finger, etc. as the target item by enlarging it to an enlarged size or displacing it from its default position, as illustrated in FIGS. 4A to 4D or 5 A to 5 C, for example.
[0176] After that, the process returns from operation S 17 to operation S 11 , and thereafter a similar process is repeated.
[Other Exemplary Display on Input/Output Panel 18 ]
[0177] FIGS. 7A to 7C illustrate a third exemplary display on the display screen of the input/output panel 18 .
[0178] FIG. 7A illustrates an exemplary display on the display screen of the input/output panel 18 in the case where a finger has been put in proximity to a position midway between two icons, namely the icon display uppermost on the left side of the display screen in FIG. 4A discussed earlier and the icon displayed below it.
[0179] In FIGS. 4A to 6 , the display state was modified for one icon at the position put in proximity to the user's finger, etc. (proximity position) and a function message was displayed. However, the display state can be modified and a function message can be displayed for a plurality of icons.
[0180] In other words, in the case where items for a plurality of icons are being displayed near the proximity position put in proximity to the user's finger, etc., the display controller 52 may take each item in that plurality of items as a target item and modify the display state of each item in the plurality of target items while also displaying related information for each item in the plurality of target items.
[0181] In FIG. 7A , two icons being displayed near the position put in proximity to a finger by the user (proximity position), namely the icon displayed uppermost on the left side of the display screen in FIG. 4A and the icon displayed below it, have become target icons.
[0182] Furthermore, the two target icons are respectively being displayed at an enlarged size, and in addition, the function names of the functions respectively assigned to the those two target icons are being displayed.
[0183] FIG. 7B illustrates an exemplary display on the display screen of the input/output panel 18 in the case where the user puts a finger in proximity to a position midway between two icons, namely the icon disposed in the upper-left of the display screen in FIG. 5A discussed earlier, and the icon displayed to its right.
[0184] In FIG. 7B , two icons being displayed near the proximity position put in proximity to a finger by the user, namely the icon disposed in the upper-left of the display screen in FIG. 5A and the icon displayed to its right, have become target icons.
[0185] Furthermore, the two target icons are respectively being displayed at an enlarged size, and in addition, the function names of the functions respectively assigned to the those two target icons are being displayed in popup form.
[0186] As above, in the case of modifying the display state and display a function message for a plurality of icons such as two icons, the user is easily able to recognize, at the same time, the functions respectively assigned to the plurality of icons.
[0187] FIG. 7C illustrates an exemplary display on the display screen of the input/output panel 18 in which text strings arrayed in a list format are displayed as items which function as buttons.
[0188] In FIG. 7C , a function explanation is being displayed for a text string given as a button that has been put in proximity to the user's finger.
[0189] As illustrated in FIG. 7C , a function explanation, etc. may be displayed even in the case where the user's finger is put in proximity to an item other than an icon, such as a text string.
[0190] Meanwhile, an embodiment of the present technology is not limited to the embodiments discussed above, and various modifications are possible within a scope that does not depart from the principal matter of the present technology.
[0191] In other words, besides a digital camera, the present technology is also applicable to an apparatus that implements a user interface which displays items such as icons or text strings.
[0192] Also, besides icon or text strings, thumbnails of videos or still images may be adopted as the items displayed on the input/output panel 18 .
[0193] For thumbnails of videos or still images displayed on the input/output panel 18 , video or still image metadata such as the shooting date of the video or still image (in the case where the video is a television broadcast program, the date when that television broadcast program was recorded (broadcast)), the title, size (file size), etc. may be displayed as related information related to a thumbnail given as an item in the case where the user's finger, etc. is put in proximity.
[0194] Additionally, in the case where the user touches a thumbnail, the video or still image corresponding to that thumbnail may be played back.
[0195] Also, although the size and position were taken to be modified as the display state of an icon put in proximity to the user's finger, etc. in the present embodiment, other properties such as the color and brightness may be modified for an icon put in proximity to the user's finger, etc.
[0196] The present disclosure contains subject matter related to that disclosed in Japanese Priority Patent Application JP 2010-284320 filed in the Japan Patent Office on Dec. 21, 2010, the entire contents of which are hereby incorporated by reference.
[0197] It should be understood by those skilled in the art that various modifications, combinations, sub-combinations and alterations may occur depending on design requirements and other factors insofar as they are within the scope of the appended claims or the equivalents thereof. | A display control apparatus, method and computer program storage device detect when an object is in a proximity position relative to a display. In response, a display state of a displayed item is changed. Then, a processing circuit causes a relation item to be displayed adjacent to the proximity position, the relation item being related to the displayed item. The displayed state may be changed in size, position, color and other ways to reflect the recognition of the object being detected as being proximate to a predetermined proximity location. | 6 |
This application is a continuation of application Ser. No. 420,478, filed Sept. 30, 1982, now abandoned.
BACKGROUND OF THE INVENTION
1. Field of Invention
The present invention relates to a gas particulate solid system and more particularly relates to a gas particulate solid system in which a gas flow having a downward component is directed onto the surface of a slumped bed of particles.
2. Description of the Prior Art
The use of fluidised beds for combustion purposes such as burning of fossil fuels, incineration of combustible wastes etc. is well known. The process involves blowing air through a bed of particulate refractory material to maintain it in a fluidised state. The fuel is then introduced to the bed and burns within the bed which is thus maintained at operating temperature. Fluidised bed combustors are capable of high heat outputs and good heat transfer characteristics.
Spouted bed technology is also known and comprises passing a high velocity stream of gas vertically upwards through a mass of solid particles. The high velocity gas stream causes the particles to ascend rapidly in a hollowed central spout within the bed. Particles in a cone above the gas outlet are entrained while particles lying outside the cone descend slowly in a dense phase. The spouting action creates a fountain of particles above the slowly descending bed; and at lower flow rates in a deep bed, when the fountain does not break the surface it gives very high circulation rates of solid particles within the cone and a normal fluidised bed above the cone. In each case a cycle of solid particle movement is established. Although spouted bed technology is useful, for example, in drying, coating and granulation processes, solids blending, combustion, comminution and several chemical processes, it has disadvantages which include a relatively high pressure requirement to initiate stable spout operation. Also in multiple spout systems, the pressure drop across the nozzle must be high to avoid the fluid passing through only one outlet.
SUMMARY OF THE INVENTION
The present invention relates to a further form of gas and particulate solid system which offers certain advantages over conventional fluidised and spouted bed technology.
Thus according to the present invention there is provided a gas-particulate solid system comprising a chamber capable of containing a bed of particulate solid and a supply of an oxygen containing gas characterised in that a line or lines having their outlet or outlets above the slumped bed directs the gas downwardly to impinge on the surface of the bed material so as to form a crater surrounded by circulating bed material, there also being means for introducing a fuel to the crater.
The term downwardly is intended to include a gas flow having a downward component and does not only apply to a vertical flow of gas onto the bed.
The bed of particulate solids comprises particles of a size range and bulk density appropriate to the velocity of the downward gas flow. Thus the downward gas flow must have sufficient momentum to form the crater but not be so great as to cause extensive displacement of the particulate solids. Suitable bed materials include sand, crushed firebrick, alumina and coal ash.
There may be one or more gas flow lines and they are preferably fitted with outlet nozzles to produce a gas stream appropriate for the production of craters in the bed material.
There are a number of applications in which such a gas/particulate solids system may be used. Thus it may be used for the disposal of combustible waste materials and the combustion of fossil fuels including the extraction of heat from these combustion processes. Also it may be used for improving the combustion of lean mixtures and fuels of low calorific value by recirculating heat from products to reactants without simultaneous dilution by mixing, the bed material acting as a moving heat exchanger. Other uses of the system include heating, cooling and drying of solids, particle coating and use for chemical processes including catalytic processes within the bed.
The invention also includes a method of burning gas mixtures near or below their normal composition limits of flammability using a gas particulate solid system (as hereinbefore described) in which (a) the bed material is pre-heated and then (b) the gas mixture below its normal composition limit of flammability is introduced to the crater from the line outlet and ignited. The invention further includes a method of disposing of combustible solids or liquids using a gas particulate solid system (as hereinbefore described) in which (a) an oxygen containing gas from the line outlet is directed downwardly to impinge on the surface of the bed material so as to form a crater and (b) the combustible liquid or solid is introduced to the crater and ignited.
The bed material may be preheated in a number of known ways which include burning combustible gas in the crater or directing a flame from an overhead burner onto the bed material.
Examples of gas mixtures near or below their normal composition limits of flammability include those prepared from exhaust gases from a variety of industrial processes, blast furnace gases and coke oven gases.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will now be described by way of example only and with reference to FIGS. 1 to 3 of the accompanying drawings.
FIG. 1 is a schematic diagram of a gas particulate solid system according to the invention and
FIGS. 2 and 3 are experimental layouts for single and multi nozzle systems respectively.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The gas/particulate solid system comprises a cylindrical chamber 1 containing a bed material 2. The bed material may be any suitable particulate solid and includes sand, alumina particles and coal ash. In combustion processes, the bed 2 may be contained by a refractory lined or water cooled vessel (not shown).
A pipe 3 connected to a source of pressurized gas (not shown) is located above the bed. The outlet end of the pipe 3 takes the form of a nozzle 4 which is arranged a short distance above the slumped level of the bed 2.
During use, a jet of gas from nozzle 4 is arranged to impinge on the surface of the bed 2 of solid particles in a downward direction, as shown in FIG. 1. A displacement of particles takes place from the region surrounding this volume. The cavity 5 formed below the nozzle 4 has a well defined cylindrical shape with a rounded base and is termed the crater. The new height of the expanded bed surrounding the crater forms a slope up to the wall of the bed where it is the maximum height. The amount of particles displaced and so the size of the crater and the expansion of the bed is a function of several variables and is related to the momentum flux in the jet of gas. In addition to this displacement there is a regular flow pattern of the particles and depending on the type, size and shape of particles a fountain of particles is also obtained.
The flow pattern of the fluid is also shown in FIG. 1. From the nozzle the jet increases in diameter. From the injectories of the solid particles in the fountain it can be deduced that the maximum velocity of the reverse flow of gas occurs in a narrow region near the walls of the crater. The maximum height of the solid particles is obtained in this narrow region. The flow of gas outside this narrow region is analogous to countercurrent flow to a moving bed of particles and in the more further parts to simple flow through a packed bed of particles.
The flow pattern of the particulate solids is dependent on the particle size and on the flow velocities of the fluid. If the size is small enough then the maximum reverse velocity of the fluid might be enough to entrain the particles to form a fountain. If the flow rates are much higher then the region of this annulus from which the fountain begins becomes accordingly wider. Experimental work has shown that alumina particles of 18-22 mesh size readily lead to a fountain whereas glass beads of 3 mm diameter produced movement only within the bed in addition to the crater formation, probably due to the decreased resistance to the flow of gas leading to a greater dispersion of gas into the annulus.
The particles from the fountain fall on the surface of the bed at various positions. Depending on the flux of particles through the fountain, they may move towards the crater either on or beneath the surface.
The gas particulate solid system can be used for the disposal of lean fuel gas-air mixtures. The term lean fuel gas-air mixtures refers to gas mixtures in which the percentage of fuel is lower than that required for stoichiometric combustion and may be near or below their normal composition limits of flammability. The lean limit of flammability of a methane air mixture is 5% of methane by volume.
FIG. 2 illustrates the apparatus used for the combustion of air-methane gas mixtures using sand particles of approximate diameter 1400 microns. Air and methane supplies are connected to lines 10 and 11 respectively, the pressures being measured by gauges 12 and 13 set in side arms. Lines 10 and 11 pass downstream to flowmeters 14 and 15. Each line has a non return valve 16, 17 downstream of which the lines 10, 11 join to form a single line 18 which passes downstream to a mixing coil 19 and a gate valve 20. Downstream of the gate valve 20 is a pipe nozzle 21 located just above a slumped bed 22 of sand particles contained in a metal cylinder 23.
In use, the methane air mixture is supplied to outlet nozzle 21 and ignited to form a flame in the resultant crater in the bed. The lean limit for stable combustion for three pipe sizes and various methane air flowrates are shown in Table 1.
The gas mixture is ignited and the bed allowed to heat up. The lean limit under hot start up conditions is found by gradually reducing the methane flow rate further until combustion can just be sustained, when the flowrates are again recorded. This was repeated for various flowrates and pipe separations.
TABLE 1______________________________________Lean Limit for Stable Combustion for a Single Pipe Flow Rates (l/min) Velocity %Pipe Size Air Methane Total (m/s) Methane______________________________________Small 3.2 0.19 3.4 4.7 5.6(ID = 3.9 mm) 13.2 0.72 14.0 19.5 5.1 18.0 0.87 18.8 26.1 4.6 24.5 1.20 25.7 35.7 4.7 32.0 1.35 33.4 46.4 4.0ID-internal 39.1 2.00 41.1 57.1 4.9diameterMedium 17.6 1.12 18.7 7.1 6.0(ID = 7.4 mm) 31.0 1.80 32.8 12.4 5.5 55.5 2.25 57.8 21.9 3.9 75.5 2.90 78.4 29.7 3.7Large 21.2 1.44 22.6 5.9 6.4(ID = 9.0 mm) 29.0 1.60 30.6 8.0 5.2 42.5 2.10 44.6 11.6 4.7 59.0 2.65 61.7 16.1 4.3 72.0 3.25 75.3 19.6 4.3______________________________________
FIG. 3 illustrates a multi nozzle assembly for use in the gas particulate solid system. Thus three nozzle pipes are arranged in the form of an equilateral triangle and the flow velocity is assumed to be the same for each. The lean limit for the arrangement with various methane air flow rates are shown in Table 2.
Air and methane supplies are connected to lines 24, 25 respectively, the pressures being measured by gauges 26, 27 set in side arms and the gas flow rates are measured by rotameters 28, 29. Each line has a non return valve 30, 31 downstream of which the line 24, 25 join to form a single line 32. The line 32 splits into three pipe nozzles 33, 34, 35 arranged in the form of an equilateral triangle, each nozzle being controlled by gate valves 36, 37, 38. Each nozzle is located just above a slumped bed 39 of sand particles contained in a metal cylinder 40.
The gas mixture was ignited and the bed allowed to heat up and the methane flow gradually reduced until combustion could only just be sustained. The lean limit for stable combustion of flammability was hence found for various total flowrates.
TABLE 2______________________________________Lean Limit for Stable Combustion for Three Pipes Arranged in anEquilateral Triangle of Sides 45 mm Linear JetFlowrate/(l min) % VelocityMethane Total Methane (m/sec)______________________________________1.15 21.7 5.3 10.01.65 33.2 5.0 15.42.00 40.0 5.0 18.52.10 52.6 4.0 24.43.00 65.0 4.6 30.13.10 84.1 3.7 38.93.80 100.8 3.8 46.7______________________________________
The particles circulate through the flame and fall back on the bed. The fresh gas is preheated to some extent by passage through the inlet tube. This pre-heated gas then passes into the crater inside which it receives radiation flux from the crater walls. The gas flows upwards and encounters further hot particles before reaching the surface.
At low throughputs the flame occupies the space around the crater. This is facilitated by the fact that most of the gas passes through this region. Thus virtually the complete particle circulation passes through the flame. The fact that, at moderate flow rates, the flame does not extend to the bed walls ensures that heat losses are kept at a minimum, the particles near the wall acting as a shield. At higher throughputs particle temperatures increase and combustion appears to take place throughout the fluidised region of the bed.
Table 3 gives the results of a series of experiments in which stable flames of relatively lean gas fuel mixtures were used:
TABLE 3______________________________________% Methane Total Gas Flow L/min______________________________________2.7 20.82.7 21.22.6 21.62.7 23.02.8 24.53.0 26.93.1 30.23.3 31.03.8 36.8Bed material alumina particles (22-25 mesh)Bed diameter 38 mmInlet tube diameter 15 mmNozzle diameter 1.5 mmInitial bed height 110 mmHeight of nozzle tip above 15 mminitial bed height______________________________________
The gas outlet may take various forms apart from the simple single hole arrangement. Thus by using an outlet nozzle having a number of holes in its periphery, different forms of crater may be obtained in the bed. For example, a series of outlet holes around the circumference of a nozzle will yield a bed surface taking the form of valleys and mountains spreading from the centre (nozzle). It is possible to manipulate particle movement in the bed by changing the numbers of outlet holes of the nozzle and their angle of incidence on the bed surface. This enables the movement of bed particles to be arranged to obtain the most effective performance. A bed of large area may have an array of separate nozzles and turn down may be further increased by varying the number in use at any one time.
Table 4 shows that the minimum nozzle velocity for formation of a crater within the bed increases consistently with the height of the nozzle above the bed for an air-sand system. In general, for a nozzle close to the bed surface, formation of the crater occurs at nozzle velocities above 4 to 8 meters/sec.
Other results also indicated that the bed parameters of bed crater depth and width and particle fountain height correlate with the product of the air nozzle flow and the nozzle velocity, i.e. the air momentum flux in that they are independent of nozzle diameter and within limits the height of the nozzle above the bed for a given air momentum flux.
TABLE 4______________________________________Threshold Fluidisation Data - Minimum Nozzle Velocity at WhichBed Fluidisation is SeenPipeHeight Minimum Fluidisation Velocity (m/s) at pipe ID (mm)(mm) 3.9 7.4 9.0 2 × 3.9______________________________________10 4.03 5.97 5.83 4.5820 4.03 8.03 6.38 4.8630 4.31 8.48 6.64 5.3540 5.00 10.23 8.85 5.83______________________________________
Alternative systems include using the outlet nozzle to supply an oxygen containing gas such as air to the bed and introducing fuel either liquid or solid to the crater area. In the case of solid fuels e.g. coal this may be done by using an overbed conveyor device and in the case of liquid fuel, e.g. oil, the fuel may be introduced upstream of the nozzle outlet or from a separate nozzle in the chamber. | A gas particulate solid system has a chamber capable of containing a bed of particulate solid and a supply of an oxygen containing gas. A line or lines having their outlet or outlets above the slumped bed directs the oxygen containing gas downwardly to impinge on the surface of the bed material so as to form a crater surrounded by circulating bed material. Fuel is supplied to the crater either in the gas stream or from an external source and after ignition combustion occurs in or near the crater. | 1 |
TECHNICAL FIELD
[0001] This disclosure relates to the field of automatic transmissions for motor vehicles. More particularly, the disclosure pertains to a method of changing among speed ratios.
BACKGROUND
[0002] Many vehicles are used over a wide range of vehicle speeds, including both forward and reverse movement. Some types of engines, however, are capable of operating efficiently only within a narrow range of speeds. Consequently, transmissions capable of efficiently transmitting power at a variety of speed ratios are frequently employed. Transmission speed ratio is the ratio of input shaft speed to output shaft speed. When the vehicle is at low speed, the transmission is usually operated at a high speed ratio such that it multiplies the engine torque for improved acceleration. At high vehicle speed, operating the transmission at a low speed ratio permits an engine speed associated with quiet, fuel efficient cruising.
[0003] When driving conditions change, an automatic transmission changes from one speed ratio to another speed ratio. For example, when a vehicle is cruising using a low speed ratio and a driver demands an increase in wheel torque, the transmission must downshift into a higher speed ratio. For sudden changes in driver demanded wheel torque, the transmission may skip over one or more available gear ratios in a single shift event. Many automatic transmissions have multiple shift elements, such as clutches or brakes, and select particular speed ratios by engaging particular subsets of the shift elements. To perform a shift from one speed ratio to another, one or more previously engaged shift elements are released and one or more previously disengaged shift elements are engaged. Passenger comfort is maximized if the transition is accomplished smoothly. Performance is maximized if the transition is accomplished quickly. These considerations are often in conflict.
SUMMARY OF THE DISCLOSURE
[0004] A method of shifting a transmission includes maintaining a first offgoing element in a fully engaged condition while operating in a first transmission speed ratio, reducing the torque capacity of the first offgoing element during an inertia phase, and then increasing the torque capacity of the first offgoing element at the end of the inertia phase to prevent output shaft oscillation. A first oncoming clutch is engaged at the end of the inertia phase. The torque capacity of the first offgoing clutch is then decreased to zero in response to the measured transmission speed ratio decreasing. The method may be utilized as part of double transition shift that includes releasing a second offgoing clutch and engaging a second oncoming clutch during the inertia phase. The elements may be either brakes or clutches.
[0005] In another embodiment, a transmission includes at least first and second elements and a controller programmed to downshift from a first speed ratio in which the first clutch is engaged to and the second clutch is disengaged to a second speed ratio in which the first clutch is disengaged and the second clutch is engaged by increasing the torque capacity of the first clutch at the end of the inertia phase. The transmission may also include a third clutch which is engaged in the first speed ratio and disengaged in the second speed ratio and a fourth clutch that is disengaged in the first speed ratio and engaged in the second speed ratio.
BRIEF DESCRIPTION OF THE DRAWINGS
[0006] FIG. 1 is a schematic diagram of an exemplary transmission gearing arrangement.
[0007] FIG. 2 is a graph illustrating speed relationships during execution of a downshift.
[0008] FIG. 3 is a graph illustrating torque relationships during execution of a downshift.
[0009] FIG. 4 is a flowchart illustrating a method of shifting.
DETAILED DESCRIPTION
[0010] Embodiments of the present disclosure are described herein. It is to be understood, however, that the disclosed embodiments are merely examples and other embodiments can take various and alternative forms. The figures are not necessarily to scale; some features could be exaggerated or minimized to show details of particular components. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a representative basis for teaching one skilled in the art to variously employ the present invention. As those of ordinary skill in the art will understand, various features illustrated and described with reference to any one of the figures can be combined with features illustrated in one or more other figures to produce embodiments that are not explicitly illustrated or described. The combinations of features illustrated provide representative embodiments for typical applications. Various combinations and modifications of the features consistent with the teachings of this disclosure, however, could be desired for particular applications or implementations.
[0011] An example transmission is schematically illustrated in FIG. 1 . The transmission utilizes four simple planetary gear sets 20 , 30 , 40 , and 50 . Sun gear 26 is fixed to sun gear 36 , carrier 22 is fixed to ring gear 58 , ring gear 38 is fixed to sun gear 46 , ring gear 48 is fixed to sun gear 56 , input shaft 60 is fixed to carrier 32 , and output shaft 62 is fixed to carrier 52 . Ring gear 28 is selectively held against rotation by brake 66 and sun gears 26 and 36 are selectively held against rotation by brake 68 . Input shaft 60 is selectively coupled to ring gear 48 and sun gear 56 by clutch 70 . Intermediate shaft 64 is selectively coupled to carrier 42 by clutch 72 , selectively coupled to carrier 22 and ring gear 58 by clutch 74 , and selectively coupled to ring gear 38 and sun gear 46 by clutch 76 .
[0012] As shown in Table 1, engaging the clutches and brakes in combinations of four establishes ten forward speed ratios and one reverse speed ratio between input shaft 60 and output shaft 62 . An X indicates that the corresponding shift element is engaged to establish the speed ratio.
[0000]
TABLE 1
66
68
70
72
74
76
Ratio
Step
Rev
X
X
X
X
−4.79
102%
1 st
X
X
X
X
4.70
2 nd
X
X
X
X
2.99
1.57
3 rd
X
X
X
X
2.18
1.37
4 th
X
X
X
X
1.80
1.21
5 th
X
X
X
X
1.54
1.17
6 th
X
X
X
X
1.29
1.19
7 th
X
X
X
X
1.00
1.29
8 th
X
X
X
X
0.85
1.17
9 th
X
X
X
X
0.69
1.24
10 th
X
X
X
X
0.64
1.08
[0013] All single step and two step shifts are performed by gradually engaging one shift element, called an oncoming element (ONC) while gradually releasing a different shift element, called the offgoing element (OFG). During each of these shifts, three shift elements, called holding elements, are maintained fully engaged while one shift element is maintained fully disengaged. In other transmission arrangements, the number of holding elements may be different.
[0014] During a downshift, the engine speed must increase to match the new speed ratio. The output torque may decrease while some of the power is diverted to increasing engine speed rather than being transmitted to the output. Also, since shift elements are slipping during a shift, some of the power is converted to heat, exacerbating the output torque deficiency.
[0015] Sometimes, it is desirable to downshift by more than two ratio steps. For example, if the vehicle driver presses the accelerator pedal to pass another vehicle while cruising on the highway in top gear, the shift scheduling algorithm may demand a multiple step downshift. For some multiple step downshifts, two shift elements must be releases and two shift elements must be engaged. For example, to shift from 10 th gear in the example transmission to 6th gear in the example transmission, brake 68 (OFG 1 ) and clutch 76 (OFG 2 ) must be released and clutch 70 (ONC 1 ) and brake 66 (ONC 2 ) must be engaged. While it is possible to complete such a shift in two stages, by shifting temporarily into 8 th gear for example, completing the shift in that manner would require more time and result in more output torque disturbance than making the shift in a single process. Fluctuating output torque tends to be annoying to the driver as it translates directly into fluctuating vehicle acceleration.
[0016] FIGS. 2 and 3 illustrate speed and torque relationships for a shift from 10th gear to 6th gear in the transmission of FIG. 1 . Line 60 in FIG. 2 shows the input speed as a function of time assuming that output speed is substantially constant. The remaining lines depict the relative speeds across various clutches and brakes. The scale is not necessarily identical among lines. Line 62 in FIG. 3 shows the output torque as a function of time assuming that input torque is substantially constant. The remaining lines depict the torque transmitted by various clutches and brakes. Again, the scale is not necessarily identical among these lines. FIG. 4 is a flow diagram illustrating a method of controlling shift elements to effectuate a shift such as the shift illustrated in FIGS. 2 and 3 .
[0017] The downshift is initiated at 122 in FIG. 4 by gradually reducing the commanded torque capacity of brake 68 (OFG 1 ) as shown between 84 and 86 in FIG. 3 . When the torque capacity becomes less than the capacity required to maintain 10th gear, brake 68 will begin to slip and input speed will begin to rise marking the beginning of the inertia phase. As shown by line 62 in FIG. 3 , the output torque drops during this phase as power is diverted to increasing engine speed. The torque capacity of brake 68 (OFG 1 ) determines how much the output torque drops and how quickly the engine speed increases as shown at 124 in FIG. 4 . If the torque capacity of brake 68 is close to zero, then very little of the engine power will be transmitted to the output but the engine speed will increase rapidly. On the other hand, if the torque capacity of brake 68 is maintained close to the level that brake 68 would transmit in 10th gear, then most of the engine power will be transmitted to the output shaft and engine speed will increase slowly.
[0018] As shown in FIG. 2 , as the input shaft increases in speed, the speed difference across clutch 70 (ONC 1 ) and brake 66 (ONC 2 ) decrease. During this period, the pressure supplied to clutch 70 and brake 66 may be increased in order to prepare for later engagement, but not enough to exert substantial torque. When the speed difference across clutch 70 (ONC 1 ) reaches zero at 88 in FIG. 2 and at 126 in FIG. 4 , the torque capacity of clutch 76 (OFG 2 ) is rapidly ramped to zero and the torque capacity of clutch 70 (ONC 1 ) is rapidly increased as shown at 128 in FIG. 4 . The torque capacity of brake 66 (OFG 1 ) continues to control the rate of change of the input speed as shown at 130 in FIG. 4 .
[0019] When the speed difference across brake 66 (ONC 2 ) reaches zero at 90 in FIG. 2 and at 132 in FIG. 4 , the inertia phase ends and the torque phase begins. The torque capacity of brake 66 (ONC 2 ) is rapidly increased between 92 and 94 in FIG. 3 and at 134 in FIG. 4 . Engaging brake 66 before point 92 would cause a further reduction in output torque. Because brake 66 does not immediately reach sufficient torque capacity to stop ring gear 28 , the direction of rotation of brake 66 may briefly change as shown at 96 in FIG. 2 . As shown at 98 in FIG. 2 , the input speed may also temporarily exceed the speed associated with the final gear ratio. As brake 66 pulls the input speed back down to it final value, excess energy in various transmission components can result in windup in various shafts such as the vehicle driveshaft. Unless action is taken to dissipate this energy, the output shaft will oscillate as shown by the dotted lines at 100 .
[0020] Instead of immediately releasing brake 68 (OFG 1 ), the torque capacity of brake 68 is increased at a calibratable rate between 92 and 94 in FIG. 3 and at 136 in FIG. 4 . When the input speed begins to decrease at 98 in FIG. 2 and at 138 in FIG. 4 , the torque capacity of brake 68 is decreased at a calibratable rate as shown between 102 and 104 in FIG. 3 and at 140 in FIG. 4 . Point 102 may also be determined by a change in direction of the relative speed across either offgoing shift element 68 or 76 or of the second oncoming shift element 66 . Between points 92 and 104 , brake 68 absorbs energy, dampening any oscillation and resulting in the smooth torque transition illustrated at 106 in FIG. 3 .
[0021] While exemplary embodiments are described above, it is not intended that these embodiments describe all possible forms encompassed by the claims. The words used in the specification are words of description rather than limitation, and it is understood that various changes can be made without departing from the spirit and scope of the disclosure. As previously described, the features of various embodiments can be combined to form further embodiments of the invention that may not be explicitly described or illustrated. While various embodiments could have been described as providing advantages or being preferred over other embodiments or prior art implementations with respect to one or more desired characteristics, those of ordinary skill in the art recognize that one or more features or characteristics can be compromised to achieve desired overall system attributes, which depend on the specific application and implementation. These attributes can include, but are not limited to cost, strength, durability, life cycle cost, marketability, appearance, packaging, size, serviceability, weight, manufacturability, ease of assembly, etc. As such, embodiments described as less desirable than other embodiments or prior art implementations with respect to one or more characteristics are not outside the scope of the disclosure and can be desirable for particular applications. | A method of down-shifting a transmission avoids output shaft oscillations by briefly increasing the torque capacity of an off-going element at the end of the inertia phase. The torque capacity of the off-going element is then reduced to zero when the measured transmission speed ratio begins to decrease. The method is suitable for downshifts that involve multiple off-going elements and multiple on-coming elements such as a shift from tenth gear to sixth gear in a ten speed transmission. | 8 |
FIELD OF THE INVENTION
The present invention relates generally to structures for a multistorey parking building or parking attachment to an existing building and to devices for automated parking and, more particularly, to structures made of modular elements and to devices and platforms for automatic car distribution within a multistorey parking space.
BACKGROUND OF THE INVENTION
At present time, parking spaces are in the form of open paved squares, basement storeys of buildings or as separate concrete structures where vehicle is being parked by its driver (or valet parking). Open parking spaces occupy significant areas of already crowded cities. Multistorey concrete parking buildings with human parking (by driver or valet) are bulky, relatively expensive and ineffective since the area and the height are only partially used for vehicle placement so that the volume of a parking building is used up to 35% only. When most parking spaces are occupied, the arriving vehicles are manoeuvring or waiting with running engine which leads to increased pollution. This invention aims at solving parking problems in downtowns of big cities, at aeroports, theatres, shopping malls, stadiums and universities; at elimination of street parking in crowded areas, at decreasing pollution and at providing clean, safe, inexpensive and fast automated parking spaces.
Preliminary search did not find any patents proposing structures and devices for automated multistorey parking buildings.
SUMMARY OF THE INVENTION
The object of the invention is the structure of the multistorey parking building and the devices providing automatic operation at all stages of parking process. The parking building of the parking attachment to an existing building is manufactured as a steel frame in such a way that the volume of the structure is partitioned into boxes in which vehicles are stationed, and horizontal lanes (corridors) and vertical lanes (with elevators) where devices (shuttles or trolleys) are moving that distribute vehicles into boxes. Due to different sizes of vehicles, there may be several different types of boxes which provides for better use of the volume of the parking building. Every box has a platform on which to park a vehicle. Platforms with or without vehicles can be moved through the building by shuttles moving on special guides which serve simultaneously as supporting structure of the building. For better ventilation, boxes are separated vertically by grid desk plating or solid floors with holes. Walls of the underground part of the parking building are made of concrete and the upper part can be made with any appropriate materials, with or without windows. Vertical transportation of shuttles or trolleys is provided by special elevators with guides. Guides in elevators and guides in horizontal corridors are aligned when elevators stop. Every platform has two guides tracks and the mechanism to precisely check and fix the vehicle on the platform.
The automatic parking process is as follows. At the entrance, a driver puts his vehicle on the platform set on a shuttle which awaits customers, leaves the vehicle and pays the fee to the automatic parking-dispenser which immediately gives the driver a code-number and directs the shuttle with the vehicle to the vacant box with that code-number. The driver leaves the premises. Upon arrival to the box, the platform with the car is moved from the shuttle into the box, the vacant shuttle is directed to a vacant box with the platform but without a vehicle, the platform is transferred onto the shuttle which returns to the entrance to wait for another customer. There are several shuttles in the building; among them there is a vacant shuttle for vehicle delivery and another one with a platform to take a vehicle for parking. If the parking is full, then the shuttles stand still where they are until a driver arrives to pick up his vehicle. The driver dials his code-number and pays the balance to the parking-dispenser; then the closest shuttle is directed to the box, makes delivery of the vehicle and awaits another customer. All operations are automatic and computerized including the inventory of vacant and occupied boxes, control of shuttles and elevators and additional services, if any (e.g., automatic car wash). In case of equipment failure, a technician on duty delivers a vehicle by manual operations.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a plan view of the automated multistory parking according to the embodiment of the present invention claimed in claim 6 below;
FIG. 2 is a section on the line I--I in FIG. 1 claimed in claim 6 below;
FIG. 3 is a section on the line II--II in FIG. 1 claimed in claim 6 below;
FIG. 4 shows the platform for a parking vehicle claimed in claim 6 below;
FIG. 5 is a view on the line III--III in FIG. 4 claimed in claim 6 below;
FIG. 6 is a section on the line IV--IV in FIG. 4 claimed in claim 6 below;
FIG. 7 is a view from under the shuttle claimed in claim 6 below;
FIG. 8 is a view on the line V--V in FIG. 7 claimed in claim 6 below;
FIG. 9 is a section on the line VI--VI in FIG. 7 claimed in claim 6 below;
FIG. 10 is a longitudinal view of the shuttle with the platform claimed in claim 6 below;
FIG. 11 is a longitudinal view of the trolley claimed in claim 9 below;
FIG. 12 is a view on the line VII--VII in FIG. 11 claimed in claim 9 below;
FIG. 13 is a transverse view of the shuttle and the platform with roller conveyer for moving the platform to lateral directions claimed in claim 7 and 8 below;
FIG. 14 is a section on the line VIII--VIII in FIG. 13 claim in claim 7 and 8 below.
NOTE: Shuttles are devices which distribute platforms with or without vehicles into or out of the boxes and are circulating in lanes (corridors) and on elevetors. Trolleys represent moving platforms that are normally stationed in boxes (with or without vehicles) and are circulating in lanes (corridors) and on elevators in order to deliver a vehicle parked on a trolley into a box for storage and to take it out of the box to the exit on request of the driver of the vehicle.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
An automated multistorey parking as seen in FIGS. 1 to 3 consists of structures: column 1, horizontal longitudinal elements 2, horizontal transverse elements 3, longitudinal guides 4 and transverse guides 5 (e.g. channel-shaped). At intersections of guides 4 and 5, the vertical parts of guides 4 are truncated. The said elements are assembled in such a way that the entire volume of the building is partitioned into boxes 7 (where vehicles are parked), lanes (corridors) 7A where shuttles or trolleys are moving that distribute vehicles into the vacant boxes and elevator pits 6A for vertical vehicle delivery. Floors between boxes 7 are manufactured as grid desk plating (not shown on drawings). Guides 4 and 5 on which shuttles are moving represent also elements of supporting structures of the multistorey parking building and simultaneously serve as a base for installation of the grid deck plating. Vertically, between floors, shuttles or trolleys with vehicles are moved by elevators 6, which also have guides 4 and 5. All guides of each floor are on the same horizontal level. Elevator 6 moving a shuttle or a trolley with a vehicle to certain floor of the parking, stops in such position that his guides 4 and 5 are aligned with guides 4 and 5 of the floor so that shuttle or a trolley with a vehicle can move horizontally in two perpendicular directions.
In every box 7 there is platform 8 with edges bent up in order not to spill dirt on the top of lower vehicle. Vehicle are put on platform at the entrance by driver. The platform 8 (see drawings 4 to 6) has two guide-tracks 9A of enough width to accommodate wheels 12 of different vehicles and track borders 9. One or both tracks 9A have a mechanism fixing wheels of a vehicle on the platform. Inside track borders 9 there are two strips 10 moved in transverse direction by mechanisms 11 (e.g., hydraulic jacks) that fasten wheel 12 in tracks 9A. One, two or all four wheels of a vehicle can be fixed. Platform 8 is fastened on a shuttle 14, e.g., by means of studs (pins) 13.
The shuttle 14 (see drawings 7 to 9) has a plate or frame 14 fitted with wheels 15 with a motor 16. The shuttle 14 has also the bottom frame 18 with transverse wheels 17 and motor 19. The frame 18 is connected with the frame 14 of the shuttle by jacks 20 that change the vertical position of transverse wheels 17. Mechanism 21 brings in motion simultaneously hydraulic jacks 20 for lowering or lifting wheels 17 in order that the shuttle 14 could be transferred from longitudinal motion along guides 4 onto transverse motion along guides 5, and also for putting the platform 8 on special supports in a box 7 (these supports are not shown on FIG. 3 of the box 7). Special holes 22 are for fixing the platform 8 on the shuttle 14.
Shuttle 14 (with platform 8 and a vehicle) in motion along the longitudinal guides 4 is shown in FIG. 10. At a stop near a vacant box 7, the mechanism 21 starts and hydraulic jacks 20 lower wheels 17 into guides 5, simultaneously lifting wheels 15; the shuttle 14 moving along guides 5 enters box 7, leaves on special supports (not shown) the platform 8 with a vehicle and returns to guides 4 for the next operation (next parking or vehicle delivery).
In FIG. 11, a version is shown where the platform is fixed permanently to the shuttle to form a trolley 23 which either remaines in a box 7 with a vehicle parked thereon or moves to the exit (entrance) to deliver a car and waits there for a new vehicle. This solution is different from the previous one in that there are no shuttles nor platforms but there are as many trollery 23 as there are boxes 7, and each trolley has a platform as its integral part and is used for parking a vehicle into a parking box.
In FIG. 12 the transverse view on the VII--VII of a trolley 23 with a vehicle on longitudinal guides 4 is shown (transverse wheels 17 are not shown).
As a possible version, in FIGS. 13 and 14, a shuttle 14 is shown fitted with longitudinal wheels 15 only. For moving platform 8 in the transverse direction (arrow B or C), shuttles 14 and boxes 7 are fitted with roller conveyers 25, and platform 8 has guides 26. The platform 8 is moved in and out of boxes 7 by the mechanism 27, e.g., hydraulic telescopic shaft. In order to decrease the swinging of shuttle 14 in speedy motion and when mechanism 27 is working, the shuttle 14 is fitted with rollers 24 and lanes (corridors) 7A are fitted with guide strips 28.
Control equipment is not shown on drawings. The parking process is computer-controlled. There is no personnel in the parking building and no driver can enter the parking which ensures absolute security for the parked vehicles and their contents. In case of a failure, the alarm system calls a technician on duty for inspection and repairs. The parking building is fitted with ventilation and fire prevention systems. | A multistorey parking apparatus comprising a multistorey parking building with appropriate partitioning, fixing and moving elements characterized in that the said apparatus is capable of automatically, safely and pollution free taking in, distributing and storing motor vehicles in the parking building and delivering them out on demand without drivers and without running the engine. | 4 |
The present invention relates to electrochemical systems for the storage and delivery of electrical energy and, in particular, to apparatus for building such systems.
BACKGROUND OF THE INVENTION
Industrial electrochemical systems, such as secondary batteries, fuel cells and electrolysers, typically consist of modules which each comprise a number of repeating layered sub-assemblies clamped together to form a stack. For example, in a secondary battery of the redox flow type each sub-assembly typically consists of an electrically insulating flow-frame (i.e. a device which supports the other constituent parts of the sub-assembly and which also defines channels for the flow of electrolytes), a bipolar electrode, an ion-selective membrane or a combined membrane-electrode material and, optionally, other component layers such as meshes or electrocatalytic materials. A plurality of such sub-assemblies may be sandwiched together between suitable end-plates so as to create a plurality of electrochemical cells in series. Each cell thus comprises the positive and negative surfaces of two bipolar electrodes with an ion-selective membrane positioned therebetween so as to define separate anolyte-containing and catholyte-containing chambers within each cell, said chambers optionally comprising additional components such as meshes or electrocatalytic materials. The two electrolytes are typically supplied from two reservoirs to the cell chambers via an electrolyte circulation network. Electrochemical systems of this type are well known to a person skilled in the art.
In the manufacture of components for the creation of such assemblies there are a number of important considerations. In particular, it is desirable to suppress shunt currents within the electrolyte circulation networks. Shunt currents occur because of the conductive pathways that are created by the network of electrolyte connections linking the cell chambers. They are a particular problem for stacks which contain a large number of bipoles and their occurrence decreases the efficiency of the cell. Additionally, it is advantageous to make efficient use of all the available surface area of the electrode. In order to do this the electrolytes must be distributed evenly over the surfaces of the electrodes upon entering the cell chambers. Furthermore, in order to ensure that the fluids which are inside the stack are isolated from each other and contained successfully with minimal leakage to the outside, it is necessary for satisfactory seals to be provided between the individual components within the stack.
The occurrence of shunt currents within such cell arrays is discussed by P. G. Grimes and R. J. Bellows in a paper entitled “Shunt current control methods in electrochemical systems-applications”, appearing in Electrochemical Cell Design, R. E. White, Ed.: Plenum Publishing Corp, 1984, page 259. Typically, shunt currents are reduced by the provision of labyrinthine pathways for the electrolytes between the electrolyte circulation networks and the individual cell chambers. One method for achieving such a pathway has been to connect long-tubes between the electrolyte circulation networks and each of the individual cell chambers. However this method suffers from the disadvantage that it requires at least two seals, one at either end of the tube, which complicates the assembly procedure and can cause problems with electrolyte leakage especially since the seals must cope with pressure differentials which usually exist between the internal system and the external environment. Another method for providing a labyrinthine pathway involves forming a long groove into the surface of the flow-frame from a point in communication with the electrolyte circulation network to a point in communication with the individual cell chamber. On stacking the sub-assemblies a plate is sandwiched between successive layers so as to seal the groove and form a labyrinthine pathway for the electrolyte. This method suffers from the disadvantage that the costs of forming the grooves can be high and an extra layer, i.e. the plate, must usually be incorporated into the assembly to provide efficient sealing. This method also often requires large frame areas upon which to form the grooves. Electrolyte leakage is a particular problem in methods for controlling shunt currents which involve labyrinthine pathways for the electrolytes. Efficient fluidic sealing of the pathways is required to prevent leakage and this problem may be exacerbated by the fact that high pumping pressures are often required to push the electrolytes through the narrow pathways. Other solutions to the problem of shunt currents include electrically breaking the circuit by arranging for the flow to break up into droplets or spray or by using some form of syphon; even mechanical water wheel type structures have been proposed. Such solutions are rarely used in practice however because the mechanical and flow regimes are difficult to implement. Other solutions, rather than eliminate the shunt currents, attempt to control their effects, for example, by deliberately shunting the current through an auxiliary electronic circuit or by passing an appropriate current through the common manifold or channel interconnectors. However, these techniques do not necessarily reduce overall power loss.
It would be advantageous to provide a flow-frame, suitable for forming a sub-assembly as described above, which is a repeating structural unit within an array of electrochemical cells formed from a stack of said sub-assemblies. The flow-frame would advantageously provide a framework for supporting all the other elements of the cell array within a sealed environment together with means for providing resistance to shunt currents and means for distributing an even flow of electrolyte through the chambers of each cell.
SUMMARY OF THE INVENTION
Accordingly, the present invention provides a flow-frame for forming a sub-assembly; said sub-assembly comprising a bipolar electrode and an ion-selective membrane mounted on said flow-frame and wherein said sub-assembly may be stacked together with other such sub-assemblies to create an array of electrochemical cells, each cell thus comprising two electrode surfaces with an ion-selective membrane positioned therebetween so as to define separate anolyte-containing and catholyte-containing chambers within each cell; wherein said flow-frame is formed from an electrically insulating material and comprises
(i) a chamber-defining portion for supporting an electrode and a membrane within a defined space,
(ii) at least four manifold-defining portions which, on stacking said flow-frames, define four manifolds through which the anolyte and the catholyte are supplied to and removed from said anolyte-containing and catholyte-containing chambers,
(iii) at least two chamber entry ports for allowing the anolyte and the catholyte to flow from said manifolds into said anolyte-containing and catholyte-containing chambers, and
(iv) at least two chamber exit ports for allowing the anolyte and the catholyte to flow from said anolyte-containing and catholyte-containing chambers into said manifolds,
characterised in that one or more of the manifold-defining portions also define a pathway for the passage of the anolyte/catholyte between the manifold and the chamber entry/exit port.
Thus, in the present invention, the pathway for the passage of the anolyte/catholyte between the manifolds and the chamber entry/exit ports is formed within the manifold-defining portions of the flow-frame. The pathway may comprise grooves cut into one surface of the manifold-defining portions of the flow-frame. On stacking the flow-frames the grooves are sealed by the flat surface of the manifold-defining portion of the adjacent frame to form sealed pathways. Preferably the pathway defined within the manifold-defining portions does not allow electrolyte to travel in a straight line directly between the manifold and the chamber entry/exit ports. Preferably it causes the electrolyte to take a tortuous or labyrinthine path between the manifold and the chamber entry/exit ports.
The pathway is advantageously incorporated into the manifold-defining portions because pressure differentials which would drive leaks are kept relatively small, reducing the problems associated with the requirement for efficient fluidic sealing of said pathway. Furthermore, because the pathway is formed within the manifold-defining portions any leakage caused by inefficient sealing is contained within the manifold and does not contaminate other parts of the assembled module. Thus the flow-frame of the present invention is more tolerant to leakage than flow-frames known in the art.
Preferably the pathway is substantially spiral in shape. A substantially spiral pathway is preferred for a number of reasons. Firstly, such a pathway avoids sudden drops in fluid pressure which can be caused by the presence of sharp corners in the pathway. Secondly, it achieves the aim of separating fluids at different electrical potentials whilst occupying the minimum space possible. Thirdly, it maintains a near-circular manifold cross-section which is ideal for the efficient flow of electrolytes within the manifold. Finally, it is relatively easy to manufacture.
Preferably, the manifold-defining portions are themselves distanced from the main chamber-defining portion. This further reduces the risks of shunt currents travelling between the chambers and the manifolds.
In a preferred embodiment of the present invention the pathway is defined by a part which is releasably. insertable within said manifold-defining portions. As indicated above the magnitude of the problems associated with shunt currents depends upon the number of bipolar electrodes which make up the complete stack. The greater the number of bipoles the more serious are the losses caused by the occurrence of shunt currents. It is further known that the problems associated with shunt currents also vary according to the nature of the electrolytes in a given system, the position and performance of an individual sub-assembly within the stack itself and the nature of the array of stacks. An advantage of the provision of said releasably insertable parts is that it allows the customisation of individual flow-frames within each sub-assembly to adjust the resistance to shunt currents and simultaneously to adjust the resistance to electrolyte flow in the manifold depending upon the position of the sub-assembly within the stack and also depending upon the size and nature of the stack as a whole. Furthermore, it allows customisation of the individual manifold-defining portions within each flow-frame depending upon the identity of the electrolyte within the manifold and whether it is being supplied to, or removed from, the cell chamber. A further advantage associated with the provision of releasably insertable parts is that when the sub-assemblies are stacked to form a cell array the releasably insertable parts may be staggered relative to one another so that the points within the manifold from which electrolyte is drawn into the pathways are distanced from one another so as to further reduce the effects of shunt currents.
Around the perimeter of the chamber-defining portion of the flow frame it is necessary that the surface topography thereof remains substantially continuous so that when a membrane is included in the layered sub-assembly an efficient seal is formed to ensure that the anolyte and catholyte chambers remain substantially isolated. Such isolation may be achieved with an elastomeric seal, a weld, or by other means. In a preferred embodiment, extending around the perimeter of one surface of the chamber-defining portion of the frame and within the integral sealing means described below is provided a small, substantially continuous, raised portion so that, on stacking the frames, a mechanical pinch is formed between said raised portion on one frame and a flat or grooved surface on the chamber-defining portion of the adjacent frame in the stack. The mechanical pinch is designed to secure a membrane in position when it is included as a part of the sub-assembly in order to limit cross-contamination of electrolytes at the edge of the membrane. The advantages of using a mechanical pinch as described above are that it is relatively easily manufactured as part of the frame and it achieves a sufficiently tight grip to isolate the anolyte and catholyte given that they tend to have only modest pressure differentials. In a preferred embodiment such a mechanical pinch may also be created between the grooves which are cut into the manifold-defining portions by providing a small substantially continuous raised portion between said grooves. In this case the pinch ensures that when the flow-frames are stacked the grooves which create the labyrinthine pathway are isolated from one another so that fluid and current cannot flow between adjacent grooves.
The flow of the electrolytes from the manifolds to the electrolyte chambers, and vice versa, must be effected whilst maintaining the mutual isolation of the anolyte and catholyte containing chambers. The electrolytes enter and exit the anolyte and catholyte chambers by means of the chamber entry/exit ports. In flow-frames known in the art these commonly take the form of flow channels situated entirely within the frame thickness. However this type of channel is difficult to machine or mould. Accordingly, in a preferred embodiment of the present invention one or more of the chamber entry/exit ports comprise optionally releasable inserts shaped so that on insertion into the flow-frame they form flow channels between the end of the pathway defined by the manifold-defining portions and the anolyte/catholyte containing chambers. The outer surface of said insert is preferably shaped so that on placement of the insert within the chamber entry/exit ports the surface topography of the chamber-defining portion of the flow-frame remains continuous in the vicinity of the chamber entry/exit ports. This is advantageous because, as mentioned above, it enables a sufficiently tight seal to be formed between successive sub-assemblies upon stacking and ensures that the membrane layer is tightly gripped between successive flow-frames so as to substantially isolate the anolyte-containing and catholyte-containing chambers from one another. The opposite, inner surface of the insert which contacts the floor of the chamber entry/exit port has one or more grooves cut into the surface, the size and shape of the grooves being determined by the desired flow characteristics for the insert. Preferably the grooves are designed so as to direct the flow of anolyte/catholyte evenly over the surfaces of the electrodes. The flow characteristics desired for a particular chamber entry/exit port within a flow-frame will depend upon a number of factors including the overall size of the stack, the position of the flow-frame within the stack and the flow properties of the electrolytes in question. The inserts can be customised accordingly. Preferably, the inserts are releasably inserted into place so that the flow characteristics of the cell entry/exit ports for a particular flow-frame can be altered simply by inserting a different shaped insert rather than redesigning the entire flow-frame. A further advantage of this design is that the inserts are relatively easy to manufacture and it avoids the need to machine flow channels through the thickness of the flow-frame.
In addition to the provision of releasable inserts within the chamber entry/exit ports, the distribution of the electrolytes over the surfaces of the electrode may be further improved by the inclusion of appropriately sculpted flow distribution means extending over substantially the entire width of both ends of the flow-frame and located at a point adjacent to the chamber entry/exit ports. Upon the formation and stacking of electrode/membrane/frame sub-assemblies the flow distribution means, together with the membrane, define channels for the flow of the electrolytes along the width of either end of the frame and apertures opening into the cell chambers on either side of the electrode for the flow of the electrolytes onto or away from the electrode surfaces. The resistance to fluid flow across the width of the ends of the flow-frame is determined by the cross-sectional area of the channels whilst the resistance to fluid flow onto the surface of the electrode is determined by the size of the aperture opening into the cell chambers. Together, the cross-sectional area of the channels and the size of the aperture act so as to spread the flow of the electrolytes evenly over the surfaces of the electrode. Thus, in a preferred embodiment of the present invention, the resistance to flow across the width of the flow-frame is lowest at the points closest to the chamber entry/exit ports by provision of a channel with a large cross-sectional area and highest at the points furthest from the chamber entry/exit ports by provision of a channel with a low cross-sectional area. The size of the aperture into the cell chambers remains constant across the width of the flow-frame. Thus, at a point close to the chamber entry/exit ports the electrolytes flow easily along the width of the frame either spreading out over the width of the frame or being drawn in from across the width of the frame. In contrast, at a point further from the entry/exit ports the electrolytes flow less easily along the width of the flow frame and are therefore directed towards or drawn from the electrode surfaces. Thus, the electrolytes are supplied to and removed from the electrode surfaces with a more even flow over the entire width of the electrode. In the present invention, the variations in resistance to fluid flow apply simultaneously and in an opposite fashion at either end of the frame.
Preferably the entire perimeter of the flow-frame is provided with means for forming a seal between adjacent frames when they are stacked to form a sub-assembly. More preferably said sealing means comprises an integral sealing means as described in our co-pending application number WO97/24778. The integral sealing means comprises a continuous groove on one face of the frame which defines a female opening having a width of w and a depth of h and a continuous upstand on the other face of the frame having a width of >w and a height of <h . The sealing means is designed to hold the frames together when they are formed into a stack and to prevent the escape of the electrolytes from the cells.
Preferably, extending inwardly from the chamber-defining portion of the frame, is provided means for supporting an electrode within the space defined by said chamber-defining portion.
The flow-frame of the present invention may be formed from any electrically insulating material. Preferably however it may be formed from one or more polymers selected from polyethylene, polypropylene and copolymer blends of ethylene and propylene, acetal, nylons, polystyrene, polyethylene terephthalate, polyvinylidene fluoride, polyvinyl chloride, polytetrafluoroethylene, fluorinated ethylenepropylene copolymer, polyfluoramide, chlorinated polyoxymethylene and many others. The desired configuration for the flow-frame may be formed from these polymeric materials by machining, injection moulding, compression moulding or extrusion.
The present invention also includes within its scope an electrochemical apparatus comprising a flow-frame as hereinbefore described.
The present application also includes within its scope an electrochemical apparatus comprising a plurality of flow-frames, and either a plurality of bipolar electrodes and a plurality of ion-selective membranes or a plurality of combined membrane-electrode materials and, optionally, a plurality of meshes and/or electrocatalytic materials sandwiched together so as to create an array of electrochemical cells.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention will now be described by way of example with reference to the drawings in which:
FIG. 1 is a schematic representation of a flow-frame according to the present invention.
FIG. 2 is a magnified representation of portion X of FIG. 1 showing, in detail, a manifold-defining portion of a flow-frame according to the present invention, including the optionally releasable spiral pathway defining parts but not the optionally releasable inserts.
FIGS. 3A, 3 B and 3 C show cross-sectional views along lines A—A, B—B and C—C respectively.
FIG. 4 is a representation of a releasable insert according to the present invention.
FIG. 5 is an exploded view of a stack of sub-assemblies, each sub-assembly being formed from a flow-frame according to the present invention, a bipolar electrode, an optional mesh or catalytic layer and a membrane. Such a stack may form part of an array of electrochemical cells.
DETAILED DESCRIPTION OF THE INVENTION
Referring to FIG. 1, the flow-frame comprises a substantially rectangular chamber-defining portion 1 with four substantially circular manifold-defining portions 2 , 3 , 4 and 5 positioned two at each end of the rectangular chamber-defining portion. The chamber-defining portion serves to support a bipolar electrode and a membrane within the space created therein. The frame/electrode/membrane sub-assembly thus formed may sandwiched together with a plurality of other such sub-assemblies so as to create a plurality of electrochemical cell in series (see FIG. 5 ). Each cell thus comprises the positive and negative surfaces of two bipolar electrodes with a membrane positioned therebetween so as to define separate anolyte-containing and catholyte-containing chambers within each cell. It will be understood by those skilled in the art that the positioning of the manifold-defining portions relative to the chamber-defining portion and the chosen rectangular and circular shapes of the frame and manifold-defining portions respectively are not critical to the present invention. In the illustrated embodiment the manifold-defining portions 2 and 4 define, upon stacking the frames, manifolds 6 and 7 which may supply/remove the catholyte to/from the catholyte-containing chambers. The other manifold-defining portions 3 and 5 define, upon stacking the frames, manifolds 8 and 9 which may supply/remove the anolyte to/from the anolyte-containing chambers.
Referring to FIG. 2 and FIG. 3A, the manifold-defining portions 2 and 3 (only 3 is shown in FIG. 2 but the same structural features are also present in 2 , 4 and 5 ) contain optionally releasable ring-shaped members 10 and 11 (only 11 is shown in FIG. 2) which are shaped so as to provide a tight fit within the manifold-defining portions 2 and 3 . Although the illustrated embodiment of the present invention provides a tight fit for retaining the ring-shaped members 10 and 11 within the manifold-defining portions 2 and 3 other means for locating and securing the ring-shaped members in position are envisaged and are included within the scope of the invention. The releasable ring-shaped members 10 and 11 comprise two parallel surfaces 12 and 13 , one of which is a substantially flat surface and the other of which comprises a spiral groove 14 cut therein. On stacking the frames, the groove 14 is sealed by the coming together of flat surface 13 of one frame with flat surface 12 of the adjacent frame so as to define an extended spiral pathway for the passage of the anolyte/catholyte between the manifold 8 and the chamber entry/exit port 15 . Surface 16 delineates the circumferential face of the optionally releasable members which provides a tight fit with the inner face of the manifold-defining portions. The optionally releasable members may be removed and replaced by a member with a different groove length or different groove cross-sectional area as required. Attention is drawn to the relative orientation of the optionally releasable members 10 and 11 in FIG. 3A of the illustrated embodiment. It will be noted that the grooves are present on opposite faces of the resultant flow frame. Thus the two chamber entry/exit ports which form part of the two manifold-defining portions at one end of the frame supply anolyte/catholyte to opposite faces of an electrode when said electrode is mounted within the rectangular space defined by the chamber-defining portion.
Referring to FIG. 2 and FIG. 3B, adjacent to the perimeter of the flow-frame and extending all the way around the perimeter are means 17 and 18 for forming a seal between successive frames when they are stacked to form an array of electrochemical cells. The means comprise a continuous groove 17 which defines a female opening having a width of w and a depth of h and a continuous upstand 18 having a width of >w and a height of <h.
Referring to FIG. 2 and FIG. 3C, at each end of the rectangular chamber-defining portion, at a point adjacent to the chamber entry/exit ports, there are provided sculpted portions 19 and 19 ′ extending over substantially the entire width of the chamber-defining portion which define channels 20 , 20 ′, 21 and 21 ′ on either side of the sculpted portions 19 and 19 ′. The cross-sectional areas Y, Y′, Z and Z′ of the channels 20 , 20 ′, 21 and 21 ′ respectively vary along the length of the sculpted portions, and do so in an opposite fashion at either end of the chamber-defining portion. That is, Y is large when Y′ is small and vice versa, whilst Z is large when Z, is small and vice versa. The cross-sectional areas are larger at points close to the chamber entry/exit ports and smaller at points further from the chamber entry/exit ports.
Referring to FIG. 2 and FIGS. 3B and 3C, extending inwardly from the sculpted portions 19 and 19 ′ at each end of the frame and from the inner faces 22 of the sides of the frame, there is provided a continuous lip 23 to which an electrode (not shown) may be attached on forming a sub-assembly.
Referring to FIG. 2 and FIGS. 3B and 3C, extending around the perimeter of one surface of the rectangular chamber-defining portion of the frame, inside the means 17 and 18 for forming a seal between successive frames, is provided a small, substantially continuous, raised portion 24 for forming a mechanical pinch, on stacking the frames, between the raised portion 24 on one frame and the flat surface 25 of the chamber-defining portion of the adjacent frame in the stack. This mechanical pinch is designed to secure the membrane in position when it is included as part of the sub-assembly and to minimise the crossover and/or mixing of electrolytes. The continuity of this raised portion is maintained in the region of the chamber entry/exit ports by an identical raised portion on the surface 33 of the inserts as described below.
Extending from the outer edge of the flow-frame there is provided a lip 26 which aids handling of the flow-frame on assembling and disassembling stacks of sub-assemblies.
Referring to FIG. 4, the insert for the chamber entry/exit ports comprises a body 30 which is shaped so as to provide a tight fit within the chamber entry/exit ports. The surface 31 of the inserts which contacts the floor of the chamber entry/exit ports is provided with a plurality of grooves 32 , in this case four, for the passage of the electrolyte. The opposite surface 33 of the insert is shaped so that on placement of the insert within the chamber entry/exit ports the surface topography of the rectangular portion of the frame, including the raised portion 24 remains continuous in the vicinity of the chamber entry/exit ports. The insert of the illustrated embodiment also possesses three shaped projections 34 , 35 and 36 which extend from the body 30 of the insert into the regions containing the sculpted portions 19 and 19 ′. These projections are shaped so as to distribute the flow of electrolyte evenly over the surfaces of the electrode. The design of the releasable inserts can be altered so as to provide different flow characteristics for the flow frame which can thus be customised according to the characteristics desired.
Referring to FIG. 5, there is shown an exploded view of a small stack comprising four sub-assemblies. The first two sub-assemblies and the flow-frame for the third sub-assembly are shown clamped together. Of the first two sub-assemblies, only the flow-frames ( 40 and 41 ) are visible. The third and fourth sub-assemblies are exploded to show the constituent layers thereof. The flow-frame 42 for the third sub-assembly supports a bipolar electrode 43 within the space defined by said flow-frame 42 . The bipolar electrode may optionally be surfaced on one side with a layer 44 which may be formed from a porous and/or electrocatalytic material. Although not illustrated, it will be appreciated by a person skilled in the art that such a layer of porous and/or electrocatalytic material may alternatively be used to surface the other side of the bipolar electrode. Furthermore, two such layers may be used to surface both sides of the bipolar electrode. The next layer in the sub-assembly is the membrane 45 . This layer is slightly larger in area than the bipolar electrode 43 and optional layer 44 . Components 42 to 45 make up the third sub-assembly. Similarly, the fourth sub-assembly is made up of a flow-frame 46 , a bipolar electrode 47 , an optional layer 48 and a membrane 49 . The stack may comprise many more than the four sub-assemblies shown in FIG. 5 and in an electrochemical cell comprising such a stack, suitable end-plates (not shown) will be provided at either end of the stack. | A flow-frame for forming a subassembly; said sub-assembly comprising a bipolar electrode and an ion-selective membrane mounted on said flow-frame and wherein said sub-assembly may be stacked together with other such subassemblies to create an array of electrochemical cells; wherein said flow-frame is formed from an electrically insulating material and comprises at least four manifold-defining portions which also define pathways for the passage of the anolyte/catholyte. Such pathway may define a labyrinthine path which may be spiral in shape between the manifold and the chamber entry/exit port. | 2 |
BACKGROUND OF THE INVENTION
The present invention refers to a communications system for selectively sending prerecorded messages from a transmitter unit to mobile, passing-by receiver unit. In particular the invention is related to selectively sending voice messages from at least one but generally several fixed transmitters to randomly roaming receivers individually coming within range of a particular transmitter, wherein each message content is customized or dependant on the location of the transmitter sending it. More particularly, the present invention is directed to selectively beaming messages of interest to people of the general public passing by predetermined locations or stations.
The present invention may be put to different applications, such as educational, cultural or commercial. For instance, visitors to a museum may listen to prerecorded summaries of each object as they walk by or stop to look. Another application selectively beams publicity material to prospective buyers, such as to entice them to sale offers and the like.
One such application particularly targeted by the present invention is inside a supermarket wherein a plurality of transmitters are located in relation to particular products or brands and each push-cart, or at least a great number thereof, is provided with a stand-alone receiver unit. Each transmitter contains at least one customized voice message, such as a special discount offer for a particular product on a shelf nearby or advertising a brand in the midst, which it may transmit to a selected receiver once the latter has been detected within the range of the former and a communication link, such as radio or infrared, is set up therebetween. The cart-mounted receiver may contain a small loudspeaker for relaying the message to the supermarket customer. In other applications, such as in the museum referred to hereinabove, the receiver may be a portable unit to be carried by the visitor and she or he may be provided with earphones to avoid disturbing people nearby.
Hence the invention is directed mainly to relaying different messages to people according to their whereabouts at each moment. In cases such as in a supermarket, the invention affords an attractive improvement over the system sometimes used heretofore consisting in sequentially broadcasting a same message to everyone. Such a system is of limited use, cannot be focussed precisely on people in front of particular merchandise and its penetration is relatively superficial, particularly since it is generally repetitive.
SUMMARY OF THE INVENTION
An object of the present invention is to provide a system of one or more generally fixed transmitter units and one or more generally roaming reciever units capable of establishing the presence of one nearby the other and thereafter transmitting a message prerecorded in the transmitter message to the receiver unit.
Another object of the present invention is to provide method and means for each transmitter to detect a receiver in the range thereof and hook both up to transmit a message signal from the transmitter to the receiver.
These and other objects and advantages of the present invention are achieved by means of a system comprising one or more generally fixed transmitter units for wirelessly transmitting recorded information messages, such as voice messages, in a first area proximal to each transmitter unit and one or more mobile receiver units for roaming around a second area including the first area for receiving the transmitted messages when in the first area. According to the invention, the system comprises means in each of the transmitter and receiver units for selectively establishing a link for the receiving unit to receive the information messages from the transmitter unit when inside the first area, by means of a method comprising the steps of: sending a "listening" control signal from the receiving means for pickup by the transmitting means whenever the receiving means substantially enters the first area; picking the "listening" signal up at the transmitting means and responding thereto by transmitting the information message from the transmitting means into the first area; enabling the receiving means to receive the message from the transmitting means; detecting reception of the information message at the receiving means and, in response thereto, continue sending the "listening" control signal to the transmitting means; continue transmitting the information message into the first area while the "listening" signal is picked up at the transmitting means; and terminating the link between the transmitting and receiving means when the transmitting means stops receiving the "listening" control signal.
In a preferred embodiment, the method further comprises: issuing a "sending" control signal from the transmitting means into the first area in response to picking the "listening" signal up at the transmitting means, detecting the "sending" control signal at the receiving means and responding thereto by enabling reception of the information message thereat, and stopping issue of the "sending" control signal upon termination of the transmitted message. More preferably, each transmitting means is adjusted to transmit at a respective preselected transmission carrier frequency and the "sending" control signal encodes the carrier frequency of the message to be transmitted which is decoded by a "listening" receiving means to tune its receiver stage to the right carrier frequency.
In preferred embodiments disclosed hereinafter, the recorded messages are transmitted wirelessly via radio signals and the control signals are transmitted either by radiofrequency or infrared signals.
Each transmitter unit for the system of the invention comprises: storage means for storing signals defining the contents of at least one information message pertaining thereto, receiving means for receiving a "listening" control signal from one such receiver unit entering into the first area, detecting means for detecting the presence of the "listening" control signal at the receiving means and generating in response thereto a "transmit enable" signal, and transmitting means responsive to the "transmit enable" signal to retrieve an information message from the storage means and transmit the retrieved message into the first area. Preferably, the storage means contain a plurality of the information messages recorded therein and each transmitter unit further includes selector means for sequentially selecting one of the recorded messages in response to the detecting means detecting a new "listening" control signal in the receiving means in the transmitter unit. Furthermore, each mobile receiver unit of the invention comprises: transmitting means for sending out a "listening" control signal for detection by the receiving means of one such transmitter unit, receiving means for receiving the information message, and output means for relaying the received message in useful form.
In the preferred embodiments, each transmitter unit further includes: control transmitting means for transmitting a "sending" control signal in response to receiving the "listening" control signal from one such receiver unit, means for setting a carrier frequency for the first transmitting means thereof to transmit the information message, and means for encoding the carrier frequency in the "sending" signal; and each receiver unit further includes: second receiving means for detecting the "sending" control signal from the transmitter unit and generating an "audio enable" signal in response thereto, detector means for sampling the output from the first receiving means and deactivating the "audio enable" signal in response to termination or interruption of the received message, the detector means further responding to the presence of the message at the output of the first receiving means to enable the transmitting means of the receiver unit to continue sending out the "listening" control signal to the receiving means of the transmitter unit, and decoding means for decoding the carrier frequency in the "sending" signal for tuning the first receiving means thereof to the decoded carrier frequency.
In the preferred embodiment, each carrier-frequency setting means comprises a tone generator connected to the control transmitting means to cause the latter to transmit the "sending" signal of a control frequency encoding the carrier frequency, and the decoding means in the receiver unit comprises a frequency decoder circuit to recover the carrier frequency. For instance, the carrier frequency may be set to one of two preset carrier frequencies and the frequency decoder circuit comprises two frequency discriminator devices each tuned to a different preset frequency of the tone generator.
The receiver units may further include timer means connected to inhibit the transmitting means from sending the "listening" control signal during a preselected time after the detector means determines that reception of the transmitted message has terminated.
According to the specific application of the invention, the receiver units may be mounted on supermarket push-carts and each include loudspeakers for propagating the transmitted messages in audible form to cart users, or otherwise be user-portable and be connected to earphones to enable a user to hear the transmitted message in audible form without disturbing other parties.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a block diagram of a transmitter unit according to a first embodiment of the present invention.
FIG. 2 is a block diagram of a receiver unit according to the first embodiment of the present invention.
FIG. 3 is a block diagram of a transmitter unit according to a second embodiment of the present invention.
FIG. 4 is a block diagram of a receiver unit according to the second embodiment of the present invention.
FIG. 5 is a schematic of an electronic circuit for a transmitter unit according to the first embodiment of the present invention.
FIG. 6 is a schematic of an electronic circuit for a receiver unit according to the first embodiment of the present invention.
FIG. 7 is a schematic of an alternative electronic circuit for a transmitter unit according to the first embodiment of the present invention.
FIG. 8 is a schematic of an alternative electronic circuit for a receiver unit according to the first embodiment of the present invention.
FIG. 9 is a flow chart of the operation of the transmitter unit of FIG. 5 according to the method of the invention.
FIG. 10 is a flow chart of the operation of the receiver unit of FIG. 6 according to the method of the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Refering first to FIG. 1, the transmitter unit illustrated in block diagram form therein comprises a memory 1 wherein at least one information voice message is recorded, to be transmitted when the memory 1 is enabled by means 2 such as a memory selector. The selector 2 responds to a "transmit enable" signal by enabling the memory 1 and addressing the first message to be transmitted. Thereafter, the selector addresses the next message recorded in the memory 1 each time a new "transmit enable" signal is received at the selector 2. The selected message proceeds in signal form to a transmitter stage 3 for sending out in a manner to be received by a mobile receiver unit inside an area proximal thereto.
Such a mobile receiver unit transmits a "listening" control signal generally continually, which is picked up by a receiver stage 4 in the transmitter unit to set a flip-flop 5 which enables a tone generator 6. In response, the tone generator 6 issues the "transmit enable" signal to prompt the selector 2 to begin sending the message and, at the same time, drives a control transmitter stage 7 to send a wireless "sending" control signal to the receiver unit to enable the latter to receive the information message. The voice message may be preceded by a tone burst from the generator 6 to call a user's attention at the receiver end.
The message signal at the input 9 of the transmitter is further sampled by an audio signal detector 8, which resets the flip-flop 5 when the message ends to terminate communications between the transmitter and receiver units.
FIG. 2 illustrates a receiver unit operatively couplable to the transmitter unit of FIG. 1 upon entry into a range area thereof. The wireless voice message signals are received at a receiver stage 10 followed by an audio amplifier 11. The amplifier 11 receives the voice message signals and relays them on to a loudspeaker or a pair of earphones which conveys the message in useful audible form to a user. In an application of the transmitter-receiver system of the invention in a supermarket, the loudspeakers may be mounted on supermarket push-carts so as to be directly available to each customer.
A control receiver stage 12 detects the "sending" control signal from the transmitter unit and passes it on to a decoder circuit 13. In response to receipt of the "sending" signal, the decoder 13 triggers a multivibrator circuit or flip-flop 14. The input 16 to the amplifier 11 is sampled by a detector circuit 15 to keep the flip-flop 14 set until the message ends or reception thereof is interrupted, such as may happen if the user moves out of range of the area of the transmitter unit.
The receiver unit further comprises a tone generator 17 driving a transmitter stage 18 for sending the above-referred "listening" signals to the receiver stage 4 of the transmitter unit. The tone generator 17 is temporarily disabled for a predetermined time-interval, which may be a few seconds or a few minutes long per choice of design, by a timer 19 each time the detector 15 indicates termination of the voice message, in order to provide a silent interval between one message and another, for instance if the transmitter unit transmits multiple messages or the receiver unit crosses directly from the area of one transmitter unit into another.
FIGS. 3 and 4 show a second embodiment of the invention based on the same principles as the above-described first embodiment. The same reference numerals are used for like parts which are not further described in relation to this second embodiment. The transmitter unit of FIG. 3 comprises a plurality of selectable memories 1A, 1B and 1C.
The selector 2 may be designed or programmed to cycle through all the memories before recycling back to the first memory 1A, sending out each message therein in turn to a receiver unit within range, or alternatively may include means to preselect just one memory 1A, 1B or 1C to cycle through. The former alternative may be preferable in a supermarket application, to accomodate various messages in each transmitter unit, while the latter alternative is suitable for a museum which may be visited by people of different languages, each memory 1A, 1B and 1C recording messages in a different language.
Power output of the messages transmitter stages 3 may be specified at 1 watt or less. In the embodiments of FIGS. 1 and 3, the tone generator 6 issues single-frequency control signals of one of two presettable frequencies to cause the transmitter stage 3 to generate a carrier of a selected one of two predetermined carrier frequencies. This enables transmitter units to be located near one another without interference. When a roaming receiver unit hooks on to a transmitter unit by means of its "listening" signal, the transmitter unit responds by issuing the "sending" tone signal through stage 7, wherein the tone frequency encodes the carrier frequency. To this end, the control receiver stage 12 in FIG. 4 is connected to a pair of decoders 13A and 13B, each designed to discriminate a different one of the control frequencies. Thus, the decoder 13A, 13B tuned to the selected frequency outputs a true signal to a tuner circuit 20 which tunes the message receiver stage 10 to the selected carrier frequency. A transmitter unit close by within interference range will be programmed to the other carrier frequency, deaf to the receiver stage 10 listening to the other unit.
The operation of the rest of the receiver unit circuit in FIG. 4 is like the circuit of FIG. 2, the set input of the flip-flop 14 being ORed to the outputs of both decoders 13A and 13B.
Two alternative circuits implementing the first embodiment are described hereafter, begining with FIG. 5 which illustrates a transmitter unit using integrated-circuit technology for modulating a radiofrequency carrier with a voice message recorded in a memory module M1. Memory module M1 is preferably an ISD 1000 A integrated circuit comprising digitally-addressed analog cells for recording a 20-second long audio or voice message; although other non-volatile record means may be used such as magnetic tape cassettes or compact optical disks. The overall contro functions, including the selector and flip-flop functions of FIG. 1, are carried out by a suitable microcontroller unit U1, such as a PIC 16 C 84 12-bit microcontroller, programmed with the routine charted in FIG. 9 described hereinafter.
An infrared optical receiver U3, such as an IS1U60 device, receives a "listening" control signal from a receiver unit to be described hereinafter, upon entry into the range of the transmitter unit. The infrared receiver U3 relays the control signal to the microprocessor U1 which responds by generating a single-tone control signal which actually encodes a "sending" data. The "sending" signal issues from pin 9 of the microcontroller U1 through a 2.2 kohm resistor to a transistor Q6. This transistor Q6 is a power transistor, such as a 2N 2222 device, which powers infrared transmitters LD1 and Ld2 to convey the "sending" control signal to the nearby receiver unit. Two series-connected LBT 53FT B3 devices are used as infrared transmitters for range and reliability.
At the same time, the microcontroller U1 issues a "transmit enable" signal via a base resistor R11 and a transistor switch Q5, preferably a 2N 2907 transistor, to activate memory M1 to play back a first message recorded therein. The message memory output is coupled by a 0.1 μF capacitor C21 to modulate a radiofrequency carrier generated within a transmitter stage module M2. The module M2 is preferably a Radio Shack TRC512 device, complete with RF oscillator, FM modulator and RF power output functions to supply a voice-message-modulated radiosignal to an antenna connected thereto for transmission into the area proximal thereto.
The memory module M1 is programmed to cycle through different messages or to recycle back to the first message as long as the receiver unit is within range. When the receiver unit moves out of range or when the receiver unit detects an end of message, that is no audio signal to amplify, then sensor U3 stops receiving the infrared "listening" control signal and microcontroller U1 responds by switching transistors Q5 and Q6 off.
FIG. 6 illustrates a battery-operated receiver unit for mounting to a supermarket push-cart. A wheel of the push-cart (not illustrated) is coupled to a movement sensor module M3 which powers the electronic circuit down when the push cart is not in use, in order to save battery life. The control functions of this unit are carried out by a PIC 16 C 84 microcontroller U1, programmed with the routine charted in FIG. 10 described hereinafter.
An infrared receiver unit U3 receives a "sending" control signal from a transmitter unit when in the range thereof. At this stage, this control signal is interpreted as "ready to send" and it contains data in order for the microcontroller U1 to determine if it wants to receive the message. In the affirmative, it issues a "listening" control signal via resistor R15 and transistor Q6 to be relayed wirelessly via emitters LD1 and LD2. All these components are similar to like components of the transmitter unit of FIG. 5.
In order to enable reception of the message signal carrier, pin 12 of the microcontroller U1 generates a signal through transistor Q5 to power the rest of the circuit up, including the receiver stage centred on an FM decoder circuit U2, preferably an MC 3361 device. The "sending" control signal has one of two preselected carrier frequencies encoded therein, causing the microcontroller to issue a true signal from a corresponding one of pins 10 or 11 thereof, to enable either oscillator circuit O1 or, alternatively, oscillator circuit O2, to tune the FM receiver stage U2. A capacitor C20 may be adjusted to the required frequency. For instance, the preselectable carrier frequencies may be 49.405 MHz and 49.435 MHz, respectively.
The audio or message signal is recovered by means of a ceramic filter CF1 and a quad coil and outputted by pin 9 of decoder U2 to an audioamplifier U4, for instance an LM 386 integrated circuit, for conveyance to a loudspeaker mounted on the pushcart.
An alternative implementation of the embodiment of FIGS. 1 and 2 is set forth in FIGS. 7 and 8. Basically, this embodiment differs from FIGS. 5 and 6 in that the message signal is an infrared optical signal. Otherwise, the method of operation is similar. An MC 4046 frequency modulator U2 receives a "transmit enable" signal from pin 10 of the PIC 16 C 84 microcontroller U1 and sends a modulated carrier signal to the base of a 2N 2222 transistor Q1. Transistor Q1 drives five serially connected infrared LBT 53FT B3 light-emitter devices to convey the message carried signal to the receiver unit of FIG. 8 when in range thereof.
According to FIG. 8, a quadruple amplifier U4 conditions and amplifies the infrared message contained signal received by a MRF 901 infrared sensor S1. The signal is passed through filter L1-C7 and acts on an MC 4046 phase-locked loop (PLL) circuit U2 which decodes the audio signal therefrom. The message signal proceeds from pin 10 of PLL circuit U2 to the amplifier U4 and thereonto the loudspeaker.
The method of operation referred to herein is summarized by the flow charts illustrated in FIGS. 9 and 10, which refer particularly to the example of FIGS. 5 and 6 of the first embodiment, although basically similar to the example of FIGS. 7 and 8. Step 100 reloops until a "listening" signal is received at control receiver stage 4, U3, whereafter step 110 decodes the signal and step 120 checks whether it comes from a new receiver entering the transmitter area. This avoids repeting the message to a chart left in the area.
Step 130 instructs the microcontroller 5-6, U1 send the transmitter module M2 the "transmit enable" signal in order to start transmitting the message after step 140 has waited for receipt of a "start sending" signal and step 150 has selected the carrier channel and enabled the audio module M1. Transmission proceeds nested in loop 160 thereafter from module M2 until module M1 outputs an "end of message" byte. Thereafter, transmission is disabled, modules M1 and M2 are inhibitted and the unit returns in step 170 to the idling loop 100 until a new receiver unit enters the area.
The receiver microcontroller is programmed to send "listening" control signals in step 200 and wait for a return "sending" signal in step 210, whereafter the RF in and audio stages 10-11, U2-U4 are enabled. Step 220 waits for a reset signal audio detector 15 to cause step 230 to disable said stages and return to step 200 to resume sending "listening" infrared signals until silencer 15 times out.
The restrictive description and drawings of the specific embodiment examples are to enable one skilled in the art to make and use the invention. The purview of the invention and the scope of patent protection are measured and defined by the ensuing claims. | A system having several transmitters at fixed locations, such as in a supermarket, and a mobile receiver installed in each push-cart. Whenever a push-cart comes within the range of a transmitter, an exclusive link is set up therebetween for relaying to the receiver an audio message prerecorded in the transmitter for the push-cart user to hear. The receivers beam each "listening" control signals within a predetermined range, in response to which a transmitter within the range of one such receiver relays back a "sending" control signal and sends its prerecorded message which the receiver tunes into. The control signals are single-frequency signals modulating infrared carriers. The message signals are recorded preferably in analog solid-state memories and frequency-modulating radio or infrared carriers in different embodiments. Other uses include public galleries and museums, where one such receiver may be carried by the user instead of installing in a cart. | 6 |
This application is a continuation-in-part of my patent application, Ser. No. 08/410,392, filed Mar. 27, 1995, now U.S. Pat. No. 5,711,768 which is a continuation-in-part of Ser. No. 08/242,532, filed May 13, 1994, now U.S. Pat. No. 5,431,702, which is a continuation-in-part of Ser. No. 037,086, filed Mar. 25. 1993, abandoned.
This invention relates to a process for the production of mechanically stable briquettes or pellets useful as fuel from municipal sanitary sewage sludge solids and to the compositions so produced. An important aspect of this invention is that it provides a method for the production of a solid fuel product which may contain as much as 70 to 95 weight percent sewage sludge solids.
In one of its more specific aspects, this invention relates to a novel briquetted or pelleted fuel product containing a major amount of sewage sludge solids. In another specific aspect, this invention relates to a process for forming briquettes or solid pellets composed essentially of sewage sludge solids and lime, and to the resultant products. In another of its specific aspects, this invention relates to a process for production of solid fuel briquettes or pellets consisting essentially of sewage sludge solids, and a coke forming binder, and to resulting products. This invention includes fuel pellets or briquettes having novel compositions and physical properties.
Depending upon the desired properties of the fuel pellets or briquettes, products of the process of this invention may contain from about 50 to about 95 dry weight percent sewage sludge solids, and typically contain 70 weight percent or more sewage sludge solids on a dry weight basis. The product pellets or briquettes may comprise lime, organic binder, coking agent, or a combination thereof. Typical compositions are shown in the examples.
The process of this invention is designed to help solve the problem of disposition of sewage sludge. This is accomplished by converting dried or partially dried sewage sludge into usable fuel products. Wet sewage sludge from a municipal sanitary sewage treatment process, after removal of water by filtration, is in the form of a somewhat gelatinous mass typically containing 93 to 97 weight percent water and 3 to 7 weight percent sewage sludge solids. The sewage sludge solids may be concentrated by further dewatering methods, suitably by centrifuging the wet sewage sludge to yield a dewatered sewage sludge containing from about 50 to about 75 weight percent water. Typically, dewatered sewage sludge has little or no fuel value as such.
In accordance with this invention, wet sewage sludge is dewatered to the extent economically feasible by mechanical means, for example, by centrifuging and/or filtering the wet sewage sludge, after which the dewatered sewage sludge is further dried if necessary. A moisture content in the range of 5 to 25 weight percent is generally desirable. The reduction in water content of the sewage sludge solids may be accomplished by atmospheric drying in large area sand filter beds or by heat. Heat produced in the process, for example, waste heat from a gasifier or combustion gas turbine in a cogeneration cycle may be used effectively in further drying of the dewatered sewage sludge.
BACKGROUND OF THE INVENTION
The problems of disposal of municipal sewage sludge continue to grow in spite of a number of methods employed for or proposed for its disposal. In the United States, ocean dumping has been banned under Federal law. Alternative methods of disposal include dewatering the sewage sludge by the use of filters or centrifuges and burying the dewatered sewage sludge in land fill areas. Metropolitan areas are rapidly running out of available land fill sites. Many places in the United States prohibit inclusion of sewage sludge in land fills.
Incineration of sewage sludge solids has been proposed, but is not an attractive method of disposal due to the water content of moist centrifuged sludges or filter cake solids, which typically contain 65 to 75 weight percent water after concentration by conventional filtering or centrifuging methods.
The use of undewatered sewage sludge as fuel has been proposed heretofore in U.S. Pat. No. 4,405,332 to Rodriguez et al. As disclosed therein, raw sewage sludge is mixed with pulverized solid fuel, e.g., coal, to form a pumpable mixture. only very small percentages of sewage sludge solids may be disposed of by this method. This patent discloses a pumpable liquid fuel composition comprising 60 to 75 percent by weight solid fuel, e.g. coal, and from 25 to 40 weight percent undewatered sewage sludge consisting of 85 to 99.5 weight percent water (0.5 to 15 weight percent sewage sludge solids).
U.S. Pat. Nos. 4,552,266 and 4,615,711 to Muller discloses fuel briquettes containing from 0.3 to 0.6 parts sewage sludge solids per part autumn foliage (23 to 37.5 weight percent sewage sludge solids), and from 0.6 to 1.0 part sewage sludge solids per part solid residue resulting from solvent extraction of autumn foliage (37.5 to 50 weight percent sewage sludge solids) in each case mixed with cellulosic wastes.
U.S. Pat. No. 3,910,775 to Jackman discloses a process for treatment of garbage or refuse, coal fines, and raw sewage to form fuel briquettes containing undisclosed amounts of the garbage and sewage sludge components, which presumably are in the ratio normally occurring in municipal wastes.
My U.S. Pat. Nos. 4,152,119, 4,225,457, and 5,431,702 disclose processes for producing briquettes suitable as fuel in a moving bed gasifier from municipal solid wastes and crushed coal.
Among the various processes for disposal of sewage sludge are those which involve gasification of the sewage sludge solids by partial oxidation with air or oxygen to produce useful industrial and fuel gases. In my U.S. Pat. No. 5,431,702, dewatered sewage sludge containing 25 to 50 weight percent solids (50 to 75 weight percent water) is mixed with 1.5 to 5 parts by weight relatively dry waste paper or refuse derived fuel per part sewage sludge solids. This mixture, which may contain from about 4 to about 25 weight percent sewage sludge solids, is molded under pressure into briquettes or extruded to form pellets containing from about 5 to about 25 weight percent sewage sludge solids. In a preferred embodiment, these briquettes or pellets also contain 1 to 3 parts by weight crushed coal basis the weight of the sewage sludge solids, i.e. and the resulting mixture, which contains up to 12.5 weight percent sewage sludge solids, pressed into briquettes suitable for use as fuel in a moving bed type gasifier, e.g. a Lurgi gasifier or a slagging gasifier.
In the earlier processes for the production of briquettes containing sewage sludge solids, cellulosic solids, including paper waste and municipal solids waste, are employed to provide sufficient structural strength to the briquettes to withstand normal handling. Caking coal also has been employed to provide high temperature structural strength when the briquettes are used as fuel in a large moving bed gasifier, e.g., a Lurgi type gasifier.
BRIEF DESCRIPTION OF THE INVENTION
By the process of this invention, high structural strength briquettes with a high sewage sludge solids content may be made from dry or partially dried sewage sludge. The fuel briquettes of this invention may contain 50 weight percent or more sewage sludge solids and may be formulated to possess the strength necessary to support the burden in a moving bed gasifier without undue crushing of the briquettes.
In accordance with a preferred embodiment of my invention, the preparation of fuel briquettes containing 50 weight percent or more sewage sludge solids, two distinct types of binders are employed. A water soluble or hydrophilic organic binder, for example molasses, is mixed with the sewage sludge solids in an amount necessary to impart sufficient green strength to the pressed or extruded pellets to permit them to withstand normal handling without undue breakage. In general, the amount of water soluble or hydrophilic organic binder required depends on its solids content. Binder solids contents in the product in the range of 5 to 8 weight percent on the basis of the weight of sewage sludge solids in the product are preferred. A carbonaceous coking agent, e.g. solid bitumen or pitch, or solid asphaltic petroleum residuum, in particle form, is added to the sewage sludge solids/organic binder mixture to form a high temperature binder and provide high crush strength to the briquettes when heated to coking temperature in a gasifier. The mixture may also contain from about 25 to about 50 weight percent coal basis the weight of the sewage sludge solids. In accordance with a preferred embodiment, a mixture of dry or partially dried sewage sludge solids, lime, organic binder, crushed coal, and bitumen or pitch is formed into briquettes or pellets by mechanical compression from a briquette press or extrusion device as known in the art. Prior to formation into briquettes or pellets, the moisture content of the mixture should be in the range of from about 12 to about 22 weight percent. Compression at a pressure in the range of from about 1,000 to about 10,000 pounds per square inch, preferably at a pressure in the range of from about 3,000 to about 5,000 psi produces stable briquettes or pellets. The resulting briquettes or pellets are suitable for use as fuel in a moving bed gasifier.
As disclosed and claimed in my copending application, Ser. No. 07/410,392, sewage sludge solids which have been dried to a moisture content in the range of from about 0 to about 25 weight percent moisture (75 to 100 weight percent sewage sludge solids) are mixed with lime and optionally a hydrophilic or water soluble organic binder to form a composition having a moisture content in the range of from about 12 to about 22 weight percent and the composition compressed into briquettes or pellets at a pressure in the range of from about 1,000 to about 10,000 pounds per square inch, preferably at a pressure in the range of from about 3,000 to about 5,000 pounds per square inch. The resulting briquettes are suitable for use as fuel in conventional furnaces designed to burn particulate fuels. The briquettes or pellets may be further dried in ambient air or in heated air or flue gas if desired.
Briquettes or pellets consisting primarily of sewage sludge solids may be comminuted, mixed with a coking agent, e.g., pitch or bitumen, or petroleum residuum, or a mixture of non-caking coal and coking agent, and pressed into briquettes or pellets, suitably at a pressure in the range of from about 1,000 to about 10,000 psi, preferably 3,000 to 5,000 psi. The coking agent imparts sufficient high temperature crush strength to the briquettes or pellets to permit their use as fuel in a moving bed gasifier. Briquettes containing caking coal generally do not require any additional coking agent as binder.
Pellets produced without a coking agent i.e. from sewage sludge solids, lime, and water soluble or hydrophilic organic binder only are preferred when the sewage sludge solids are to be shipped some distance from the municipal sewage sludge source to the consumption site. For example, sewage sludge solids from the Eastern seaboard may be pelleted and shipped to the Appalachian area or to the Western states for conversion to coal-containing briquettes or pellets. The coal-containing briquettes or pellets may be gasified to produce fuel gas or synthesis gas, heat and power at the conversion site or shipped to other areas for such purposes.
BRIEF DESCRIPTION OF THE DRAWING
The FIGURE is a flow diagram illustrating one preferred procedure for carrying out the process of this invention.
DETAILED DESCRIPTION OF THE INVENTION
With reference to the drawing, sewage sludge from an available source, for example, sludge from a municipal sanitary sewage treatment plant, is supplied from line 5 to a dewatering operation 6. Sewage sludge from such plants which are suitable for use in the process of this invention may be in the form of primary (undigested) sludge, sludge-activated sludge, digested sludge, or a combination of the various sludges typically produced at sewage treatment facilities. In accordance with one embodiment of this invention, sewage sludge supplied through line 5 is dewatered mechanically by means of a centrifuge, vacuum filter, filter press or screw press or combination thereof in a dewatering step 6 yielding dewatered sewage sludge (DSS), usually referred to as a DSS cake, containing from 20 to 40 weight percent sewage sludge solids (60 to 80 weight percent water). Water removed from the sewage sludge dewatering step 6 is discarded through line 7.
The resultant dewatered sewage sludge cake is passed through line 8 to dryer 10 wherein it is dried to a solids content of 65 weight percent or higher. The dryer suitably is in the form of a rotary kiln or steam-heated dryer of a type known in the art. As illustrated in the FIGURE, air or flue gas is supplied to the dryer through line 11 and moisture-laden air or flue gas discharged from the dryer through line 12.
The partially dried sewage sludge solids (SSS) leave the dryer through line 13 from which they are supplied to mixer 15 where they are thoroughly blended with a hydrophilic or water soluble organic binder material from line 14. If desired, coal may be supplied to mixer 15 through line 9 and coking agent may be supplied from line 19. Lime or other fluxing agent is supplied through line 16. The resultant mixture containing from about 12 to about 22 weight percent water is passed through line 17 to a briquetting facility 18 where briquettes or pellets are formed by an extrusion device or a briquette press at a pressing pressure typically in the range of 1,000 to 10,000 pounds per square inch (psi), preferably in the range of 3,000 to 5,000 psi. The pellets or briquettes leave the briquetting facility through line 20. To assure uniformity of product size, the pellets or briquettes may be screened and/or dried in a screening and drying operation designated generally by the numeral 21. The product briquettes exit the process through line 22. Broken pieces and fines generated in the process are returned to the mixing step 15 through line 23.
The moisture content of the feed mixture supplied through line 17 to the briquetting step 18 from the mixing step 15 is an important factor affecting not only the operation of the briquetting machines but also the strength of the ensuing briquettes or pellets, hereinafter referred to as the "green strength" of these products. A moisture content of the feed mixture in the range of 12 to 22 weight percent produces pellets and briquettes having sufficient green strength to withstand normal handling with only nominal breakage. The optimum moisture content of the feed mixture depends to some extent upon the characteristics of the particular feed materials employed, the relative proportion of each material in the feed mixture, and upon the compaction method.
For typical sewage sludge solid mixtures formed into briquettes using a rotary press, the moisture content of the briquette forming composition supplied to the briquetting press is preferably in the range of from about 14 to about 19 weight percent. Pellet extrusion requires a higher moisture content (up to 22 percent) in the feed mixture in order to prevent charring of the sewage sludge solids during extrusion. Preferably, briquettes are formed by pressing the feed composition in a rotary briquetting press of the type available from Bepex Corporation, Minneapolis, Minn. wherein the briquettes are formed under a pressure above about 1000 psi, suitably in the range of 3000 to 5000 psi. Briquettes leaving the press are steaming hot from the energy expended in their formation under pressure. The freshly pressed briquettes may be further dried before use as fuel, primarily to permit the green briquettes to develop increased mechanical strength. Briquettes having a moisture content in the range of from about 10 to about 12 weight percent have excellent green strength.
Product briquettes or pellets obtained by the process of this invention without the addition of coal or coking agent component may comprise at least 80 weight percent sewage sludge solids (dry basis).
Pellets or briquettes produced for use as fuel in a fixed bed or a moving bed gasifier, e.g. a Lurgi type gasifier or a slagging bed gasifier, require not only adequate green strength, but also high temperature crush strength. High crush strength is provided by adding a high temperature coking agent to the sewage sludge mixture in mixer 15 through line 19. Either caking coal or non-caking coal with an added coking agent may be included as a component of the mixture. Coking agents suitable for use include normally solid pitch or bitumen. Non-caking coal may be included in the product briquettes or pellets to improve the heating value of the product. In that case, the non-caking coal is added to the mixture with one or more coking agents or supplied through line 19. In general, the amount of coal, including coking agent when added, is supplied to the mixture in an amount in the range of from about 25 to about 100 weight percent, basis the dry weight of the sewage sludge solids, i.e., in a ratio of 1:4 to 1:1.
Water soluble or hydrophilic organic binders may be selected from the group black liquor from the paper industry, black strap molasses, starch, brewery waste, residual syrup from the refining of sugar beets, polysaccharides, lignin sulfonates, and the like. The concentration of organic binder additive required may be determined by trial for any given binder and source of sewage sludge. The amount of organic binder solids in the product may range from 0 to 8 weight percent and is preferably at the minimum concentration that will endow the briquette or pellet with adequate physical strength to avoid crushing during normal handling procedures. All of the above-mentioned organic binders are suitable for the production of briquettes or pellets by my process with sufficient green strength to permit handling, transporting and utilization of the pellets as fuel in conventional furnaces. When the briquettes or pellets are to be used as fuel in a fixed or moving bed gasifier where high temperatures occur in the burden passing through the pyrolysis and coking zones of the gasifier, caking coal or coking agents are included in their compositions. Coking agents include normally solid pitch or bitumen, suitably from petroleum refinery residues, which form coke in the pyrolysis and coking sections of a gasifier. Such pellets or briquettes gravitate without substantial loss of structural strength or excessive deformation through the moving bed to the hearth section of the gasifier where they are gasified with air or oxygen and steam in known manner as described more particularly in my U.S. Pat. No. 4,225,173.
In order to endow the "green" briquettes or pellets, i.e., pellets or briquettes from the briquette press, extruder, or compactor, with anti-fungal stability during transport and storage, from about 3 to about 12 weight percent lime is included in the formulation. The lime acts as a bonding agent and serves as a fluxing agent when the pellets are consumed in a slagging gasifier.
The agglomerates, in the form of pellets or briquettes, including extruded cylinders, or pressed forms, may be employed as furnace fuel or as a gasifier feedstock, either as such, or in admixture with a non-caking combustible solid, for example, lump coal of controlled size, petroleum coke, wood char, or "Simplex" briquettes. Simplex briquettes are comprised of paper waste and/or refuse derived fuel as more particularly described in my U.S. Pat. No. 4,152,119. Employing a feed-stock comprised primarily of sewage sludge solids in the form of pellets or briquettes is advantageous from the standpoint of maximizing the tipping fee income that normally attends the disposal of sewage sludge in an environmentally benign manner. An admixture with coal or petroleum coke, on the other hand, will enhance the energy yield in the form of a clean synthesis or fuel gas. The latter is a desirable fuel for advanced gas turbines of an IGCC (integrated gasification, combined cycle) power plant. This mode of operation is preferred for municipalities or principalities that command a relatively modest supply of sewage sludge solids. The co-processing of petroleum coke, or Simplex briquettes leads to economies of scale in the gasification and power generating components of the plant.
The feedstock described above may be processed in a variety of gasifiers, including especially the following: an oxygen-blown, high-pressure slagging gasifier (of the British Gas/Lurgi type), an oxygen-blown, high pressure dry-bottom gasifier (of the Lurgi type), an air-blown low-pressure, dry-bottom gasifier (of the Wellman Galusha type), and a fluid bed gasifier (of the Winkler type). The use of a slagging gasifier, for example, as disclosed in my U.S. Pat. No. 4,340,397, is recommended when processing sewage sludges from industrialized metropolitan centers (such as Newark, N.J.) where the sludge is likely to be contaminated with unacceptable concentrations of toxic heavy metals. In a slagging gasifier of the type recommended, the toxic heavy metals are encapsulated in a glassy frit, which has been shown to be non-leachable by accepted EPA standards. Dry-bottom gasifiers may be operated at a sufficiently high temperature to effect partial sintering of the ash. This mode of operation reduces the leachability of the resultant ash. The inclusion of coal, or a coking agent, e.g. bitumen or pitch, serves to reduce the concentration of heavy metals in the resultant ash or slag. When employed, coking agent, i.e. bitumens, may comprise from about 2 to about 30 weight percent of the composition, dry basis, depending on the total charge to the gasifier. When the charge to the gasifier is limited to the briquettes or pellets produced as described herein, the coking binder content of the briquettes or pellets is limited to an amount which will avoid sticking together of the briquettes or pellets during coking in the gasifier. In general, compositions containing not more than 12 weight percent coking agent, and preferably from about 2 to about 8 weight percent coking agent, are most satisfactory.
The product gas from the gasifier typically is passed through a standard gas clean-up train to remove acid gases and other air pollutants. Hydrogen sulfide may be recovered by one of several commercially available processes and converted to elemental sulfur in a Claus unit. These procedures are state-of-the-art, and need not be further described here, as they are not part of this invention, per se.
EXAMPLES
Compositions of briquettes which may be produced in accordance with this invention may vary somewhat depending upon variables inherent in sewage sludges and in water soluble organic binders, e.g. molasses, and hydrophilic organic binders, e.g. food starch. Representative suitable components and product compositions are illustrated in the following examples (Tables I and II).
Suitable formulations for any given combination of components may be determined by preparing test briquettes using a two part die and a hydraulic press. Green test specimens are dried and subjected to handling, such as by tumbling in a rock tumbler. Test specimens containing a coking agent are evaluated for crush strength by heating them to 1000° F. in a ceramic furnace followed by cooling and pressing the briquettes between flat plates.
In the following Examples 1-3, and 7, 8, 10, and 11, a commercially available anhydrous lignin sulfonate containing 5 percent moisture as received, and marketed under the trade name Norlig, is employed as the water soluble organic binder. In Example 4, the water soluble organic binder is molasses; in Examples 5 and 9, the water soluble organic binder is black liquor from the paper industry; and in Example 6, only lime and water are used as binders.
In Examples 1-6 (Table I), the briquettes are formed without an added coking agent. In Examples 7-10, sewage sludge briquettes suitable for use in a fixed or moving bed gasifier are produced with pyrolized pitch from petroleum refinery residue as coking agent or coking binder. In Example 11, coking coal requires no added coking agent and acts as high temperature binder. In Example 11, non-caking coal is combined with pitch which acts as a coking binder. All briquettes contain high concentrations of sewage sludge solids.
TABLE I______________________________________ ExampleComponent (parts by weight) 1 2 3 4 5 6______________________________________Concentrated Sludge 100 100 100 100 100 100Sewage Sludge Solids 76 80 85 80 85 100Water 24 20 15 20 15 0Lime 4.6 4.8 5.1 4.8 5 8Organic Binder 5.6 6.0 6.3 9.8 12 --Solids 5.3 5.7 6.0 6.4 6 --Water 0.3 0.3 0.3 3.4 6 16Total 110.2 110.8 111.4 114.6 117 124Total Solids 86.2 90.5 96.1 91.2 96 108Total Water 24.3 20.3 15.3 23.4 21 16Wt. % Moisture 22 18.4 13.7 20.4 18 12.9Briquette Composition (wt. % dry basis)Sewage Sludge Solids 88.5 88.4 88.4 87.7 88.5 92.6Lime 5.4 5.3 5.3 5.3 5.2 7.4Binder Solids 6.2 6.3 6.2 7.0 6.3 --______________________________________
TABLE II______________________________________ ExampleComponent (parts by weight) 7 8 9 10 11______________________________________Concentrated Sludge 100 100 100 100 100Sewage Sludge Solids 80 70 75 70 70Water 20 30 25 30 30Lime 6 5 5 8 6Organic Binder 6 5 9 5 8Solids 5.7 4.75 4.5 4.75 7.6Water 0.3 0.25 4.5 0.25 0.4Coking BinderPitch 20 35 35 8 --Coal (dry weight)Non-caking -- -- -- 35 --Caking -- -- -- -- 70Total 132 144.5 149 156 184Solids 111.7 114.8 119.5 125.8 150Water 20.3 30.2 29.5 30 34Wt. % Moisture 15 21 19.8 19.2 18.4Briquette Composition (wt. % dry basis)Sewage Sludge Solids 71.6 61 62.7 55.7 47Lime 5.4 4.4 4.2 6.4 4Organic Binder Solids 5.1 4.1 3.8 3.8 5Coking AgentPitch 17.9 30.5 29.3 6.4 --Coal -- -- -- 27.8 44______________________________________ | Pellets or briquettes useful as fuel are produced from sewage sludge solids. Mechanically stable pellets or briquettes result from combining a major portion of sewage sludge solids with lesser amounts of lime and binder materials suitable for imparting stability to the product and pressing or extruding the combined components into desired shapes. Coal may be included in the pellet or briquette composition for improved fuel value. | 2 |
BACKGROUND OF THE INVENTION
This invention relates to polymers containing amide moieties and a process for their preparation. More specifically, this invention relates to polymers containing amide and imidazole, benzimidazole, benzoxazole, or benzothiazole moieties and a process for their preparation. These polymers may be useful in coatings, adhesives, composites, and as prepolymers in polyurea/urethane systems.
P. Papadopoulos, "Reactions of Imidazoles with Isocyanates at Elevated Temperature", 42 J. Org. Chem. 3926 (1977) describes a process for reacting imidazoles
SUMMARY OF THE INVENTION
This invention is, in one aspect, a polymer comprising a backbone portion containing a plurality of at least one of the following units: ##STR1## wherein each R 1 is a C 1-4 alkyl moiety, y is a whole number from 1 to 4, and m is a whole number from 1 to 3.
In a second aspect, this invention is a process for preparing a polymer comprising a backbone portion containing at least one amide moiety and a plurality of imidazole, benzimidazole, benzoxazole, or benzothiazole moieties, which comprises contacting a polyisocyanate with a compound containing at least two end moieties selected from the following: imidazole, benzimidazole, benzoxazole, or benzothiazole, under reaction conditions sufficient to form the corresponding polymer containing amide moieties.
In a third aspect, this invention is a urethane and/or urea polymer comprising a backbone portion containing at least one urea or urethane moiety, at least one amide moiety, and a plurality of imidazole, benzimidazole, benzoxazole, or benzothiazole moieties.
The process of the invention is suitable for the preparation of thermoset polymers which are advantageously free of surface defects, since a solvent is not required and no volatiles are evolved during the curing process.
DETAILED DESCRIPTION OF THE INVENTION
The polymers of the first aspect of the invention comprise a backbone portion containing at least one of the following units: ##STR2## wherein each R 1 is a C 1-4 alkyl moiety, y is a whole number from 1 to 4, and m is a whole number from 1 to 3. The other ring carbon atoms may be substituted with a C 1-4 alkyl moiety, but are preferably unsubstituted. The recurring unit is most preferably:
These polymers which contain amide moieties and imidazole, benzimidazole, benzoxazole, or benzothiazole moieties, may be prepared by contacting a polyisocyanate with a compound containing at least two end moieties selected from the following: imidazole, benzimidazole, benzoxazole, or benzothiazole under reaction conditions sufficient to form the corresponding polymer containing amide moieties. Preferably, these compounds are of the following formula:
R.sup.1 --R.sup.2).sub.x (I)
wherein R 1 is a substituted or unsubstituted hydrocarbon radical which does not interfere with the reaction, and is preferably C 1-10 alkyl, C 1-10 alkyleneoxy, or trimethylbenzyl: R 2 is separately in each occurrence a moiety of the following formula: ##STR3## wherein each R 1 is a C 1-4 alkyl moiety, y is a whole number from 1 to 4, m is a whole number from 1 to 3, and x is an integer from 2-3. The other ring carbon atoms may be substituted with a C 1-4 alkyl moiety, but are preferably unsubstituted. Preferably, R 1 is a C 2-6 alkyl, a dialkylether, or trimethylbenzyl, and more preferably is butyl, hexyl, diethylether, or trimethylbenzyl, and most preferably is butyl. R 2 is most preferably ##STR4## and x is most preferably 2. Preferably, R 1 is a C 2-6 alkyl, a dialkylether, or trimethylbenzyl, and more preferably is butyl, hexyl, diethylether, or trimethylbenzyl, and most preferably is butyl.
Suitable polyisocyanates include aliphatic or aromatic polyisocyanates or mixtures thereof. For example, any polyisocyanate having 2 or more NCO moieties per molecule may be used. Aromatic polyisooyanates are preferred for their higher reactivity and suitability in RIM applications, relative to aliphatic isocyanates. Examples of such compounds include toluene-2,4-and-2,6-diisocyanate, 2,2'-, 2,4'-, and 4,4'-methylene bis(phenyl isocyanate), polymethylene poly(phenyl isocyanate), and mixtures of these isocyanates. The preferred isocyanates include derivatives of 4,4'-methylene bis(phenyl isocyanate) and polymethylene poly(phenyl isocyanate), or mixtures thereof. When mixtures of 4,4'-methylene bis(phenyl isocyanate) and polymethylene poly(phenyl isocyanate) are used, the glass transition temperature of the polymer can be controlled by varying the ratio of the two isocyanates employed. In general, the higher the amount of polymethylene poly(phenyl isocyanate), the higher the glass transition temperature of the resulting polymer, as shown in the table below.
TABLE I______________________________________Glass Transition Temperatures of PolyamidePolymersMolar Ratio of Polymethylene Polyisocyanate Tg(°C.) to 4,4'-Methylene Bis(Phenyl Isocyanate)______________________________________ 1:0 160 1:1 148 1:2 131 1:6 109______________________________________
The bisimidazoles shown in formula (I) may be prepared by reacting imidazole with a dihalo-functional substituted or unsubstituted hydrocarbon, which is preferably a C 1-10 dihaloalkane. More preferably, the imidazole is reacted with a C 1-5 dihaloalkane, and most preferably with a 1,4-dichlorobutane. The molar ratio of imidazole:dihaloalkane is preferably at least about 2:1 Preferably, the reaction is carried out in the presence of a metal hydroxide such as sodium hydroxide, potassium hydroxide, or calcium hydroxide, and is more preferably carried out in the presence of a 50-85 percent solution of sodium hydroxide. Most preferably, the solution of sodium hydroxide is an 85 percent Preferably, the metal hydroxide is present in a molar ratio in the range of from about 0.1:1.0 to about 1:1, more preferably in the range from about 0.7:1 to about 1:1, and most preferably about 1:1, relative to the amount of imidazole.
When a metal hydroxide is contacted with the imidazole, it will advantageously dissociate one of the acidic protons from the imidazole ring to form water. Such water is preferably removed from the reaction mixture by azeotropic distillation with the addition of a solvent capable of forming an azeotropic mixture with water, which is preferably an aromatic solvent. Suitable solvents include toluene and benzene, and are preferably employed in a molar ratio of about 1:10 to about 10:1, relative to the amount of imidazole.
The reaction is also preferably carried out in the presence of an organic polar solvent, such as, for example, dimethyl sulfoxide (DMSO), dimethylformamide, and dimethyl acetamide. Most preferably, DMSO is used as the polar solvent. Such solvent is preferably employed in a molar ratio of about 1:10 to about 20:1, relative to the amount of imidazole.
Bisdibenzimidazoles may be prepared from unsubstituted benzimidazoles using the same procedure described above, optionally in the presence of an acetone solvent and an electrophilic diiodoalkane. Bisdibenzoxazoles, bisdibenzothiazoles, and bisdibenzimidazoles may be prepared in a similar reaction using 1-alkyl benzimidazoles in a Friedel-Crafts reaction using acid chlorides and Lewis acids. In such a procedure, benzoxazole, benzothiazole, or 1-alkyl benzimidazole is contacted with a bifunctional acid chloride such as, for example, terephthaloyl chloride in the presence of a Lewis acid such as, for example, aluminum chloride or iron chloride, under conditions sufficient to form the corresponding bisdibenzoxazole, bisdibenzothiazole, or bisdibenzimidazole. A process for the N-Alkylation of benzimidazoles is described in Kikugawa, G., "A Facile N-Alkylation of Imidazoles and Bisimidazoles, " Synthesis, February 1981, pp. 124-25.
Alternatively, bisdibenzimidazoles may be prepared by the diazotization of 5- or 6-aminobenzimidazole azole which is synthesized by the reduction of 5- or 6-nitrobenzimidazole as described in Nazarov, V. N. and V. I. Krashnoshtan, "Synthesis of 5,5' (or 6,6')-Bibenzimidazole from Non-Carcinogenic Compounds", 52 Tr.Mosk. Khim.-Tekhnol.Inst. 110-11 (1967), the relevant portions of which are incorporated by reference. Bisdibenzoxazoles and bisdibenzothiazoles may also be prepared in a similar procedure from the corresponding nitrobenzoxazole and nitrobenzothiazole compounds.
In the process for preparing the polymers of the first aspect of the invention, the isocyanate and bisimidazole, bisdibenzimidazole, bisdibenzoxazole, or bisdibenzothiazole are preferably present in amounts such that the ratio of isocyanate functionalities to imidazole, benzimidazole, benzoxazole, or benzothiazole moieties in the reaction mixture is in the range from about 1.25:1 to about 1:1, more preferably from about 1.1:1 to about 1:1, and most preferably about 1:1.
The reaction may be conducted at any temperature which will allow the reaction to proceed, but is preferably above about 25° C., more preferably above about 160° C., and most preferably above about 180° C., and is preferably below about 240° C., and more preferably below about 230° C. Lower temperatures may be used, but may require the use of an inert solvent, such as, for example, N-methyl-2-pyrrolidone. The reaction may be conducted at any pressure which will allow the reaction to proceed, but is preferably in the range of from about 30 psi to about 10,000 psi, and more preferably in the range of from about 200 to about 4,000 psi. The duration of the process is preferably at least about 15 minutes, and more preferably at least about 30 minutes, and is preferably no longer than about 6 hours, more preferably no longer than about 5 hours, and most preferably no longer than about 4 hours.
Preferably the glass transition temperature of the product of the reaction is at least about 25° C., more preferably at least about 50° C., and most preferably at least about 100° C. The molecular weight of the polymer of this first aspect of the invention is preferably at least about 5,000, more preferably at least about 10,000, and most preferably at least about 20,000. The polymers of the first aspect of the invention are advantageously highly resistant to solvents. A polymer prepared from 1,6-hexamethylene-N,N'-diimidazole and a 2 to 1 mixture of diphenylmethane-4,4'-diisocyanate (MDI) and PAPI 580™ polymethylene poly(phenylisocyanate) is insoluble in methanol, tetrahydrofuran, and ethyl acetate, and swells in carbon tetrachloride.
The polymers of the first aspect of the invention may also be prepared as an isocyanate-functional prepolymer. These prepolymers are the reaction product of a compound containing at least two end moieties selected from the following: imidazole, benzimidazole, benzoxazole, and benzothiazole with an excess over stoichiometry of a polyisocyanate. These prepolymers are prepared in the same manner as the polymers of the invention, except that an excess over stoichiometry of the polyisocyanate is employed to make an isocyanate-functional prepolymer. In the process for preparing these prepolymers, the isocyanate and bisimidazole, bisdibenzimidazole, bisdibenzoxazole, or bisdibenzothiazole are preferably present in amounts such that the ratio of isocyanate functionalities to imidazole, benzimidazole, benzoxazole, or benzothiazole moieties in the reaction mixture is in the range from about 1.3:1 to about 2:1, more preferably in the range of from about 1.3:1 to about 1.5:1, and is most preferably about 1.3:1. These prepolymers preferably have isocyanate functionalities in the range of from about 2 to about 4, more preferably in the range of from about 2 to about 3, and most preferably in the range of from about 2 to about 2.2.
In a third aspect, this invention is a urethane and/or urea polymer containing at least one urea or urethane moiety, amide moieties, and imidazole, benzimidazole, benzoxazole, or benzothiazole moieties. This polymer may be prepared by the reaction of an isocyanate-functional prepolymer containing amide moieties and imidazole, benzimidazole, benzoxazole, or benzothiazole moieties with a polyahl or mixtures of polyahls. A polyahl is a compound having a plurality of active hydrogen moieties that are reactive with the Zerewitinoff reagent such as, for example, hydroxy moieties or amine moieties. Many such polyahls of a lower moleoular weight are commonly called chain-extenders when used with isocyanate-functional prepolymers and are optionally employed with catalysts and a variety of other additives. High molecular weight polyahls can also be used. Examples of such polyahls are described in U.S. Pat. No. 4,394,491, the relevant portions of which are hereby incorporated by reference.
The molecular weight of the urethane and/or urea polymer of this third aspect of the invention is preferably at least about 5,000, more preferably at least about 10,000, and most preferably at least about 20,000.
The chain-extenders useful to make the urethane and/or urea polymers of this invention are preferably difunctional. Mixtures of difunctional and trifunctional chain-extenders are also useful in this invention. The chain-extenders useful in this invention include diols, amino alcohols, diamines or mixtures thereof. Low molecular weight linear diols such as 1,4-butanediol and ethylene glycol have been found suitable for use in this invention. Other chain-extenders including cyclic diols such as 1,4-cyclohexanediol and 1,4-cyclohexanedimethanol: aromatic ring-containing diols such as bishydroxyethylhydroquinone: amide- or ester-containing diols or amino alcohols are useful. Aromatic diamines and aliphatic diamines are suitable chain-extenders. Examples include ethylenediamines, 1-(2-aminoisopropyl-4-methyl-4-aminocyclohexane), 1,2-propanediamine, 1,4-butanediamine; 1,6-hexanediamine, diethyltoluenediamine and 1,4-bis(aminomethyl)cyclohexane. Additional examples of useful chain-extenders can be found in U.S. Pat. No. 4,297,444: 4,202,957: 4,476,292: 4,495,309 and 4,218,543.
Catalysts such as tertiary amines or an organic tin compound or other polyurethane catalysts may be used. The organic tin compound may suitably be a stannous or stannic compound, such as stannous salt of a carboxylic acid, a trialkyltin oxide, a dialkyltin dihalide, a dialkyltin oxide, etc., wherein the organic moieties of the organic portion of the tin compound contain from 1 to 18 carbon atoms. For example, dibutyltin dilaurate, dibutyltin diacetate, diethyltin diacetate, dihexyltin diacetate, di-2-ethylhexyltin oxide, dioctyltin dioxide, stannous octoate, stannous oleate, etc., or a mixture thereof, may be used. Other catalysts include organo zinc, mercury and lead compounds. For some polymers, a catalyst is not needed.
Tertiary amine catalysts include trialkylamines (e.g., trimethylamine, triethylamine), heterocyclic amines, such as N-alkylmorpholines (e.g., N-methylmorpholine, N-ethylmorpholine, dimethyldiaminodiethyl ether, etc.), 1,4-dimethylpiperazine, triethylenediamine, etc., and aliphatic polyamines, such as N,N,N',N'-tetramethyl-1,3-butanediamine.
Optional additives include anti-foaming agents such as glycerine, an ethyl acrylate-2-ethylhexyl acrylate copolymer, dimethyl siloxane copolymers and silicones; antioxidants such as esters of β-(3,5-di-tert-butyl-4-hydroxyphenyl) propionic acid with monohydric or polyhydric alcohols, for example, methanol, octadecanol, 1,6-hexanediol, neopentyl glycol, thiodiethylene glycol, diethylene glycol, triethylene glycol, pentaerythritol, tris-hydroxyethyl isocyanurate, and dihydroxyethyl oxalic acid diamine; UV absorbers and light stabilizers such as 2-(2'-hydroxyphenyl)benzotriazoles and sterically hindered amines such as bis-(2,2,6,6-tetramethylpiperidyl-sebacate, bis-(1,2,2,6,6-pentamethylpiperidyl)-sebacate, n-butyl-3,5-di-tert-butyl-4-hydroxybenzyl malonic acid, bis-(2,2,6,6-pentamethylpiperidyl)ester, condensation product of 1-hydroxyethyl-2,2,6,6-tetramethyl-4-hydroxypiperidine and succinic acid, condensation product of N,N'-(2,2,6,6-tetramethylpiperidyl)-hexamethylene diamine and 4-tert-octylamino-2,6-dichloro-1,3,5-s-triazine, tris(2,2,6,6-tetramethylpiperidyl)-nitrilotriacetate, tetrakis-(2,2,6,6-tetramethyl-4-piperidyl)-1,2,3,4-butane-tetracarbonic acid and 1,1'-(1,2-ethanediyl)-bis-(3,3,5,5-tetramethylpiperazinone): plasticizers such as phthalates, adipates, glutarates, epoxidized vegetable oils, and the like; fungicides; pigments: dyes: reactive dyes: moisture scavengers: and the like. In addition, fillers and reinforcing materials such as chopped or milled glass fibers, chopped or milled carbon fibers and/or other mineral fibers are useful.
The urethane and/or urea polymers of the present invention can be fabricated by any fabrication technique known in the art. Useful processes include hand casting (see, for example, U.S. Pat. No. 4,476,292) and reaction injection molding (see, for example, U.S. Pat. Nos. 4,297,444 and 4,495,309). The relevant portions of these references are hereby incorporated by reference. The urethane and/or urea polymers of this invention are useful in the production of structural parts for automotive applications such as fenders, doors and body panels as well as in other applications such as computer housings, sports equipment and the like.
ILLUSTRATIVE EMBODIMENTS
The following examples are given to illustrate the invention and should not be interpreted as limiting it in any way. Unless stated otherwise, all parts and percentages are given by weight.
EXAMPLE 1 °
Reaction of 1,4-Tetramethylene-N,N'-diimidazole with Methylenediphenylisocyanate
Preparation of 1,4-Tetramethylene-N,N'-diimidazole
Imidazole (68 g, 1 mole), 50 percent NaOH solution (80 g, 1 mole), toluene (120 ml), and DMSO (120 ml) are mixed and heated until all of the water is removed. 1,4-Dichlorobutane (63.5 g, 0.5 mole) is added and the mixture is stirred at 60° C. for 2 hours. Sodium chloride is removed by filtration and DMSO is removed by distillation. The resulting liquid is poured into 300 ml of water. A white solid forms immediately which weighs 93 g after drying, for a 95 percent yield. NMR, IR, and Mass Spectrometry are consistent with the structure of 1,4-tetramethylene-N,N'-diimidazole which may be used without further purification.
Polyamide Formation
1,4-Tetramethylene-N,N'-diimidazole (51.57 g) is heated at 80° C. under vacuum for 24 hours and then heated to 130° C. Diphenylmethane-4,4'-diisocyanate (MDI) (45 g) and PAPI 580™ polymethylene poly(phenylisocyanate) (24.6 g) are mixed, heated to melt and added to the diimidazole with stirring. A solid is formed in the reaction mixture almost immediately. The solid is heated to melt at 180° C. and then degassed under vacuum. After 5 minutes, the melted solid becomes viscous. It is poured into a 3.5×6" mold for further curing. The mold is heated at 220° C. under 800 psi pressure for 2.5 hours. The mold is allowed to cool and the pressure is released. The resulting polymer has the following properties:
______________________________________Flexural modulus 438 ksiFlexural strength 16.1 ksiIzod .8 ft-lb/inTensile modulus 200 ksiTensile strength 4 ksiElongation at break 2.2%Tg 131° C.______________________________________
TGA shows 2 percent weight loss at 325° C. under nitrogen and at 311° C. in air.
EXAMPLE 2
Preparation of Polyamide from 1,6-Hexamethylene-N,N'-diimidazole and a 2 to 1 Mixture of Diphenylmethane-4,4'-diisocyanate (MDI) and PAPI 580™ Polymethylene Poly(phenylisopoly(phenyl isocyanate)
1,6-Hexamethylene-N,N'-diimidazole (40.6 g) is prepared using the same procedure of Example 2 using 1,6-dichlorohexane, and is heated at 90° C. under vacuum for 17 hours. The temperature is increased to 140° C. MDI (31 g) and PAPI 580™ polymethylene poly(phenylisocyanate) (16.9 g) are melted and combined. The isocyanate liquid is then poured into the 1,6-hexamethylene-N,N'-diimidazole. The liquid mixture is stirred and heated to 150° C., and a vacuum is then applied. The mixture is then heated to 178° C. and becomes very viscous. The viscous liquid is poured into a 3.5-6" mold and compressed to a thickness of about 1/8". The mold is heated and the temperature increased from 170° C. to 205° C. in 20 minutes. The mold pressure is 800 psi. Polymerization is completed at 205° C. in 3 hours. The resulting polymer has the following properties:
______________________________________Flexural modulus 380 ksiFlexural strength 17.3 ksiIzod 0.74 ft-lb/inTensile modulus 390 ksiTensile strength 5.6 ksiElongation at break 1.5%Tg 123° C.______________________________________
EXAMPLE 3
Preparation of Polyamide from Bis-2-N-imidazoleethyl Ether and PAPI 580™ Polymethylene Poly(phenylisocyanate)
Bis-2-N-imidazoleethyl ether (13.4 g) was heated at 60° C. under vacuum for 24 hours. The temperature was then increased to 120° C. and PAPI 580™ polymethylene poly(phenylisocyanate) (17.8 g) was added. The mixture was stirred and degassed at 120° C. The solution is poured into a 0.5×3" mold, compressed to a thickness of about 1/8, and cured under pressure at 210° C. for 2.5 hours. The resulting polymer has a flexural strength of 7.6 ksi and a flexural modulus of 450 ksi.
EXAMPLE 4
Reaction of 1,4-Tetramethylene-N,N'-dibenzimidazole with Polymethylene Poly(phenylisocyanate)
Preparation of 1,4-Tetramethylene-N,N'-dibenzimidazole
Powdered KOH (15.7 g) and benzimidazole (7 g) are mixed in 100 ml acetone. After five minutes, diiodobutane (9.27 g) is added. A solid forms after about an hour. The solid is collected, washed with water, and crystallized in ethanol. NMR and mass spectrometry are consistent with the structure of 1,4-tetramethylene-N,N'-dibenzimidazole.
Polyamide Formation
1,4-Tetramethylene-N,N'-dibenzimidazole (4.3 g) is dried under vacuum for 24 hours and then at 170° C. for 2 hours. PAPI 580™ polymethylene poly(phenylisocyanate) (4.1 g) is added and the mixture is stirred and degassed at 180° C. The mixture becomes very viscous after 10 minutes. It is poured into a mold and heated at 200° C. under 3 tons of pressure for 0.5 hour. The temperature is raised to 210° C. for 1 hour, and then raised to 220° C. for 1.5 hours, and then raised to 230° C. for 1 5 hours. The Tg of the polymer is 170° C. | A polymer comprising a backbone portion containing at least one amide moiety and a plurality of imidazole, benzimidazole, benzoxazole, or benzothiazole moieties is prepared by contacting a polyisocyanate with a compound containing at least two end moieties selected from the following: imidazole, benzimidazole, benzoxazole, or benzothiazole, under reaction conditions sufficient to form the corresponding polymer containing amide moieties are disclosed. The process of the invention is suitable for the preparation of thermoset polymers which are advantageously free of surface defects, since a solvent is not required and no volatiles are evolved during the curing process. Urethane and/or urea polymers comprising a backbone portion containing at least one urea or urethane moiety, at least one amide moiety, and a plurality of imidazole, benzimidazole, benzoxazole, or benzothiazole moieties are also disclosed. | 2 |
FIELD OF THE INVENTION
The present invention relates generally to synthetic filaments and to their processes and systems for manufacture. More specifically, the present invention relates to processes and systems for making melt-spun, synthetic polymeric yarns of bulked continuous filaments (BCF).
BACKGROUND AND SUMMARY OF THE INVENTION
I. Definitions
As used herein, certain terms have the following meanings:
“Filament” or “filaments” mean fibrous strands of extreme or indefinite length. In contrast, “staple fibers” mean fibrous strands of definite and short lengths.
“Yarn” means a collection of numerous filaments which may or may not be entangled, twisted or laid together.
“One-step” means a process for making yarn where the yarn is not wound-up between spinning, drawing and texturing.
“Texturing” means any operation on filaments which results in crimping, looping or otherwise modifying such filaments to increase cover, resilience, bulk or to provide a different surface texture or hand. A “bulked continuous filament” is therefore a “filament” which has been subjected to one or more “texturing” operation(s).
II. Background of the Invention
One-step processes for manufacturing melt-spun polymeric yarns of bulked continuous filaments (BCF) are known as evidenced by the following U.S. Pat. Nos.: 5,804,115; 5,487,860; 4,096,226; 4,522,774; and 3,781,949 (the entire content of each cited U.S. Patent being incorporated expressly hereinto by reference). In general, such processes involve the continuous sequential operations (i.e., without any intermediate winding of the yarn) of spinning, drawing and texturing. The resulting BCF yarn is thereafter wound on a package either sold as is or subjected to further processing (e.g., coloration, entangling with other yarns, fabric formation, and the like).
Conventional one-step BCF yarn production techniques typically involve the melt-spinning of multiple polymeric filament streams which, when cooled form the precursor (or undrawn) filaments of the later BCF yarn. These undrawn filaments are then typically immediately directed to separated pairs of godet rolls (sometimes referred to as “duos” in art parlance) operating at different rotational speeds. The BCF yarn will therefore be drawn between such duos at a desired draw ratio dependent on the duo speed differential, yarn temperature, yarn speed and the like. The duos are typically heated to the same temperature in order to elevate the filament temperature prior to texturing.
The thus drawn and heated yarn is then subjected to a texturing operation, usually accomplished by feeding the drawn continuous filament yarn into a fluid jet texturing unit at a rate faster than the rate at which the textured yarn is drawn off and subjecting the yarn in the unit to a turbulent region of a fluid jet, usually at elevated temperature (e.g., a so-called fluid jet texturing method). The resulting textured continuous filament yarn exhibits increased bulk as compared to the non-textured yarn being fed into the texturing unit to achieve the BCF yarn which may then be wound up to form a yarn package.
III. Summary of the Invention
Broadly, the present invention is embodied in processes and apparatus whereby the morphology of BCF yarns can be variably controlled. More specifically, according to the present invention, the BCF yarn is melt-spun, drawn and textured, wherein prior to texturing, the yarn is subjected to differential temperature condition. Most preferably, such differential temperature condition is accomplished using the duo rolls employed in drawing the BCF, such that one of the rolls is maintained at a greater temperature as compared to the other of the rolls. Most preferably, it is the upstream-most roll (relative to the general conveyance path of the filament toward the texturing unit) which is the hotter of the duo rolls.
These and other aspects and advantages will become more apparent after careful consideration is given to the following detailed description of the preferred exemplary embodiments thereof.
BRIEF DESCRIPTION OF THE ACCOMPANYING DRAWINGS
Reference will hereinafter be made to the accompanying drawings, wherein like reference numerals throughout the various FIGURES denote like structural elements, and wherein;
FIG. 1 schematically represents a preferred system in accordance with the present invention; and
FIGS. 2A-2B, 3 A- 3 B and 4 A- 4 B each represent graphical forms of data obtained from the Examples below.
DETAILED DESCRIPTION OF THE INVENTION
Accompanying FIG. 1 schematically represents a particularly preferred system 10 in accordance with the present invention. In this regard, a conventional extruder 12 supplies molten polymeric material via line 12 - 1 to a spinning head 14 . The spinning head 14 includes spinnerettes (not shown) having multiple small orifices through with the molten polymer material is extruded to form streams 14 - 1 , 14 - 2 , 14 - 3 and 14 - 4 which are cooled and solidified in the quench chamber 16 to form corresponding multi-filament yarns. The now solidified yarns 14 - 1 through 14 - 4 may brought into contact with a finish applicator 18 - 1 , 18 - 2 , 18 - 3 and 18 - 4 , respectively, whereby a liquid finish is applied onto the surface of the yarns as may be desired.
It should be noted here that four yarns are shown only for the purpose of illustration. Thus, more or less yarns may be spun as desired for the finished yarn product.
The yarns 14 - 1 through 14 - 4 are then guided by guides 20 - 1 , 20 - 2 , 20 - 3 and 20 - 4 to a pretensioner godet 22 . The pretensioner godet 22 serves to prevent slippage of the filaments on the draw rolls and stabilized filament movement. The pretensioned yarns are then drawn in a draw zone 24 between separated pairs of duos 26 - 1 , 26 - 2 and 28 - 1 , 28 - 2 , respectively. The tensioned yarns (now collectively identified by TY in FIG. 1) may then be separately or collectively subjected to texturing by a conventional texturing unit 30 . Most preferably, texturing unit 30 is a fluid jet texturizer wherein a fluid jet at elevated temperature is brought into contact with the drawn yarns to texturize the same. The textured BCF yarns (identified by BCF in FIG. 1) are then wound into a yarn package via winder 32 .
In accordance with the present invention, the duo rolls 28 - 1 , 28 - 2 are heated to a desired differential temperature (sometimes hereinafter referred to as “split”). Thus, unlike the conventional practice of maintaining the duo rolls 28 - 1 and 28 - 2 at substantially the same elevated temperature, one of the rolls 28 - 1 or 28 - 2 will be at a greater temperature as compared to the other of the rolls 28 - 1 or 28 - 2 . Although the precise temperature differential employed will depend upon a variety of factors, including for example, the desired a-crystal structure of the filaments, subsequent fluid jet temperature, desired wet bulk, and the like, it is preferred that the duos exhibit a temperature differential of greater than about 10° C. The temperature differential should preferably be no more than about 40° C., and typically no more than about 30° C. Most preferably, it is the upstream-most roll (e.g., roll 28 - 1 as shown in FIG. 1) relative to the texturing unit 30 that is the hotter of the rolls 28 - 1 , 28 - 2 . At such temperature differentials, the wet bulk of the BCF yarn will typically be less than about 25%, and usually between about 10% to about 20%. Wet bulk of between about 13%-19% is especially preferred for BCF carpet yarns.
By way of example, it is desired to produce a BCF yarn having about 16.5% wet bulk and as high an α-crystal content as possible. If the temperature of the duo rolls 28 - 1 and 28 - 2 were constant, then a temperature of about 168° C. would be required. Such a condition would result in a maximum a-crystal content of about 45%. According to the present invention, however, the α-crystal content can be increased by using a temperature differential (or “split”) between the duo rolls 28 - 1 and 28 - 2 wherein one roll is at a temperature of about 190° C. and the other roll is at a temperature of about 160° C. The resulting BCF would then exhibit an α-crystal content of about 53%. The temperature split could be even greater, for example, 198° C. for one of the rolls 28 - 1 , 28 - 2 and 148° C. for the other of the rolls 28 - 1 , 28 - 2 to achieve an even greater α-crystal content, but a practical upper limit of split temperature exists wherein the yarn would begin to stick to the rolls during a spinning interruption.
The filaments may be formed of any synthetic fiber-forming melt-spinnable materials, especially polyesters, polyamides and polyolefins. Suitable polyesters include (but are not limited to) polyethylene terephthalates, polybutylene terephthalates, polytrimethylene terephthalates and copolymers and mixtures thereof. Suitable polyamides include (but are note limited to) nylon 6, nylon 6, 6, nylon 6, 9, nylon 6, 10, nylon 6, 12, nylon 11 nylon 12 and copolymers and mixtures thereof. Suitable polyolefins include polypropylene, polypropylene derivatives and copolymers and mixtures thereof.
The present invention will be further understood by reference to the following non-limiting Examples.
EXAMPLES
In the following Examples, the “wet bulk”, “cylinder bulk” and “alpha %” data were obtained as follows:
Wet Bulk: “Wet bulk” of a BCF yarn is determined by immersing a length of the BCF yarn tensioned with a weight of 1.35 grams in water at an elevated temperature of 70° C. for about 30 seconds. The wet bulk represents the percent contraction of the BCF yarn which is calculated using the starting length of the BCF yarn and the length of the BCF yarn after being immersed in the elevated temperature water.
Cylinder Bulk: “Cylinder bulk” (sometimes abbreviated “cyl bulk”) of a BCF yarn is the specific volume (cc/gm) of a yarn sample under a compression load of about 9 kg. The cylinder bulk is determined by compressing, within a PTFE cylinder using the compression rod of an Instron gage, under a compression load of about 9 kg, a yarn sample weighing 5 grams which has been boiled previously in water for 30 minutes and allowed to dry.
Alpha %: “Alpha %” is the percent of alpha crystallinity in the BCF yarn is determined by infrared spectrometry with a photoacoustic detector and a wire grid polarizer to collect spectral data.
The alpha % represents the percent alpha crystallinity of an average of several yarn samples using their respective peak heights at two characterized frequencies for known alpha and gamma crystal absorbances.
A single position RIETER JO/ 10 SDT machine similar to that depicted schematically in FIG. 1 was used to run samples of BCF nylon 6 (ULTRAMID® nylon commercially available from BASF Corporation) yarns at different combinations of duo 2 temperatures, texturing air temperature and texturing block heat. The individual rolls of the duo 2 (corresponding to duo rolls 28 - 1 and 28 - 2 in FIG. 1) were varied to yield different temperature differences. For the purposes of these examples, the term “duo 2 temperature” is defined as the temperature of the hotter roll, and the term “duo 2 split” is defined as the absolute temperature difference (ΔT) between the hotter and cooler roll. Wet bulk, cylinder bulk and alpha % data were obtained and plotted against each of the duo 2 temperature and duo 2 split and appear as FIGS. 2A-2B, 3 A- 3 B and 4 A- 4 B, respectively.
As can be seen from such FIGURES, the “bulk” of the BCF yarn (i.e., as evidenced by the wet bulk and cylinder bulk) increased with an increase in the duo 2 temperature. Similarly, a decrease in the duo 2 split (i.e., a hotter roll temperature) resulted in increased bulk. Such an effect is apparent from FIGS. 2A-2B, and 3 A- 3 B.
However, the data reveal a different result for the percentage of alpha crystals in the filaments. Specifically, for the duo 2 temperature (texturing air temperature and block heater temperature as well), the alpha crystal content increases with temperature. However, there is not an effect of the duo 2 temperature split on the alpha content. This effect is apparent from FIGS. 4A-4B.
Therefore, the data show that, by choosing the combination of the duo 2 temperature, texturing air temperature and block heater temperature, a desired level of crimp can be made in the yarn. For a high crimp (high bulk) yarn, this will require high temperatures and the alpha crystal structure is preferred. For a low crimp (low bulk) yarn, if the temperatures were lowered, then gamma crystals would predominate. However, by increasing the split between the roll temperatures for the duo 2 , then low bulk can be maintained, with predominantly alpha crystals.
While the invention has been described in connection with what is presently considered to be the most practical and preferred embodiment, it is to be understood that the invention is not to be limited to the disclosed embodiment, but on the contrary, is intended to cover various modifications and equivalent arrangements included within the spirit and scope of the appended claims. | Processes and apparatus are provided whereby the morphology of bulked continuous filament (BCF) yarns can be variably controlled. More specifically, according to the present invention, the BCF yarn is melt-spun, drawn and textured, most preferably in a one-step spin-draw-texture (SDT) process, wherein prior to texturing, the yarn is subjected to a differential temperature condition. Most preferably, such differential temperature condition is accomplished using the duo rolls employed in drawing the BCF, such that one of the rolls is maintained at a greater temperature as compared to the other of the rolls. Most preferably, it is the upstream-most roll (relative to the general conveyance path of the filament toward the texturizer) which is the hotter of the duo rolls. | 3 |
TECHNICAL FIELD
[0001] The invention generally relates to the field of mechanical locking of floorboards. The invention relates to an improved locking system for mechanical locking of floorboards, a floorboard provided with such an improved locking system, as well as a method for making such floorboards. The invention generally relates to an improvement to a locking system of the type described and shown in WO 9426999.
[0002] More specifically, the invention relates to a locking system for mechanical joining of floorboards of the type having a body, opposite first and second joint edge portions and a balancing layer on a rear side of the body, adjoining floorboards in a mechanically joined position having their first and second joint edge portions joined at a vertical joint plane, said locking system comprising
[0003] (a) for vertical joining of the first joint edge portion of the first floorboard and the second joint edge portion of the adjoining floorboard mechanically cooperating means in the form of a tongue groove formed in the first joint edge portion and a tongue formed in the second joint edge portion,
[0004] (b) for horizontal joining of the first joint edge portion of the first floorboard and the second joint edge portion of an adjoining floorboard mechanically cooperating means, which comprise
[0005] a locking groove which is formed in the underside of said second floorboard and which extends parallel to and at a distance from the vertical joint plane at said second joint edge portion and which has a downward opening, and
[0006] a strip made in one piece with the body of said first floorboard, which strip at said first joint edge portion projects from said vertical joint plane and at a distance from the joint plane has a locking element, which projects towards a plane containing the upper side of said first floorboard and which has at least one operative locking surface for coaction with said locking groove, and
[0007] said strip forming a horizontal extension of the first joint edge portion below the tongue groove.
FIELD OF APPLICATION OF THE INVENTION
[0008] The present invention is particularly suitable for mechanical joining of thin floating floorboards made up of an upper surface layer, an intermediate fibreboard body and a lower balancing layer, such as laminate flooring and veneer flooring with a fibreboard body. Therefore, the following description of the state of the art, problems associated with known systems, and the objects and features of the invention will, as a non-restricting example, focus on this field of application and, in particular, on rectangular floorboards with dimensions of about 1.2 m * 0.2 m and a thickness of about 7-10 mm, intended to be mechanically joined at the long side as well as the short side.
BACKGROUND OF THE INVENTION
[0009] Thin laminate flooring and wood veneer flooring are usually composed of a body consisting of a 6-9 mm fibreboard, a 0.2-0.8 mm-thick upper surface layer and a 0.1-0.6 mm lower balancing layer. The surface layer provides appearance and durability to the floorboards. The body provides stability, and the balancing layer keeps the board level when the relative humidity (RH) varies during the year. The RH can vary between 15% and 90%. Conventional floorboards of this type are usually joined by means of glued tongue-and-groove joints at the long and short sides. When laying the floor, the boards are brought together horizontally, whereby a projecting tongue along the joint edge of a first board is introduced into the tongue groove along the joint edge of a second board. The same method is used on both the long and the short side. The tongue and the tongue groove are designed for such horizontal joining only and with special regard to how the glue pockets and gluing surfaces should be designed to enable the tongue to be efficiently glued within the tongue groove. The tongue-and-groove joint presents coacting upper and lower contact surfaces that position the boards vertically in order to ensure a level surface of the finished floor.
[0010] In addition to such conventional floors which are connected by means of glued tongue-and-groove joints, floorboards have recently been developed which are instead mechanically joined and which do not require the use of glue. This type of a mechanical joint system is hereinafter referred to as a “strip-lock system” since the most characteristic component of this system is a projecting strip which supports a locking element.
[0011] WO 9426999 (Applicant Välinge Aluminium AB) discloses a strip-lock system for joining building panels, particularly floorboards. This locking system allows the boards to be locked mechanically at right angles to as well parallel to the principal plane of the boards at the long side as well as at the short side. Methods for making such floorboards are disclosed in WO 9824994 and WO 9824995. The basic principles of the design and the installation of the floorboards, as well as the methods for making the same, as described in the three above-mentioned documents are usable for the present invention as well, and, therefore, these documents are hereby incorporated by reference.
[0012] In order to facilitate the understanding and description of the present invention, as well as the comprehension of the problems underlying the invention, a brief description of the basic design and function of the floorboards according to the above-mentioned WO 9426999 will be given below with reference to FIGS. 1 - 3 in the accompanying drawings. Where applicable, the following description of the prior art also applies to the embodiments of the present invention described below.
[0013] [0013]FIGS. 3 a and 3 b are thus a bottom view and a top view respectively of a known floorboard 1 . The board 1 is rectangular with a top side 2 , an underside 3 , two opposite long sides 4 a, 4 b forming joint edges, and two opposite short sides 5 a, 5 b forming joint edges.
[0014] Without the use of glue, both the long sides 4 a, 4 b and the short sides 5 a, 5 b can be joined mechanically in a direction D 2 in FIG. 1 c . For this purpose, the board 1 has a flat strip 6 , mounted at the factory, projecting horizontally from its long side 4 a, which strip extends throughout the length of the long side 4 a and which is made of flexible, resilient sheet aluminium. The strip 6 can be fixed mechanically according to the embodiment shown, or by means of glue, or in some other way. Other strip materials can be used, such as sheets of other metals, as well as aluminium or plastic sections. Alternatively, the strip 6 may be made in one piece with the board 1 , for example by suitable working of the body of the board 1 . Thus, the present invention is usable for floorboards in which the strip is integrally formed with the board. At any rate, the strip 6 should always be integrated with the board 1 , i.e. it should never be mounted on the board 1 in connection with the laying of the floor. The strip 6 can have a width of about 30 mm and a thickness of about 0.5 mm. A similar, but shorter strip 6 ′ is provided along one short side 5 a of the board 1 . The edge side of the strip 4 facing away from the joint edge 4 a is formed with a locking element 8 extending throughout the length of the strip 6 . The locking element 8 has an operative locking surface 10 facing the joint edge 4 a and having a height of e.g. 0.5 mm. When the floor is being laid, this locking surface 10 coacts with a locking groove 14 formed in the underside 3 of the opposite long side 4 b of an adjoining board 1 ′. The short side strip 6 ′ is provided with a corresponding locking element 8 ′, and the opposite short side 5 b has a corresponding locking groove 14 ′.
[0015] Moreover, for mechanical joining of both the long sides and the short sides also in the vertical direction (direction D 1 in FIG. 1 c ), the board 1 is formed with a laterally open recess 16 along one long side 4 a and one short side 5 a. At the bottom, the recess is defined by the respective strips 6 , 6 ′. At the opposite edges 4 b and 5 b, there is an upper recess 18 defining a locking tongue 20 coacting with the recess 16 (see FIG. 2 a ).
[0016] [0016]FIGS. 1 a - 1 c show how two long sides 4 a, 4 b of two such boards 1 , 1 ′ on an underlay U can be joined together by means of downward angling. FIGS. 2 a - 2 c show how the short sides 5 a, 5 b of the boards 1 , 1 ′ can be joined together by snap action. The long sides 4 a, 4 b can be joined together by means of both methods, while the short sides 5 a, 5 b —when the first row has been laid—are normally joined together subsequent to joining together the long sides 4 a, 4 b and by means of snap action only.
[0017] When a new board 1 ′ and a previously installed board 1 are to be joined together along their long sides 4 a, 4 b as shown in FIGS. 1 a - 1 c, the long side 4 b of the new board 1 ′ is pressed against the long side 4 a of the previous board 1 as shown in FIG. 1 a, so that the locking tongue 20 is introduced into the recess 16 . The board 1 ′ is then angled downwards towards the subfloor 12 as shown in FIG. 1 b. In this connection, the locking tongue 20 enters the recess 16 completely, while the locking element 8 of the strip 6 enters the locking groove 14 . During this downward angling the upper part 9 of the locking member 8 can be operative and provide guiding of the new board 1 ′ towards the previously installed board 1 . In the joined position as shown in FIG. 1 c, the boards 1 , 1 ′ are locked in both the direction D 1 and the direction D 2 along their long sides 4 a, 4 b, but can be mutually displaced in the longitudinal direction of the joint along the long sides 4 a, 4 b.
[0018] [0018]FIGS. 2 a - 2 c show how the short sides 5 a and 5 b of the boards 1 , 1 ′ can be mechanically joined in the direction D 1 as well as the direction D 2 by moving the new board 1 ′ towards the previously installed board 1 essentially horizontally. Specifically, this can be carried out subsequent to joining the long side of the new board 1 ′ to a previously installed board in an adjoining row by means of the method according to FIGS. 1 a - 1 c . In the first step in FIG. 2 a, bevelled surfaces adjacent to the recess 16 and the locking tongue 20 respectively co-operate such that the strip 6 ′ is forced to move downwards as a direct result of the bringing together of the short sides 5 a, 5 b. During the final urging together of the short sides, the strip 6 ′ snaps up when the locking element 8 ′ enters the locking groove 14 ′.
[0019] By repeating the steps shown in FIGS. 1 a - c and 2 a - c, the whole floor can be laid without the use of glue and along all joint edges. Known floorboards of the above-mentioned type are thus mechanically joined usually by first angling them downwards on the long side, and when the long side has been secured, snapping the short sides together by means of horizontal displacement along the long side. The boards 1 , 1 ′ can be taken up in the reverse order of laying without causing any damage to the joint, and be laid again. These laying principles are also applicable to the present invention.
[0020] For optimal function, subsequent to being joined together, the boards should be capable of assuming a position along their long sides in which a small play can exist between the locking surface 10 and the locking groove 14 . Reference is made to WO 9426999 for a more detailed description of this play.
[0021] In addition to what is known from the above-mentioned patent specifications, a licensee of Valinge Aluminium AB, Norske Skog Flooring AS (NSF), introduced a laminated floor with mechanical joining according to WO 9426999 in January 1996 in connection with the Domotex trade fair in Hannover, Germany. This laminated floor, which is marketed under the brand name Alloc®, is 7.2 mm thick and has a 0.6-mm aluminium strip 6 which is mechanically attached on the tongue side. The operative locking surface 10 of the locking element 8 has an inclination (hereinafter termed locking angle) of 80° to the plane of the board. The vertical connection is designed as a modified tongue-and-groove joint, the term “modified” referring to the possibility of bringing the tongue and tongue groove together by way of angling.
[0022] WO 9747834 (Applicant Unilin) describes a strip-lock system which has a fibreboard strip and is essentially based on the above known principles. In the corresponding product, “Uniclic”, which this applicant began marketing in the latter part of 1997, one seeks to achieve biasing of the boards. This results in high friction and makes it difficult to angle the boards together and to displace them. The document shows several embodiments of the locking system. The “Uniclic” product, shown in section in FIG. 4 b, consists of a floorboard having a thickness of 8.1 mm with a strip having a width of 5.8 mm, comprising an upper part made of fibreboard and a lower part composed of the balancing layer of the floorboard. The strip has a locking element 0.7 mm in height with a locking angle of 45°. The vertical connection consists of a tongue and a tongue groove having a tongue groove depth of 4.2 mm.
[0023] Other known locking systems for mechanical joining of board materials are described in, for example, GB-A-2,256,023 showing unilateral mechanical joining for providing an expansion joint in a wood panel for outdoor use, and in US-A-4,426,820 showing a mechanical locking system for plastic sports floors, which floor however does not permit displacement and locking of the short sides by snap action. In both these known locking systems the boards are uniform and do not have a separate surface layer and balancing layer.
[0024] In the autumn of 1998, NSF introduced a 7.2-mm laminated floor with a strip-lock system which comprises a fibreboard strip and is manufactured in accordance with WO 9426999. This laminated floor, which is shown in cross-section in FIG. 4 a, is marketed under the brand name of “Fiboloc®”. In this case, too, the strip comprises an upper part of fibreboard and a lower part composed of a balancing layer. The strip is 10.0 mm wide, the height of the locking element is 1.3 mm and the locking angle is 60°. The depth of the tongue groove is 3.0 mm.
[0025] In January 1999, Kronotex introduced a 7.8 mm thick laminated floor with a strip lock under the brand name “Isilock”. This system is shown in cross-section in FIG. 4 c. In this floor, too, the strip is composed of fibreboard and a balancing layer. The strip is 4.0 mm and the tongue groove depth is 3.6 mm. “Isilock” has two locking ridges having a height of 0.3 mm and with locking angles of 40°. The locking system has low tensile strength, and the floor is difficult to install.
SUMMARY OF THE INVENTION
[0026] Although the floor according to WO 9426999 and the floor sold under the brand name Fiboloc® exhibit major advantages in comparison with traditional, glued floors, further improvements are desirable mainly by way of cost savings which can be achieved by reducing the width of the fibreboard strip from the present 10 mm. A narrower strip has the advantage of producing less material waste in connection with the forming of the strip. However, this has not been possible since narrower strips of the Uniclic and Isilock type have produced inferior test results. The reason for this is that narrow strips require a small angle of the locking surface of the locking element in relation to the horizontal plane (termed locking angle) in order to enable the boards to be joined together by means of angling, since the locking groove follows an arc having its centre in the upper joint edge of the board. The height of the locking element must also be reduced since narrow strips are not as flexible, rendering snap action more difficult.
[0027] To sum up, narrow strips have the advantage that material waste is reduced, but the drawbacks that the locking angle must be small to permit angling and that the locking element must be low to permit joining by snap action.
[0028] In repeated laying trials and tests with the same batch of floorboards we have discovered that strip locks, which have a joint geometry similar to that in FIGS. 4 b and 4 c, and are composed of a narrow fibreboard strip with a balancing layer on its rear side and with a locking element having a small locking surface with a low locking angle, exhibit a considerable number of properties which are not constant and which can vary substantially in the same floorboard at different points in time when laying trials have been performed. These problems and the reason behind the problems are not known.
[0029] Moreover, at present there are no known products or methods which afford adequate solutions to these problems which are related to
[0030] (i) mechanical strength of the joint of floorboards with a mechanical locking system of the strip lock type;
[0031] (ii) handling and laying of such floorboards;
[0032] (iii) properties of a finished, joined floor made of such floorboards.
[0033] (i) Strength
[0034] At a certain point in time, the joint system of the floorboards has adequate strength. In repeated testing at a different point in time, the strength of the same floorboard may be considerably lower, and the locking element slides out of the locking groove relatively easily when the floor is subjected to tensile stress transversely of the joint.
[0035] (ii) Handling/Laying
[0036] At certain times during the year the boards can be joined together, while at other times it is very difficult to join the same floorboard. There is a considerable risk of damage to the joint system in the form of cracking.
[0037] (iii) Properties of the Joined Floor
[0038] The quality of the joint in the form of the gap between the upper joint edges of the floorboards when subjected to stress varies for the same floorboard at different times during the year.
[0039] It is known that floorboards expand and shrink during the year when the relative humidity RH changes. Expansion and shrinking are 10 times greater transversely of the direction of the fibres than in the direction of the fibres. Since both joint edges of the joint system change by the same amount essentially simultaneously, the expansion and the shrinking cannot explain the undesirable effects which severely limit the chances of providing a strip-lock system at a low cost which at the same time is of high quality with respect to strength, laying properties, and the quality of the joint. According to generally known theories, wide strips should expand more and cause greater problems. Our tests indicate that the reverse is the case.
[0040] In sum, there is a great need for a strip-lock system which to a greater extent than the prior art takes into account the abovementioned requirements, problems and wishes. It is an object of the invention to fulfil this need.
[0041] These and other objects of the invention are achieved by a locking system, a floorboard, and a manufacturing method exhibiting the properties stated in the appended independent claims, preferred embodiments being stated in the dependent claims.
[0042] The invention is based on a first insight according to which the problems identified are essentially connected to the fact that the strip which is integrated with the body bends upwards and downwards when the RH changes. Moreover, the invention is based on the insight that, as a result of its design, the strip is unbalanced and acts as a bimetal. When, in a decrease of the RH, the rear balancing layer of the strip shrinks more than the fibreboard part of the strip, the entire strip will bend backwards, i.e. downwards. Such strip-bending can be as great as about 0.2 mm. A locking element having a small operative locking surface, e.g. 0.5 mm, and a low locking angle, e.g. 45 degrees, will then cause a play in the upper part of the horizontal locking system, which means that the locking element of the strip easily slides out of the locking groove. If the strip is straight or slopes upward it will be extremely difficult to lay the floor if the locking system is adapted to a curved strip.
[0043] One reason why the problem is difficult to solve is that the deflection of the strip is not known when the floor is being laid or when it has been taken up and is being laid again, which is one of the major advantages of the strip lock in comparison with glued joints. Consequently, it is not possible to solve the problem by adapting in advance the working measurements of the strip and/or the locking groove to the curvature of the strip, since the latter is unknown.
[0044] Nor is it preferred to solve this problem by using a wide strip, whose locking element has a higher locking surface with a larger locking angle, since a wide strip has the drawback of considerable material wastage in connection with the forming of the strip. The reason why the wider but more costly strip works better is mainly because the locking surface is substantially larger than the maximum strip bending and because the high locking angle only causes a marginally greater play which is not visible.
[0045] The strip-bending problems are reinforced by the fact that laminate flooring is subjected to unilateral moisture influence. The surface layer and the balancing layer do not co-operate fully, and this always gives rise to a certain amount of bulging. Concave upward bulging is the biggest problem, since this causes the joint edges to rise. The result is an undesirable joint opening between the boards in the upper side of the boards and high wear of the joint edges. Accordingly, it is desirable to provide a floorboard which in normal relative humidity is somewhat upwardly convex by biasing the rear balancing layer. In traditional, glued floors this biasing is not a problem, rather, it creates a desirable advantage. However, in a mechanically joined floor with an integrated strip lock the biasing of the balancing layer results in an undesirable drawback since the bias reinforces the imbalance of the strip and, consequently, causes a greater, undesirable backward bending of the strip. This problem is difficult to solve since the bias is an inherent quality of the balancing layer, and, consequently, cannot be eliminated from the balancing layer.
[0046] The invention is also based on a second insight which is related to the geometry of the joint. We have also discovered that a strip lock with a relatively deep tongue groove gives rise to greater undesirable bending of the strip. The reason behind this phenomenon is that the tongue groove, too, is unbalanced. Consequently, the tongue groove opens when, in a decrease of the RH, the balancing layer shrinks to a greater extent than the fibreboard part of the strip, causing the strip to bend downwards since the strip is an extension of the joint edge below the tongue groove.
[0047] According to a first aspect of the invention a locking system is provided of the type which is stated in the first paragraph but one of the description and which, according to the invention, is characterised in that the second joint edge, within an area (P) defined by the bottom of the tongue groove and the locking surface of the locking element, is modified with respect to the balancing layer.
[0048] Said area P, which is thus defined by the bottom of the tongue groove and the locking surface of the locking element, is the area which is sensitive to bending. If the strip bends within this area P, the position of the locking surface relative to the locking groove, and thus the properties of the joint, will be affected. Especially, it should be noted that this entire area P is unbalanced, since nowhere does the part of the balancing layer located in this area P have a coacting, balancing surface layer, neither in the tongue groove nor on the projecting strip. According to the invention, by modifying the balancing layer within this area P it is possible to change this unbalanced state in a positive direction, such that the undesirable strip-bending is reduced or eliminated.
[0049] The term “modified” refers to both (i) a preferred embodiment in which the balancing layer has been modified “over time”, i.e. the balancing layer has first been applied across the entire area P during the manufacturing process, but has then been subjected to modifying treatment, such as milling or grooving and/or chemical working, and (ii) variants in which the balancing layer at least across part of the area P has been modified “in space”, i.e. that the area P differs from the rest of the board with respect to the appearance/properties/structure of the balancing layer.
[0050] The balancing layer can be modified across the entire horizontal extent of the area P, or within only one or several parts thereof. The balancing layer can also be modified under the whole of the locking element or parts thereof. However, it may be preferable to keep the balancing layer intact under at least part of the locking element to provide support for the strip against the underlay.
[0051] According to a preferred embodiment, “modifying” means that the balancing layer is completely or partially removed. In one embodiment, the whole area P lacks a balancing layer.
[0052] In a second embodiment, there is no balancing layer at all within one or several parts of the area P. Depending on the type of balancing layer and the geometry of the joint system, it is, for example, possible to keep the whole balancing layer or parts thereof under the tongue groove.
[0053] In a third embodiment, the balancing layer is not removed completely; it is only reduced in thickness. The latter embodiment can be combined with the former ones. There are balancing layers where the main problems can be eliminated by partial removal of some layers only. The rest of the balancing layer can be retained and helps to increase the strength and flexibility of the strip. Balancing layers can also be specially designed with different layers which are adapted in such a way that they both balance the surface and can act as a support for the strip when parts of the layers are removed within one area of the rear side of the strip.
[0054] The modification can also mean a change in the material composition and/or material properties of the balancing layer.
[0055] Preferably, the modification can be achieved by means of machining such as milling and/or grinding but it could also be achieved by means of chemical working, heat treatment or other methods which remove material or change material properties.
[0056] The invention also provides a manufacturing method for making a moisture-stable strip-lock system. The method according to the invention comprises the steps of forming each floorboard from a body,
[0057] providing the rear side of the body with a balancing layer,
[0058] forming the floorboard with first and second joint edge portions,
[0059] forming said first joint edge portion with
[0060] a first joint edge surface portion extended from the upper side of the floorboard and defining a joint plane along said first joint edge portion,
[0061] a tongue groove which extends into the body from said joint plane,
[0062] a strip formed from the body and projecting from said joint plane and supporting at a distance from this joint plane an upwardly projecting locking element with a locking surface facing said joint plane,
[0063] forming said second joint edge portion with
[0064] a second joint edge surface portion extended from the upper side of the floorboard and defining a joint plane along said second joint edge portion,
[0065] a tongue projecting from said joint plane for coaction with a tongue groove of the first joint edge portion of an adjoining floorboard, and
[0066] a locking groove which extends parallel to and at a distance from the joint plane of said second joint edge portion and which has a downward opening and is designed to receive the locking element and cooperate with said locking surface of the locking element.
[0067] The method according to the invention is characterised by the step of working the balancing layer within an area defined by the bottom of the tongue groove and the locking surface of the locking element.
[0068] The adaptation or removal of part of the balancing layer in the joint system can be carried out in connection with the gluing/lamination of the surface layer, the body, and the balancing layer by displacing the balancing layer relative to the surface layer. It is also possible to carry out modifications in connection with the manufacture of the balancing layer so that the part which will be located adjacent to the locking system will have properties which are different from those of the rest of the balancing layer.
[0069] However, a very suitable manufacturing method is machining by means of milling or grinding. This can be carried out in connection with the manufacture of the joint system and the floorboards can be glued/laminated in large batches consisting of 12 or more floorboards.
[0070] The strip-lock system is preferably manufactured using the upper floor surface as a reference point. The thickness tolerances of the floorboards result in strips of unequal thickness since there is always a predetermined measurement from the top side of the strip to the floor. Such a manufacturing method results in tongue grooves of different depths in the rear side and a partial removal of a thin balancing layer cannot be performed in a controlled manner. The removal of the balancing layer should thus be carried out using the rear side of the floorboard as a reference surface instead.
[0071] It has also been an object to provide a cost-optimal joint which is also of high-quality by making the strip as narrow as possible and the tongue groove as shallow and as strong as possible in order both to reduce waste since the tongue can be made narrow and to eliminate as far as possible the situation where the tongue groove opens up and causes strip-bending as well as rising of the upper joint edge when the relative humidity changes.
[0072] Known strip-lock systems with a strip of fibreboard and a balancing layer are characterised in that the shallowest known tongue groove is 3.0 mm in a 7.2-mm-thick floorboard. The depth of the tongue groove is thus 0.42 times the thickness of the floor. This is only known in combination with a 10.0-mm-wide strip which thus has a width which is 1.39 times the floor thickness. All other such known strip joints with narrow strips have a tongue groove depth exceeding 3.6 mm and this contributes considerably to the strip-bending.
[0073] In order to fulfil the above-mentioned object a strip-lock system is provided which is characterised in that the tongue groove depth of the tongue groove and the width of the strip are less than 0.4 and 1.3 times the floor thickness respectively. This joint affords good joint properties and especially in combination with high rigidity of the tongue groove since it can be designed in such a way that as much material as possible is retained between the upper part of the tongue groove and the floor surface as well as between the lower part of tongue groove and the rear side of the floor while, at the same time, it is possible to eliminate the strip-bending problems as described above. This strip-lock system can be combined with one or more of the preferred embodiments which are disclosed in connection with the solution based on a modification of the balancing layer.
[0074] The opposite joint edge of the board is also unbalanced. In this case, the problems are not nearly as serious since the surface layer is not biased and the unbalanced part is more rigid. However, in this case, too, an improvement can be achieved by making the strip as thin as possible. This permits minimal removal of material in the locking groove part of the joint system, which in turn results in maximum rigidity in this unbalanced part.
[0075] According to the invention there is thus provided a strip-lock system having a joint geometry characterised in that there is a predetermined relationship between the width and thickness of the strip and the height of the locking element on the one hand and the floor thickness on the other. Furthermore, there is provided a minimum locking angle for the locking surface. All these parameters separately and in combination with each other and the above inventions contribute to the creation of a strip-lock system which can have high joint quality and which can be manufactured at a low cost.
BRIEF DESCRIPTION OF THE DRAWINGS
[0076] [0076]FIGS. 1 a - c show in three stages a downward angling method for mechanical joining of long sides of floorboards according to WO 9426999.
[0077] [0077]FIGS. 2 a - c show in three stages a snap-action method for mechanical joining of short sides of floorboards according to WO 9426999.
[0078] [0078]FIGS. 3 a and 3 b are a top view and a bottom view respectively of a floorboard according to WO 9426999.
[0079] [0079]FIG. 4 shows three strip-lock systems available on the market with an integrated strip of fibreboard and a balancing layer.
[0080] [0080]FIG. 5 shows a strip lock with a small tongue groove depth and with a wide fibreboard strip, which supports a locking element having a large locking surface and a high locking angle.
[0081] [0081]FIG. 6 shows a strip lock with a large tongue groove depth and with a narrow fibreboard strip, which supports a locking element having a small locking surface and a low locking angle.
[0082] [0082]FIGS. 7 and 8 illustrate strip-bending in a strip lock according to FIG. 5 and FIG. 6.
[0083] [0083]FIG. 9 shows the joint edges of a floorboard according to an embodiment of the invention.
[0084] [0084]FIGS. 10 and 11 show the joining of two floorboards according to FIG. 9.
[0085] [0085]FIGS. 12 and 13 show two alternative embodiments of the invention.
DESCRIPTION OF PREFERRED EMBODIMENTS
[0086] Prior to the description of preferred embodiments, with reference to FIGS. 5 - 8 , a detailed explanation will first be given of the background to and the impact of strip-bending.
[0087] The cross-sections shown in FIGS. 5 and 6 are hypothetical, unpublished cross-sections, but they are fairly similar to “Fiboloc®” in FIG. 4 a and “Uniclic” in FIG. 4 b. Accordingly, FIGS. 5 and 6 do not represent the invention. Parts which correspond to those in the previous Figures are in most cases provided with the same reference numerals. The design, function, and material composition of the basic components of the boards in FIGS. 5 and 6 are essentially the same as in embodiments of the present invention and, consequently, where applicable, the following description of FIGS. 5 and 6 also applies to the subsequently described embodiments of the invention.
[0088] In the embodiment shown, the floorboards 1 , 1 ′ in FIG. 5 are rectangular with opposite long sides 4 a, 4 b and opposite short sides 5 a, 5 b. FIG. 5 shows a vertical cross-section of a part of a long side 4 a of the board 1 , as well as a part of a long side 4 b of an adjoining board 1 ′. The body of the board 1 can be composed of a fibreboard body 30 , which supports a surface layer 32 on its front side and a balancing layer 34 on its rear side. A strip 6 formed from the body and the balancing layer of the floorboard and supporting a locking element 8 constitutes an extension of the lower tongue groove part 36 of the floorboard 1 . The strip 6 is formed with a locking element 8 , whose operative locking surface 10 cooperates with a locking groove 14 in the opposite joint edge 4 b of the adjoining board 1 ′ for horizontal locking of the boards 1 , 1 ′ transversely of the joint edge (D 2 ). The locking element 8 has a relatively large height LH and a high locking angle A. The upper part of the locking element has a guiding part 9 which guides the floorboard to the correct position in connection with angling. The locking groove 14 has a larger width than the locking element 8 , as is evident from the Figures.
[0089] For the purpose of forming a vertical lock in the direction D 1 , the joint edge portion 4 a exhibits a laterally open tongue groove 36 and the opposite joint edge portion 4 b exhibits a tongue 38 which projects laterally from a joint plane F and which in the joined position is received in the tongue groove 36 .
[0090] In the joined position according to FIG. 5, the two adjoining, upper joint edge surface portions 41 and 42 of the boards 1 , 1 ′ define this vertical joint plane F.
[0091] The strip 6 has a horizontal extent W (=strip width) which can be divided into: (a) an inner part with a horizontal extent D (locking distance) which is defined by the joint plane F and a vertical line through the lower part of the locking surface 10 , as well as (b) an outer part with a horizontal extent L (the width of the locking element). The tongue groove 36 has a horizontal tongue groove depth G measured from the joint plane F and inwards towards the board 1 to a vertical limiting plane which coincides with the bottom of the tongue groove 36 . The tongue groove depth G and the extent D of the locking distance together form a joint part within an area P consisting of components forming part of the vertical lock D 1 and the horizontal lock D 2 .
[0092] [0092]FIG. 6 shows an embodiment which is different from the embodiment in FIG. 5 in that the tongue groove depth G is greater, and the strip width W, the height LH, and the locking angle A of the locking surface are all smaller. However, the size of the area P is the same in the embodiments in FIGS. 5 and 6.
[0093] Reference is now made to FIGS. 7 and 8, which show strip-bending in the embodiments in FIGS. 5 and 6 respectively. The relevant part of the curvature which may cause problems is the area P, since a curvature in the area P results in a change of position of the locking surface 10 . Since the area P has the same horizontal extent in both embodiments, all else being equal, the strip-bending at the locking surface 10 will be of the same magnitude despite the fact that the strip length W is different.
[0094] The large locking surface 10 and the large locking angle A in FIG. 5 will not cause any major problems in FIG. 7, since the greater part of the locking surface 10 is still operative. The high locking angle A contributes only marginally to increased play between the locking element 8 and the locking groove 14 . In FIG. 8, however, the large tongue groove depth G as well as the small locking surface 10 and the low locking angle A 2 create major problems. The strength of the locking system is considerably reduced and the play between the locking element 8 and the locking groove 14 increases substantially and causes joint openings in connection with tensile stress. If the play of the boards is adapted to a sloping strip at the time of manufacture it may prove impossible to lay the boards if the strip 6 is flat or bent upwards.
[0095] We have realised that the strip-bending is a result of the fact that the joint part P is unbalanced and that the shape changes in the balancing layer 34 and the fibreboard part 30 of the strip are not the same when the relative humidity changes. In addition, the bias of the balancing layer 34 contributes to bending the strip 6 backwards/downwards.
[0096] The deciding factors of the strip-bending are the extent of the locking distance D and the tongue groove depth G. The appearance of the tongue groove 36 and the strip 6 also has some importance. A great deal of material in the joint portion P makes the tongue groove and the strip more rigid and counteracts strip-bending.
[0097] FIGS. 9 - 11 show how a cost-efficient strip-lock system with a high quality joint can be designed according to the invention. FIG. 9 shows a vertical cross-section of the whole board 1 seen from the short side, with the main portion of the board broken away. FIG. 10 shows two such boards 1 , 1 ′ joined at the long sides 4 a, 4 b. FIG. 11 shows how the long sides can be angled together in connection with laying and angled upward when being taken up. The short sides can be of the same shape.
[0098] In connection with the manufacture of the strip-lock system, the balancing layer 34 has been milled off both in the entire area G under the tongue groove 36 and across the entire rear side of the strip 6 across the width W (including the area L under the locking element 8 ). The modification according to the invention in the form of removal of the balancing layer 34 in the whole area P eliminates both the bias and the strip-bending resulting from moisture movement.
[0099] In order to save on materials, in this embodiment the width W of the strip 6 has been reduced as much as possible to a value which is less than 1.3 times the floor thickness.
[0100] The tongue groove depth G of the tongue groove 36 has also been limited as much as possible both to counteract undesirable strip-bending and to save on materials. In its lower part, the tongue groove 36 has been given an oblique part 45 in order to make the tongue groove 36 and the joint portion P more rigid.
[0101] In order to counteract the effect of the strip-bending and to comply with the strength requirements, the locking surface has a minimum inclination of at least 45 degrees and the height of the locking element exceeds 0.1 times the floor thickness T.
[0102] In order to make the locking-groove part of the joint system as stable as possible, the thickness SH of the strip in an area corresponding to at least half the locking distance D has been limited to a maximum of 0.25 times the floor thickness T. The height LH of the locking element has been limited to 0.2 times the floor thickness and this means that the locking groove 14 can be formed by removing a relatively small amount of material.
[0103] In more basic embodiments of the invention, only the measure “modification of balancing layer” is used.
[0104] [0104]FIG. 12 shows an alternative embodiment for eliminating undesirable strip-bending. Here, the balancing layer 34 has been completely removed within the area P (including area G under the tongue groove). However, under the locking element 8 in the area L the balancing layer is intact in the form of a remaining area 34 ′, which advantageously constitutes a support for the locking element 8 against the subfloor. Since the remaining part 34 ′ of the balancing layer is located outside the locking surface 10 it only has a marginal, if any, negative impact on the change of position of the locking surface 10 in connection with strip-bending and thus changes in moisture content.
[0105] Within the scope of the invention there are a number of alternative ways of reducing strip-bending. For example, several grooves of different depths and widths can be formed in the balancing layer within the entire area P and L. Such grooves could be completely or partially filled with materials which have properties that are different from those of the balancing layer 34 of the floorboard and which can contribute to changes in the properties of the strip 6 with respect to, for example, flexibility and tensile strength. Filling materials with fairly similar properties can also be used when the objective is to essentially eliminate the bias of the balancing layer.
[0106] Complete or partial removal of the balancing layer P in the area P and refilling with suitable bonding agents, plastic materials, or the like can be a way of improving the properties of the strip 6 .
[0107] [0107]FIG. 13 shows an embodiment in which only part of the outer layer of the balancing layer has been removed across the entire area P. The remaining, thinner part of the balancing layer is designated 34 ″. The part 34 ′ has been left intact under the locking element 8 in the area L. The advantage of such an embodiment is that it may be possible to eliminate the major part of the strip-bending while a part ( 34 ″) of the balancing layer is kept as a reinforcing layer for the strip 6 . This embodiment is particularly suitable when the balancing layer 34 is composed of different layers with different properties. The outer layer can, for example, be made of melamine and decoration paper while the inner layer can be made of phenol and Kraft paper. Various plastic materials can also be used with various types of fibre reinforcement. Partial removal of layers can, of course, be combined with one or more grooves of different depths and widths under the entire joint system P+L. The working from the rear side can also be adapted in order to increase the flexibility of the strip in connection with angling and snap action.
[0108] Two main principles for reducing or eliminating strip-bending have now been described namely: (a) modifying the balancing layer within the entire area P or parts thereof, and (b) modifying the joint geometry itself with a reduced tongue groove depth and a special design of the inner part of the tongue groove in combination. These two main principles are usable separately to reduce the strip-bending problem, but preferably in combination.
[0109] According to the invention, these two basic principles can also be combined with further modifications of the joint geometry (c) which are characterised in that:
[0110] The strip is made narrow preferably less than 1.3 times the floor thickness;
[0111] The inclination of the locking surface is at least 45 degrees;
[0112] The height of the locking element exceeds 0.1 times the floor thickness and is less than 0.2 times the floor thickness;
[0113] The strip is designed so that at least half the locking distance has a thickness which is less than 0.25 times the floor thickness.
[0114] The above embodiments separately and in combination with each other and the above main principles contribute to the provision of a strip-lock system which can be manufactured at a low cost and which at the same affords a high quality joint with respect to laying properties, disassembly options, strength, joint opening, and stability over time and in different environments.
[0115] Several variants of the invention are possible. The joint system can be made in a number of different joint geometry where some or all of the above parameters are different, particularly when the purpose is to give precedence to a certain property over the others.
[0116] Applicant has considered and tested a large number of variants in the light of the above: “smaller” can be changed to “larger”, relationships can be changed, other radii and angles can be chosen, the joint system on the long side and the short side can be made different, two types of boards can be made where, for example, one type has a strip on both opposite sides while the other type has a locking groove on the corresponding sides, boards can be made with strip locks on one side and a traditional glued joint on the other, the strip-lock system can be designed with parameters which are generally intended to facilitate laying by positioning the floorboards and keeping them together until the glue hardens, and different materials can be sprayed on the joint system to provide impregnation against moisture, reinforcement, or moisture-proofing, etc. In addition, there can be mechanical devices, changes in the joint geometry and/or chemical additives such as glue which are aimed at preventing or impeding, for example, a certain type of laying (angling or snap action), displacement in the direction of the joint, or a certain way of taking up the floor, for example, upward angling or pulling along the joint edge. | The invention relates to a locking system for mechanical joining of floorboards ( 1 ) constructed from a body ( 30 ), a rear balancing layer ( 34 ), and an upper surface layer ( 32 ). A strip ( 6 ), which is integrally formed with the body ( 30 ) of the floorboard and which projects from a joint plane (F) and under an adjoining board ( 1 ), has a locking element ( 8 ) which engages a locking groove ( 14 ) in the rear side of the adjoining board. The joint edge provided with the strip ( 6 ) is modified with respect to the balancing layer ( 34 ), for example by means of machining of the balancing layer under the strip ( 6 ), in order to prevent deflection of the strip ( 6 ) caused by changes in relative humidity. The invention also relates to a floorboard provided with such a locking system, as well as a method for making floorboards with such a locking system. | 4 |
TECHNICAL FIELD
The present invention relates to methods and systems for processing call signaling messages. More particularly, the present invention relates to scalable methods and systems for processing call signaling messages.
RELATED ART
Voice-over-IP technology allows voice and data that was traditionally sent over time division multiplexed (TDM) connections to be sent over an Internet protocol network, such as the Internet. Voice-over-IP communication is desirable because it reduces the need for dedicated circuits between communicating entities. However, providing voice-over-IP communications requires the addition of many components to the conventional public switched telephone network (PSTN).
FIG. 1 is a block diagram of a conventional solution for voice-over-IP-enabling the conventional PSTN network. In FIG. 1 , a calling party 100 attempts to establish voice-over-IP communication with a called party 102 . Both calling party 100 and called party 102 may utilize conventional PSTN telephones. When calling party 100 dial or keys in the telephone number for called party 102 , the dialed digits are sent to service switching point (SSP) 104 . Service switching point 104 may be a conventional PSTN end office capable of sending and receiving SS7 call signaling messages over SS7 signaling link 106 and establishing voice communications over TDM voice trunk 108 . Signal transfer point (STP) 110 routes call signaling messages to and from SSP 104 over SS7 signaling link 106 .
Continuing with the example, signal transfer point 110 routes call signaling messages to SSP 112 through SS7 signaling link 114 , STP 116 , and SS7 signaling link 118 in order to set up a call with called party 102 . SSP 112 conventionally maintains call state information for called party 102 and establishes voice communications between called party 102 and calling party 100 via the TDM voice trunk selected by SSP 104 . Thus, in the conventional case, a call can be established between calling party 100 and calling party 102 using only conventional SS7 network elements.
However, in this example, it is assumed that calling party 100 desires to establish a communication with called party 102 via IP connection 122 . In order to accomplish this IP connectivity, media gateways 124 include hardware and software for converting between TDM and IP communications. In addition, in order to set up calls using media gateways 124 , the network must also include one or more media gateway controllers. In the illustrated embodiment, the network includes six media gateway controllers 126 . Media gateway controllers 126 control media gateways 124 via IP links 128 and 130 using any number of media gateway control protocols, such as the media gateway control protocol as defined in Arango et al., RFC 2705, “Media Gateway Control Protocol (MGCP) version 1.0,” (October 1999), the Megaco protocol as defined in Cuervo et al., draft-IETF-megaco-merged-01.txt, “Megaco Protocol,” (May 2000), or any one of a variety of proprietary and non-proprietary protocols used for controlling media gateways.
Media gateway controllers 126 receive call signaling messages from SSPs 104 and 112 through STPs 110 and 116 and SS7 signaling links 132 . Call signaling messages received from SSPs 104 and 112 may be formatted according to the SS7 ISUP protocol. Thus, media gateway controllers 126 each include SS7 and IP communication capabilities.
Conventionally, media gateway controllers 126 have been implemented using stand-alone servers, such as the NETRA™ 1400 available from Sun Microsystems. The NETRA™ 1400 is a server that includes 1-4 Ultrasparc II processors on its motherboard, a 72.8 GB hard drive, a CD-Rom drive, and 4-6 PCI slots. A media gateway controller requires both SS7 and IP network connections. Accordingly, two of the six possible PCI slots may hold Ethernet cards—one for communicating with media gateways and one for an administrative interface. The remaining four slots can hold SS7 cards, each of which is capable of handling two 56 kbps SS7 signaling links. Call processor functions, such as maintaining call state information, are handled by programs executing on the motherboard processors.
A problem with implementing media gateway controllers using stand-alone servers, such as Sun NETRA™ servers, is lack of a reliable way to scale the network. For example, each NETRA™ server is capable of handling at most eight 56 kbps SS7 signaling links. Adding additional SS7 signaling link capabilities requires additional NETRA™ servers. Adding additional NETRA™ servers decreases reliability of the network because of the failure rate caused by hard drives and other components of such servers. In addition, even if redundant NETRA™ servers are used to increase reliability, there is no known mechanism for performing sub-second switchover from one server to a backup server in the event that one server fails.
Another problem with using Sun NETRA™ servers to implement media gateway controller functionality is that inbound SS7 signaling link capacity is less than outbound IP signaling link capacity. For example, conventional SS7 link interface modules may be capable of processing two 56 kbps SS7 signaling links and outbound IP signaling link capacity can be 100 Mbps. This mismatch results in inefficient utilization of outbound signaling link capacity.
In light of all these difficulties associated with conventional media gateway controller solutions, there exists a long-felt need for a scalable and reliable call processing node.
DISCLOSURE OF THE INVENTION
According to one aspect, the present invention includes a scalable call processing node having a plurality of link interface modules for receiving SS7 messages over SS7 signaling links. The link interface modules perform call server selection based on first message parameters in the SS7 messages. The link interface modules are capable of processing at least about n calls per second, where n is an integer. The scalable call processing node also includes a plurality of call server modules. The call server modules receive SS7 messages from the link interface modules and perform call processing operations based on message parameters in the received SS7 messages. The call server modules are capable of handling at least m calls per second, where m is variable relative to n by changing the relative numbers of link interface and call server modules. The call processing node also includes a plurality of transporter modules operatively associated with the call server modules for formulating media gateway compatible messages based on call processing messages and forwarding the media gateway compatible messages to media gateways.
Because the call processing node according to the present invention is scalable, call processing capabilities can be increased or decreased according to network demand. In addition, outbound signaling link capacity can be more efficiently utilized by matching that capacity with inbound signaling link capacity. Finally, due to the absence of multiple mechanical components, such as disk drives, fast switchover capabilities, and decentralized power supplies, the scalable call processing node according to the present invention provides increased reliability over conventional media gateway controller solutions.
Accordingly, it is an object of the present invention to provide a call processing node that is both scalable and reliable.
BRIEF DESCRIPTION OF THE DRAWINGS
A description of preferred embodiments of the present invention will now be explained with reference to the accompanying drawings of which:
FIG. 1 is a block diagram of a conventional communications network in which media gateway controllers are implemented by Sun NETRA™ servers;
FIG. 2 is a block diagram of a communications network including a scalable call processing node according to an embodiment of the present invention;
FIG. 3 is a block diagram illustrating the scalability of a call processing node according to an embodiment of the present invention;
FIG. 4 is a block diagram of exemplary call server module hardware according to an embodiment of the present invention;
FIG. 5 is a flow chart illustrating exemplary steps that may be performed by call server modules in performing call server switchover according to an embodiment of the present invention;
FIG. 6 is a block diagram illustrating message flow through a scalable call processing node according to an embodiment of the present invention;
FIG. 7 is a block diagram illustrating exemplary call tables used by a call server module according to an embodiment of the present invention;
FIG. 8 is a block diagram illustrating trunking and media gateway connections set up by a scalable call processing node according to an embodiment of the present invention;
FIG. 9 is a flow chart illustrating exemplary call processing operations performed by a scalable call processing node using the call tables illustrated in FIG. 7 ;
FIG. 10 is a flow chart illustrating routing decisions made by a scalable call processing node according to an embodiment of the present invention;
FIG. 11 is a block diagram of a telecommunications network including a scalable call processing node according to an embodiment of the present invention; and
FIG. 12 is a block diagram of a telecommunications network including a call server module according to an alternative embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
Scalable Call Processing Node and Operating Environment
FIG. 2 is a block diagram of a scalable call processing node and an exemplary operating environment for such a node according to an embodiment of the present invention. In FIG. 2 , scalable call processing node 200 includes a plurality of cards 201 - 206 connected to each other via interprocessor message transport (IMT) bus 207 . Exemplary cards that may be included in scalable call processing node 200 include link interface modules 201 , call server modules 202 , transporter modules 203 , translation service modules 204 and 205 , and operations, administration, and maintenance (OAM) modules 206 . Each of these modules will now be explained in more detail.
Link interface modules 201 may comprise SS7 link interface modules. SS7 link interface modules 201 may each include processes for sending and receiving SS7 signaling messages over SS7 signaling links and internally routing SS7 signaling messages based on one or more parameters in the SS7 signaling messages. According to the present invention, link interface modules 201 may also be capable of performing call server selection based on one or more parameters in the received SS7 signaling messages. This function will be explained in more detail below.
Exemplary link interface modules suitable for use with the present invention include two-port link interface modules, eight-port link interface modules, and twenty-four-port ATM link interface modules. Two-port link interface modules are capable of handling two 56 kbps SS7 signaling links. Eight-port LIMs are capable of handling eight 56 kbps SS7 signaling links. Finally, twenty-four-port ATM link interface modules are capable of processing 24 SS7 over ATM signaling links. The hardware associated with such link interface modules may be similar to hardware on LIMs available from Tekelec, Inc., of Calabasas, Calif. (hereinafter, “Tekelec”) in the EAGLE® STP or the IP 7 SECURE GATEWAY™ products.
Call server modules 202 include processes and databases for performing call control related functions. For example, call server modules 202 may each include one or more databases for performing trunk selection based on parameters in a received ISUP message. Call server modules 202 may also store call state information, such as the sequence of ISUP messages received for a given call. According to an important aspect of the invention with regard to reliability, call server modules 202 preferably replicate call state information of other call servers to allow subsecond switchover in the event of failure of one of the call server modules. This function will be discussed in more detail below.
Transporter modules 203 receive messages from call server modules 202 and translate the messages between SS7 and media-gateway-controller-compatible protocols, depending on whether the destination of a message is an MG, an MGC, or an SS7 network element. For example, transporter modules 203 may each translate between ISUP and one or more of the following protocols:
MGCP, as defined in any one of the above-described IETF or RFC documents; Session initiation protocol (SIP), as defined in Handley et al., RFC 2543, “SIP: Session Initial Protocol” (March 1999); Transport adapter layer interface (TALI), as described in, “Transport Adapter Layer Interface 2.0 Technical Reference,” Tekelec (May 2000); and Tone and announcement server (TAS), as defined by one or more protocols for communicating with a tone and announcement server.
Translation service modules 204 may include databases and processes for performing number portability translations, such as local or mobile number portability translations. For example, TSM modules 204 may be configured to perform triggered number portability translations in response to TCAP queries received from end offices or triggerless number portability translations in response to ISUP messages received from end offices. Functionality for performed triggered number portability translations is described in “Feature Guide LNP LSMS,” PN/910-1598-01, Tekelec, Rev. A (January, 1998). Functionality for performing triggerless number portability is described in U.S. patent application Ser. No. 09/503,541, filed Feb. 14, 2000.
Translation service modules 205 may include databases and processes for translating from national ISUP versions to a universal ISUP protocol. For example, translation service modules 205 may receive messages formatted in Japanese ISUP, ANSI ISUP, or any other national ISUP version. Translation service modules 205 translate the national ISUP versions into a universal ISUP version understood by transporter modules 203 and IP nodes in the IP network. The universal ISUP version is referred to herein as the normalized call control protocol (NCCP). Translation service modules 205 may also include processes and databases for translating between the normalized call control protocol to a national ISUP version. For example, if a normalized call control protocol message is received by translation service modules 205 , translation service modules 205 may translate the message to the appropriate national ISUP version based on the destination of the message.
OAM modules 206 allow provisioning and maintenance of the remaining modules of scalable call processing node 200 . For example, OAM modules 206 may include serial interfaces for communication with external user terminals 208 to allow provisioning of databases in scalable call processing node 200 .
In the embodiment illustrated in FIG. 2 , scalable call processing node 200 communicates with a variety of other network entities. For example, in the illustrated example, scalable call processing node 200 communicates with media gateway controllers 209 , media gateways 210 , tone and announcement server 211 , peripheral interface system 212 , and integrated access device 213 . Each of these elements will now be discussed in more detail.
MGCs 209 control media gateways 210 via one of the media gateway control protocols discussed above. Transporter modules 203 may communicate with MGCs 209 via any suitable protocol, such as ISUP or SIP. Accordingly, MGCs 209 may include functionality for converting from other telephony protocols, such as ISUP or SIP, to the appropriate media gateway control protocol. MGCs 209 also store call state information for setting up and tearing down connections in media gateways 210 . An example of an external MGC suitable for use with embodiments of the present invention includes any of the Sun NETRA™-based systems described above.
Media gateways 210 perform the functions of conventional media gateways described above. For example, media gateways 210 translate between circuit-switched and packet-switched communications to allow voice and data communications over an IP network. Media gateways 210 may be controlled by media gateway controllers 209 external to scalable call processing node 200 or by call server modules 202 that are internal to scalable call processing node 200 . Exemplary media gateways suitable for use with embodiments of the present invention include the Model No. AS5300 media gateways available from Cisco Systems, Inc.
Tone and announcement server 219 plays tones to telephony users in response to predetermined network conditions. For example, tone and announcement server 219 may play normal busy tones, fast busy tones, and recorded announcements to end users. An exemplary tone and announcement server suitable for use with the present invention includes any of the TAS servers available from Radisys Corporation or Cognitronics Corporation.
Peripheral interface system 220 provides a management network for monitoring communications between the elements illustrated in FIG. 2 . For example, peripheral interface system 220 may allow provisioning of databases in any of the elements illustrated in FIG. 2 , software updates, CDR generation and analysis, billing, etc. Exemplary peripheral interface system components for CDR collection and analysis include the CDR generator as described in commonly-assigned copending U.S. patent application Ser. No. 09/537,075, filed Mar. 28, 2000, the disclosure of which is incorporated herein by reference in its entirety. Exemplary peripheral interface system components for database provisioning and software updates include a standard server, such as a Java user interface server.
Integrated access device 213 provides end user access to an IP network. For example, integrated access device 213 may allow end user telephone handsets and end user computer terminals to access the IP network. Integrated access device 213 may communicate with tone and announcement server 219 via an ATM signaling link. Integrated access device can be used as a substitute for public branch exchange (PBX) systems used in conventional telephone networks. An exemplary integrated access device suitable for use with embodiments of the present invention is the ClariNet or the Piccolo available from Woodwind Communications.
Scalability
FIG. 3 is a block diagram illustrating the scalability of scalable call processing node 200 according to an embodiment of the present invention. In FIG. 3 , scalable call processing node 200 includes first and second shelves 301 and 302 . Each shelf is a mechanical structure in a telecommunications network equipment housing. Each shelf is capable of holding a plurality of modules or cards. As used herein, the terms “modules” or “cards” refer to printed circuit boards that are removably connectable to IMT bus 207 and that are physically housed in shelves, such as shelves 301 and 302 . Scalable call processing node 200 preferably utilizes the same internal architecture with regard to shelves and IMT bus 207 as the EAGLE® STP available from Tekelec. The EAGLE® STP is capable of holding up to 16 shelves with a maximum of 16 cards per shelf. Therefore, like the EAGLE® STP, scalable call processing node 200 is preferably scalable up to 16 shelves per system wherein each shelf is capable of holding up to 16 cards, for a total of 16 2 or 256 total cards. In the illustrated embodiment, each of the shelves 301 and 302 is capable of housing a maximum of 16 cards.
In the illustrated embodiment, first shelf 301 includes two link interface modules 201 , and second shelf 302 includes four link interface modules 201 . Thus, the system illustrated in FIG. 3 includes a total of six SS7 link interface modules. For purposes of the present example, it is assumed that each link interface module comprises an eight port LIM capable of handling eight 56 kbps SS7 signaling links. Since SS7 data is transmitted serially, each byte includes eight data bits, plus a start bit and a stop bit, for a total of 10 bits. In addition, for purposes of this example, it is assumed that the ISUP messages required to set up and tear down a call require an average of 500 bytes. Accordingly, the following expression illustrates the incoming call processing capacity of scalable call processing node 200 illustrated in FIG. 3 :
capacity
=
(
6
LIMs
)
(
8
ports
LIM
)
(
56
k
bits
/
s
1
port
)
(
1
data
byte
10
bits
)
(
1
call
500
bytes
)
(
.4
)
=
537.6
calls
/
sec
(
1
)
In Equation 1, the number of calls processed by the LIMs illustrated in the scalable call processing node 200 illustrated in FIG. 3 is discounted by a factor of 0.4 since SS7 signaling links are usually only operated at 40% capacity. Thus, LIMs 201 illustrated in FIG. 3 are capable of handling 537 calls per second.
Scalable call processing node 200 illustrated in FIG. 3 includes eight call server modules 202 for performing call server functions. Each call server module may be capable of handling a maximum of from about 100 to about 400 calls per second using currently available call server hardware, which will be discussed in more detail below. Thus, since scalable call processing node 200 includes eight call server modules, and each call server module is capable of processing from about 100 to 400 calls per second, the call server processing capacity of scalable call processing node 200 is from about 800 calls per second to about 3200 calls per second. A call processing capability of 3200 calls per second greatly exceeds the capacity of any media gateway controller presently known. For example, in a press release dated Aug. 2, 2000, Sonus Networks claimed that their PSX6000™ soft switch achieved 1650 calls per second in network tests. This is the highest number presently know and can be greatly exceeded by a scalable call processing node according to the present invention.
Finally, scalable call processing node 200 includes two transporter modules 203 for sending messages to the media gateway controllers. Since transporter modules send messages over IP signaling links and are not required to maintain call state information, the transporter modules are typically not a bottleneck to system call processing performance. For example, using currently available Ethernet-based data communication modules available from Tekelec, transporter modules 203 are each capable of sending messages at a rate of about 100 Mbps, which results in a total call processing capacity of 20,000 calls per second.
The present invention is not limited to the embodiment illustrated in FIG. 3 . FIG. 3 simply illustrates a two-shelf system capable of handling about 537 calls per second. As stated above, using the currently available EAGLE® architecture, one call processing node can have up to 16 shelves having a maximum of 16 cards or modules per shelf. Such a system could include up to 256 cards including six OAM cards 206 . Accordingly, an alternative embodiment of the invention may include 83 eight port LIMs, for a total inbound call processing capacity of 3000 calls per second. In such an embodiment, at least eight 400 call-per-second call server modules may be included to handle the incoming calls. Finally, one transporter module may be included to provide the required outbound call translation rate. Thus, scalable call processing node 200 may be capable of processing 3000 or more calls per second, simply by adding additional call server and link interface modules. Proof of the call processing capability is illustrated by the following equations:
inbound
capacity
=
(
83
LIMs
)
(
8
ports
LIM
)
(
56
k
bits
/
s
1
port
)
(
1
data
byte
10
bits
)
(
1
call
500
bytes
)
(
.4
)
=
3000
calls
/
sec
(
2
)
call
server
capacity
=
(
8
call
servers
)
(
400
cps
1
call
server
)
=
3200
calls
/
sec
(
3
)
The call processing capability of a transporter module ranges from about 3000 to about 10,000 calls per second. In a preferred embodiment of the invention, the number of transporter modules for a given anticipated call volume is preferably doubled for load sharing and failover capabilities. Thus, if the required number of transporter modules for a given anticipated call volume is n, the number of transporter modules is preferably 2n.
Thus, it is apparent from equations (2) and (3) that the call processing capabilities of scalable processing node 200 can be extended to 3000 or more calls per second.
Module Hardware
FIG. 4 is a block diagram of exemplary module hardware suitable for use for LIMs 201 , call server modules 202 , and transporter modules 203 according to an embodiment of the present invention. For purposes of explanation, FIG. 4 illustrates exemplary hardware for a call server module 202 . Hardware for other modules is similar to that illustrated in FIG. 4 . In FIG. 4 , call server module 202 includes application processor 400 , communication processor 401 , and interprocessor memory 402 .
Application processor 400 executes programs for performing call processing operations, such as storing call state information, formulating call processing messages in response to other call processing messages received from communication processor 401 . Communication processor 401 sends and receives messages via IMT bus 207 . Interprocessor memory 402 is shared by application processor 400 and communication processor 401 . Because processors 400 and 401 utilize shared memory, the efficiency of call processing module 202 is increased. An exemplary commercially available microprocessor suitable for use as application processor 400 is the K6-2 available from AMD Corporation. An exemplary microprocessor suitable for use as communication processor 401 is the K6-2 available from AMD Corporation.
In the illustrated embodiment, call server module 202 preferably includes its own power supply 403 . Such a power supply may be configured to provide power to processors 400 and 401 and memory 402 , as well as other circuitry of call server module 202 . Power supply 403 preferably received its power from a system power supply, which is preferably an uninterruptible power supply (UPS). Any suitable commercially available power supply for providing power at logic levels can be used for power supply 403 . What is important for purposes of the present invention is that each call server module preferably includes its own power supply. Thus, if one power supply fails, only one call server module will fail. This is in contrast to the conventional solution where media gateway controllers are implemented by Sun NETRA™ servers. In those systems, if the power supply fails, all of the media gateway controller functionality of that system fails.
Subsecond Switchover
According to another aspect, the present invention includes methods and systems for performing subsecond switchover of call servers in the event that one call server fails. FIG. 5 illustrates exemplary steps that may be performed by a call processing node according to an embodiment of the present invention in performing subsecond switchover. Referring to FIG. 5 , in step ST 1 , scalable call processing node 200 establishes one call server module as a primary call server module and another call server module as a backup call server module. The decision as to whether a call server will be a primary or a backup module may depend on any suitable criteria, such as the memory address at which the call server software is located. For example, the call server software having the lowest memory address may be designated the primary call server module.
In step ST 2 , one of the LIMs 201 illustrated in FIG. 1 receives call signaling messages for a call and sends the call signaling messages to the primary and backup call server modules. For example, each LIM may make a copy of the original message and send the original along with the copy to two different call server modules. In an alternative embodiment, each LIM may send the original message to the primary call server and the primary call server may send a copy to the backup call server. In step ST 3 , the primary and backup call server modules each store state information for the call. In this context, state information includes any information required to set up, maintain or tear down a call, such as messages received, trunk information, linkset information, media gateway endpoint information, etc. Exemplary call state information that may be replicated in primary and backup call server modules will be described in more detail below with regard to FIG. 7 .
Although both call servers store the call state information, only the primary call server module actually sends call signaling messages related to the call to outbound communications modules. In step ST 4 , the backup call server module determines whether the primary call server module has failed. Referring back to FIG. 4 , this determination may be made by communication processor 401 associated with the secondary call server. For example, communication processor 401 of the backup call server may monitor a heartbeat message from the communication processor of the primary call server. If the heartbeat message fails to arrive within a predetermined time period, communication processor 401 of backup call server module may notify application processor 400 of the backup call server of the failure of the primary call server module. In step ST 5 , application processor 400 of the backup call server module switches to perform primary call server functions, such as sending the appropriate call signaling messages to a media gateway to set up a connection in the media gateway.
Thus, as illustrated in FIG. 5 , switchover may occur between call sever modules connected to the IMT bus. Because the primary and backup call server modules each receive copies of all of the call signaling messages associated with a call, because both call servers retain call state information for the call, and because the call servers are connected to a high-speed IMT bus, subsecond switchover of call servers can be achieved. Unlike the prior art where it is necessary to transfer call state information from one media gateway controller to another media gateway controller when one media gateway controller fails, this transfer is not necessary in the present embodiment. Communications can resume without transfer of call state information due to the redundant storage thereof by call server modules according to an embodiment of the present invention.
Scalable Call Processing Node Internal Architecture and Message Flow
FIG. 6 is block diagram illustrating internal architecture and message flow for a scalable call processing node according to an embodiment of the present invention. For purposes of illustration, it is assumed that the incoming message is an ISUP message and the outgoing message is a media-gateway-compatible message.
In FIG. 6 , scalable call processing node 200 includes LIM 201 , call server module 202 , transporter module 203 , translator module 205 , and IMT bus 207 . It is understood that although scalable call processing node 200 includes a single LIM, call server, translator, and transporter module, any number of these modules may be included within the scalable call processing node 200 . One module of each type is shown to simplify the explanation of the message flow.
LIM 201 includes SS7 layer 1 and 2 process 600 for performing SS7 layer 1 and 2 functions on incoming messages. I/O queue 601 stores messages for processing by higher SS7 layer processes. Message handling and discrimination (HMDC) process 602 performs discrimination of incoming messages to determine whether the messages are addressed to scalable call processing node 200 or whether the messages should be through-switched. Such a determination may be made based on a destination point code value in the incoming SS7 messages. Message handling and routing (HMRT) process 603 internally routes messages that are directed to scalable call processing node 200 . According to the present invention, HMRT process 603 may be provisioned to perform call server selection based on one or more parameters in the SS7 call signaling messages. Exemplary parameters that may be used to perform call server selection are the OPC, DPC, and CIC codes in an incoming SS7 message.
Call server module 202 includes call processor 604 and one or more call tables 604 A for maintaining call state information and setting up a connection using a media gateway. FIG. 7 illustrates exemplary call tables 604 A that may be stored in memory on call server module 202 . Referring to FIG. 7 , call tables 604 A include a translation table 700 , a routing table 701 , a signaling table 702 , an endpoint table 703 , a connection table 704 , and a state table 705 . Each of these tables may be variously configured. In the illustrated embodiment, translation table 700 maps dialed digits to trunk groups. Routing table 701 maps trunk groups to media gateways and SS7 routing sets. Signaling table 702 maps SS7 routing sets to destination point codes and linksets. Routing table 701 and signaling table 702 are used to generate SS7 call signaling messages relating to a call. Endpoint table 703 and connection table 704 contain information for establishing a connection in a media gateway. Finally, state table 705 stores call state information for each endpoint in a media gateway. The use of tables 700 - 705 to set up a call will now be described in more detail.
FIG. 8 illustrates exemplary trunking and connections in a voice-over-IP network including a scalable call processing node according to an embodiment of the present invention. In FIG. 8 , end office 800 is connected to end offices 801 - 803 by media gateway 804 . More particularly, trunk groups 4 and 5 connect end office 800 to media gateway 804 and trunk groups TG 1 -TG 3 connect media gateway 804 to end offices 801 - 803 . Each trunk group includes a plurality of channels, which are identified by CIC codes unique to each end office. STPs 805 and 806 route call signaling messages between end office 800 and end office 801 . Finally, scalable call processing node 200 sets up, maintains, and tears down connections in media gateway 804 .
FIG. 9 illustrates exemplary steps that may be performed in setting up a call between an end user connected to end office 800 and another end user connected to end office 801 illustrated in FIG. 8 using call tables 604 A illustrated in FIG. 7 . Referring to FIG. 9 , in step ST 1 , scalable call processing node 200 receives an ISUP IAM message from end office 800 . The parameters in the ISUP IAM message may be as follows:
OPC=1-1-7, DPC=2-1-1, CIC=3, ClgPty=919460-5500, CldPty=919-787-8009.
In step ST 2 , scalable call processing node 200 determines the incoming port on media gateway 804 using the OPC, DPC, and CIC codes in the message. In this example, it is assumed that the incoming port number corresponding to the OPC, DPC, CIC combination is 1002. In step ST 3 , call processing node 200 determines a trunk group for the outgoing trunk using the called party number and translation table 700 in FIG. 7 . In FIG. 7 , translation table 700 indicates that the called party digits 919-787-xxxx corresponds to trunk group TG 1 .
In step ST 4 , scalable call processing node 200 selects an outgoing trunk in trunk group 1. This selection may be performed by choosing the next available circuit within the trunk group. In this example, it is assumed that the trunk corresponding to CIC code 2 is the first available trunk in the trunk group. In step ST 5 , scalable call processing node 200 formulates an MGCP CreateConnection message and sends the message to the media gateway. This message may be formulated by transporter module 703 illustrated in FIG. 6 based on parameters received from call server module 202 . In order to determine the parameters that must be included in the CreateConnection message, call server module 202 may access endpoint table 703 illustrated in FIG. 7 . In this example, since the trunk group is TG 1 , the OPC is 1-1-10, and the CIC code is 2, the outgoing port on media gateway 804 is port number 2533. The connection ID assigned to the connection in media gateway 804 is 0. Accordingly, scalable call processing node 200 formulates an MGCP CreateConnection message with the following parameters:
ID=0, EP_ID=1002, SEC EP_ID=2533.
In response to the MGCP CreateConnection message, media gateway 804 returns connection identifiers corresponding to each end of the connection in media gateway 804 . In this example, the connection identifier for the first endpoint is assumed to be 89 and the connection identifier corresponding to the second endpoint of the connection is 90. These parameters are stored in connection table 704 illustrated in FIG. 7 .
In step ST 6 , scalable call processing node 200 determines data to be included in an IAM message sent out to end office 801 to select the outgoing trunk between end office 801 and media gateway 804 . In order to make this determination, scalable call processing node 200 uses routing table 701 and signaling table 702 illustrated in FIG. 7 . Referring to routing table 701 , if the trunk group is TG 1 , the SS7 routing set is RS 1 . Referring to signaling table 702 , if the routing set is RS 1 , the destination point code is 1-1-10, and the linksets are LS 1 and LS 2 . In step ST 7 , scalable call processing node 200 sends the IAM message to end office 801 . In this example, the parameters that may be included in the IAM message are:
OPC=2-1-1, DPC=1-1-10, CIC=2, ClgPty=919-460-5500, CldPty=919-787-8009.
The IAM message instructs end office 801 to set up a trunk corresponding to CIC code 2.
In step ST 8 , scalable call processing node 200 updates call state information in state table 705 . State table 705 preferably contains an entry for each endpoint. In the illustrated example, the endpoint corresponding to port 1001 in media gateway 804 is in the state received IAM, indicating that an IAM message has been received for that endpoint. Endpoint ID 2533 is in the state generated IAM and waiting for ACM. Step ST 8 is preferably performed any time a message relating to a connection is sent or received. The state information stored in table 705 is not to be confused with the state information exchanged between primary and backup media gateways described above with respect to FIG. 7 , which may include any or all of the information contained in call tables 604 A.
In step ST 9 , scalable call processing node 200 receives an address complete message from end office 1-1-10. In step ST 10 , scalable call processing node 200 forwards the address complete message (ACM) to end office 800 . When the called party answers the call, an answer (ANM) message is sent from end office 801 through scalable call processing node 200 to end office 800 . The ANM message follows the same path as the ACM message. Once the ANM message is received, a voice connection is established between end office 800 and end office 801 through media gateway 804 . Thus, FIGS. 7-9 illustrate the use of call tables 604 A in setting up a call using a media gateway.
Referring back to FIG. 6 , transporter module 203 includes upper layer protocol converter 605 for converting between SS7 and a media-gateway-compatible or media-gateway-controller-compatible protocol, such as MGCP, SIP, or any of the other protocols discussed above. Transporter module 203 also includes SS7-to-IP converter 606 for converting between SS7 and IP address schemes. Finally, translator module 205 includes ISUP translator 607 for converting from national to normalized ISUP and vice versa.
The internal operation of scalable call processing node 200 illustrated in FIG. 6 will now be explained with reference to the flow chart illustrated in FIG. 10 . In FIG. 10 , in step ST 1 , LIM 201 receives an ISUP message. Such a message may be an initial address message (IAM), an address complete message (ACM), an answer message (ANM), a release message (REL), or a release complete message (RLC). In this example, it is assumed that an IAM message is received. In step ST 2 , LIM 201 illustrated in FIG. 6 determines whether the message should be through-switched. As stated above, this determination may be made based on the destination point code in the message. In step ST 3 A, if the message is to be through-switched, HMDC process 602 in LIM 201 routes the message to the appropriate module for outbound processing. In this example, it is assumed that the message is not a message that is to be through-switched.
In step ST 4 , HMRT process 603 in LIM 201 performs call server selection based on the OPC, DPC, and CIC parameters in the received SS7 message. In step ST 5 , HMRT process 603 routes the message to the appropriate call server. In step ST 6 , call processor 604 performs call processing operations in response to the received SS7 message. Exemplary call processing operations that may be performed include the operations relating to setting up a connection in media gateway 804 described with respect to FIGS. 7-9 .
An additional function that may be performed by call processor 604 is determining whether translation is required. As used herein, translation refers to translation to or from a normalized ISUP protocol. In order to make this determination, call processor 604 may determine the ISUP protocol used by the called party end office based on one or more parameters, such as DPC, in the received ISUP message. In step ST 8 , if translation is required, call processor 604 may forward the message to ISUP translator 607 , where a translation is performed, and receive a translated message from translator 607 .
In step ST 9 , call processor 604 routes either the translated or the non-translated call signaling message to transporter module 203 for outbound processing. In step ST 10 , upper layer transport module 605 determines the protocol of the destination media gateway and translates the upper layer portion of the received message to the upper layer protocol of the destination. For example, upper layer transport module may translate the message from ANSI ISUP to MGCP. Lower layer transport processor 606 converts the lower level portion of the message to Internet protocol. Transporter module 203 then routes the message to an appropriate media gateway. Thus, FIG. 7 illustrates internal routing decisions performed by scalable call processing node 200 .
Call Setup Using Media Gateway Controllers and Scalable Call Processing Node
FIG. 11 is a network diagram illustrating call setup using scalable call processing node 200 and a media gateway controller 210 according to an embodiment of the present invention. In the example, steps for setting up a call between an end user associated with SSP 800 and an end user associated with SSP 802 will be described. The call is set up between media gateways 804 and 806 . Call signaling messages for the call are routed through signal transfer points 808 and 810 . The circled numerals in FIG. 11 refer to steps required for call setup which will now be described.
In step ST 1 , SSP 800 receives dialed digits from a calling party. In this example, it is assumed that the calling party number is 919-460-5500 and the called party is 219-884-8009. SSP 800 selects a trunk for voice communications by specifying circuit identification code of 50. SSP 800 then formulates and sends an IAM message to SSP 802 controlling the other end of the trunk. The OPC in such a message is 1-1-7, the DPC is 2-2-1, and the CIC is 50. In step ST 2 , the IAM message is sent to STP 808 for SS7 routing. STP 808 routes the IAM message to scalable call processing node 200 . An HMRT process on the receiving LIM of scalable call processing node 200 selects a call server module and forwards the message to the selected call server module.
In step ST 4 , scalable call processing node 200 sends an MGCP CreateConnection request to MG 804 to set up an internal connection between incoming trunk from SSP 800 and the outgoing connection to media gateway 806 . In this example, the outgoing connection to media gateway 806 may be IP, ATM, frame relay, TDM, or any other packet-based protocol for carrying the media stream between the called and calling parties. Media gateway 804 uses the information in the CreateConnection message to set up an internal connection between the TDM trunk connected to SSP 800 and the IP “trunk” connected to MG 806 . In step ST 5 , media gateway 804 sends a response to scalable call processing node 200 indicating that the CreateConnection operation was successfully performed. In step ST 6 , scalable call processing node 200 formulates a new IAM message directed to MGC 240 having the point code 1-1-8. In step ST 7 , STP 808 forwards the new IAM message through the network. In step ST 8 , MGC 210 receives the IAM message from its SS7 stack. In step ST 9 , MGC 210 generates a CreateConnection message requesting MG 806 to set up an internal connection between two trunks, the incoming trunk from media gateway 804 and the outgoing trunk to SSP 802 . In response to the CreateConnection message, media gateway 806 performs the steps necessary to set up the internal connection between the IP trunk connected to MG 804 and the TDM link to SSP 802 . In step ST 10 , MG 806 acknowledges to the CreateConnection message.
In response to the CreateConnection acknowledgement message, in step ST 11 , MGC 210 formulates a new IAM message and sends the new IAM message to SSP 802 having the point code 55-2-2 so that SSP 802 will set up the trunk. In step ST 12 , STP 810 forwards the IAM message to SSP 802 . In step ST 13 , SSP 802 completes the trunk setup operation.
At this point in the call, SSP 802 sends an ACM message to SSP 800 . In response to the ACM message, SSP 800 applies a ring-back message to the calling party and SSP 802 applies a ringing signal to the called party. When the called party answers the call, an ANM message is forwarded by SSP 802 to SSP 800 . Thus, FIG. 8 illustrates call setup using a scalable call processing node according to an embodiment of the present invention.
Call Setup Using SIP
FIG. 12 is a network diagram with identical entities to the network illustrated in FIG. 11 . However, in FIG. 12 , scalable call processing node 200 and MGC 210 exchange trunk setup messages using SIP rather than sending ISUP SS7 messages to each other through STPs 808 and 810 . The steps in FIG. 12 other than steps ST 6 , ST 7 , and ST 8 are identical to those illustrated in FIG. 11 . Hence, a description thereof will not be repeated herein. Referring to step ST 6 in FIG. 12 , scalable call processing node 200 formulates a SIP message and sends the SIP message to MGC 210 . The SIP message may be an INVITE message. The SIP INVITE message includes the outgoing trunk. Steps ST 7 and ST 8 indicate additional SIP messages that may be exchanged between scalable call processing node 200 and MGC 210 in order to set up a call between the parties. An example of a SIP INVITE message that may be formulated by scalable call processing node 200 according to the present embodiment is as follows:
INVITE sip: 19197878009@southbell.com SIP/2.0
From: sip: 19194605500@office.tekelec.com
To: sip: 19197878009@southbell.com
Call-ID: SOUTH94738299197878009@southbell.com
In response to the SIP message, MGC 210 generates the CreateConnection message requesting MG 806 to set up a trunk connecting point code 2-1-1 and point code 55-2-2. Thus, the embodiment in FIG. 12 illustrates call setup using SIP according to an embodiment of the present invention.
It will be understood that various details of the invention may be changed without departing from the scope of the invention. Furthermore, the foregoing description is for the purpose of illustration only, and not for the purpose of limitation—the invention being defined by the claims. | A scalable call processing node includes link interface modules capable of processing n calls per second and call server modules capable of processing m calls per second, n is variable relative to m by changing the relative numbers of call server and link interface modules. In addition, call server modules can perform subsecond switchover when a call server fails without requiring inter-call server transfer of call state information. | 7 |
This is a continuation of application Ser. No. 8/021,783 filed on Feb. 24, 1993, now U.S. Pat. No. 5,422,375.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a method of conducting a continuous multi-phase catalytic reaction and is particularly, though not exclusively, applicable to the catalytic conversion of syngas, produced by the reforming of methane, to hydrocarbon fuels, by a Fischer-Tropsh type of synthesis. Other reaction systems to which the method is applicable include various slurry reactions for the production of petrochemicals, the production of oxygenates from synthesis gas and dehydrogenation reactions.
2. Description of the Invention Background
Three-phase catalytic reaction systems are used in a number of chemical processes and their application in the petrochemical industry appears to be increasing. Of the three-phase systems in use, mechanically agitated, loop and bubble column slurry reactors contain small catalyst particles dispersed in the liquid. In most applications, the liquid will have to be separated from the slurry to remove liquid products or for catalyst regeneration purposes. In those cases where the liquid is an inert medium, occasionally, it may have to be replaced due to degradation or the build-up of impurities.
Mechanically agitated slurry reactors are particularly convenient for batch process due to the low mass-transfer and heat resistance. These features also make them suitable for the determination of reaction kinetics in the laboratory. A serious disadvantage and limitation of this reactor type, however, is the difficulty in the separation of catalyst particles in any continuous operation.
Commercially, it is only mechanically agitated reactors that are used in the hydrogenation of double bonds in oils from cottonseed, soybean, corn, sunflower etc. By employing a nickel catalyst, the products include margarine, shortening, soap and greases. The choice of reactor is based on the low diffusivities and high viscosities of the fatty oils. Fixed-bed operation has been proposed due to the advantage of completely catalyst-free products without filtration. A number of other hydrogenation reactions are also carried out in agitated reactors, e.g. the hydrogenation of nitrocompounds.
The operation of bubble column slurry reactors is simple, since mechanically moving parts are avoided. Combined with the low diffusional resistance and efficient heat transfer, these reactors are attractive for many industrial processes. However, solid-liquid separation is usually performed outside the reactor in elaborate filtering and settling systems. The catalyst slurry is to be recycled to the reactor, sometimes with the use of a slurry pump. Thus, serious problems may be encountered in the continuous operation of bubble column slurry reactors.
As world oil resources diminish it is becoming more attractive to use natural gas as an energy source and methods of upgrading this to higher hydrocarbon fuels are increasing in importance.
It is therefore an object of the invention to provide a continuous method of conducting a multi-phase catalytic reaction which does not suffer the drawbacks of the prior art.
It is a particular object of the invention to provide such a process which is well suited to use in the conversion of natural gas via syngas to diesel fuel.
SUMMARY OF THE INVENTION
According to the invention, there is provided a method of conducting a continuous multi-phase catalytic reaction in which the product includes at least one liquid component and the catalyst is a finely divided solid, the method comprising: introducing reactants into a slurry of reactants, product and catalyst in a reactor vessel; separating the liquid product from the remainder of the slurry by means of a filter member; establishing a mean pressure differential across the filter member; causing fluctuations or oscillations about the mean pressure differential; and maintaining the slurry in a state of constant agitation by introducing gaseous components into the slurry as a stream or swarm of bubbles.
Such a method is relatively simple yet effective. The separation step, generally considered to be particularly problematic, is achieved without undue complication and under proper operating conditions the filter member is self-cleaning.
The reactants may be CO and H 2 , for example from the reforming of methane. The reaction may then be a catalytic conversion by a Fischer-Tropsch synthesis, producing methanol and higher hydrocarbons.
Preferably, the gaseous components include any gaseous reactants. Preferably, the slurry is maintained in a turbulent state by the gas bubbles.
Preferably, a pressure differential is achieved by applying an excess pressure to the slurry side of the filter member and/or by applying a negative pressure to the product (filtrate) side of the filter member. Preferably, the pressure differential is achieved, at least in part by maintaining the slurry at a level above the level of the product on the filtrate side of the filter member, by means of a constant level device on the filtrate side of the filter member. The pressure differential should not be allowed to increase beyond a fairly low maximum limit typically less than 5 mBar (500 Pa) since the filter unit would otherwise tend to clog. Preferably, communication between the space above the slurry and the space above the filtrate prevents the build-up of pressure differentials in excess of that corresponding to the hydrostatic pressure.
The pressure fluctuations or oscillations may be achieved in various ways. The pressure fluctuations or oscillations may be carried out by the turbulent motion of the slurry in the reactor and/or by gas bubbles rising on the outside of the member, which may themselves give rise to turbulent flow conditions. This may be transferred or enhanced perhaps by resonance effects to the filtrate, preferably by way of communication between the gas volume above and the slurry and the gas volume above the filtrate. Alternatively, the pressure fluctuation may be achieved by applying a pulsating pressure to the gas volume above the filtrate.
The pressure fluctuation value may be of the order of the pressure differential, for example from 10 to 200% of the pressure differential. The actual value of the pressure differential may be from 1 to 1000 mBar, preferably 2 to 50 mBar. Very good operational results may be obtained in the range of 2 to 10 mBar in the case of a Fischer-Tropsch conversion of syngas to hydrocarbon products.
The filter member is preferably in the form of a filter unit which defines internally the filtrate zone and which includes a filter element separating the filtrate from the slurry. Preferably the filter element is generally cylindrical and its axis is generally vertical in use though it may be inclined by as much as 10° or even 30° to the vertical. The member material and catalyst are preferably selected so that the maximum hole or pore size in the filter element is of the same order of magnitude as the catalyst particle size, the particle size preferably being not less than half the pore size. However, it would be possible for the catalyst particle size to be larger than the maximum pore size, with the pore size being of the same magnitude or less.
The invention also extends to a method of converting natural gas (methane) to higher hydrocarbon fuels which involves initially reforming the methane to produce carbon monoxide and hydrogen, subjecting the CO and H 2 to catalytic conversion by a Fischer-Tropsch synthesis using the method mentioned above to form higher hydrocarbon fuels such as liquid paraffin waxes, and subsequently separating and/or cracking these products to produce the required range of hydrocarbons.
The mechanism of the Fischer-Tropsch synthesis is probably quite complicated but the formation of hydrocarbons can be summarised as follows:
nCO+(2n+1)H.sub.2 -C.sub.n H.sub.2n+2 +nH.sub.2 O
A preferred catalyst and process is described in EP-A-313375.
When diesel fuel is produced in this way it is vastly superior to conventional diesel in terms of its quality and properties. Firstly, it contains no sulphur or aromatics, which is important from an environmental point of view. Secondly, it has a very high cetane number and can therefore be blended with lower grades of diesel fractions in order to give a product which meets premium range standards. Thirdly, it contains virtually no harmful compounds that generate soot when burned and needs fewer additives for problem free use at low temperatures.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention may be carried into practice in various ways and some embodiments will now be described by way of example with reference to the accompanying drawings, in which:
FIG. 1 is a schematic section through a three-phase slurry reactor for performing a method in accordance with the invention;
FIG. 2 is a simplified schematic section through a part of a reactor showing an alternative system for achieving the fluctuations in pressure;
FIGS. 3, 4 and 5 are views similar to FIG. 2 showing three ways of adjusting the pressure differential across the filter member.
FIGS. 6 and 7 are views similar to FIGS. 3 to 5, showing two further variants.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The reactor vessel 11 in FIG. 1 comprises an outer casing 12 defining the reactor vessel 11 and within the casing 12 a filter unit 13. The housing 12 has a gas inlet 14 at the bottom which, in the case of a syngas conversion process, would constitute the reactant inlet. Above the gas inlet 14, there is a gas delivery device such as a gas-permeable fist plate 15 which supports the slurry 16 in the reactor vessel 11, and at the top of the casing 12, a gas outlet 17. The gas outlet 17 is controlled by a choke or valve 18. The casing also has an inlet 19 and an outlet 21 for the slurry.
The filter unit 13 comprises a generally vertical cylindrical filter element 22 in contact with the slurry 16. The filter element is in the form of a fine meshed screen though it could alternatively comprise helically wound metal threads, sintered metal particles or narrowly separated fine vertical threads. It houses a constant level device in the form of a vertical pipe 23 which terminates below the top of the filter unit 13. The pipe 23 leads to a filtrate outlet 24 which in turn leads to a collector 25 and to an outlet valve 26. A tube 27 extends from the space 28 within the filter unit 13 above the top of the pipe 23 to the space 29 within the top of the reactor 11 above the filtrate 16. An opening 31 in the tube 27 connects the two spaces 28,29.
In normal continuous operation, gaseous reactants are introduced to the reactor vessel 11 via the inlet 14 and the plate 15. The reactants form bubbles in the slurry 16 which pass upwards past the filter unit 13. The slurry 16 consists of a liquid phase of the reaction products and a catalyst in finely divided form. The gaseous reactants react as they contact the catalyst, thus adding to the products in the slurry.
At the same time, the products pass through the filter element 22 to form a product filtrate 32 which is free of catalyst. Any gaseous products and unreacted reactants can be vented through the outlet 17 and subsequently treated and/or recycled. The product filtrate 32 leaves the filter unit 13 via the constant level device 23 and outlet 24 and is collected in the collector 25 for regulated continuous or periodic removal.
The difference in level between the slurry 16 and the product filtrate 32, determined by the constant level device, results in a pressure differential across the filter element 22. This helps to convey the liquid product through the filter element 22.
It might be expected that, under these conditions, the catalyst would clog the filter element, however, this is found not to be the case, provided that the pressure differential is not too great. The introduction of the reactants together with the connection of the gas spaces 28, 29, and the generally turbulent conditions in the reactor vessel 11 combine to cause fluctuations in the pressure differential across the filter element 22. These in turn cause fluctuations in the liquid flow through the filter element 22 resulting in an anti-clogging effect. This may be enhanced by the movement of the gas bubbles past the surface of the filter element 22.
It will, of course, be appreciated by those skilled in the art that at start-up it will be necessary to have filled the reactor vessel with a similar material to that which will represent the product of the reaction, this being a perfectly standard procedure.
An alternative embodiment is shown in FIG. 2. In this case the filter unit 41 has no tube 27 connecting the space 28 to the space 29 in the reactor (not shown). Instead, a cylinder and piston assembly 42 is connected to the space 28. By reciprocating the piston, a pulsating pressure is produced resulting in the desired fluctuation in the pressure differential across the filter element 22. This arrangement can of course be used in conjunction with the embodiment shown in FIG. 1. Communication between the spaces above the slurry and the filtrate may be provided by a tube (not shown) having a restriction or choke limiting the transmission of pressure pulses to the space above the slurry, which would otherwise have tended to eliminate the net effect of the reciprocating piston. The tube would nevertheless control the static pressure differential.
The constant level device 23 can be made adjustable in order to provide a degree of control over the pressure differential across the filter element 22. Three ways in which this can be achieved are shown in FIGS. 3, 4 and 5.
In the filter unit 51 of FIG. 3, both the vertical pipe 52 and the tube 53 are slidably mounted with respect to the filter unit 51. Thus, vertical movement of the filter unit 51 results in an adjustment of the relative liquid level.
In the filter unit 61 of FIG. 4, the vertical pipe 62 is slidably mounted but the tube 63 is fixed relative to the filter unit 61. Thus, as the tube 62 is moved, so the liquid level within the filter unit 61 follows. In the filter unit of FIG. 5, the tube 73 is fixed, and the vertical pipe 72 is slidably mounted within a fixed sleeve 74. Thus, the level of the filtrate 16 remains fixed relative to the filter unit 71 as it is raised or lowered.
The variants shown in FIGS. 3 to 5 can be combined with either of the embodiments shown in FIGS. 1 and 2.
In the reactor 81 shown in FIG. 6, the outlet 84 from the filter unit 83 has an upward loop 85 to ensure that the filter unit 83 is filled with liquid. In the reactor 91 shown in FIG. 7, there is a tube 97 connecting the gas space in the reactor to the filtrate. The outlet 94 extends to the bottom of the filter unit 93 and there is an optional connection 96 between the outlet 94 and the space in the reactor. This connection 96 would tend to prevent any siphon effect and allow any gas remaining in the filtrate to escape. Again, the filter unit 93 will be filled
In all thate.
In all the illustrates embodiments, the geometries of the reactor, the communication means (eg. the tube 27) and the filtrate section may be varied in size and in order to optimise the pressure fluctuations by exploiting resonance-like effects.
The invention will now be further illustrated in the following Examples which were conducted on a laboratory scale.
EXAMPLE I
A stainless steel tube, with a diameter of 4.8 cm and a height of approximately 2 meters was filled with a hydrocarbon liquid and a fine powdered catalyst. The tube was operated as a slurry bubble column by bubbling gas through the slurry.
A filter unit was placed in the upper part of the reactor. The filter unit was made of Sika stainless steel sintered metal cylinder Type R20 produced by the company Pressmetall Krebsoge GmbH. The filter unit had an outer diameter of 2.5 cm, a height of 25 cm, and an average pore size of 20 μm.
In this particular experiment, the reactor was filled with a slurry consisting of a poly α-olefin liquid and approximately 10 weight % of a fine powdered cobalt on alumina catalyst. The particle size ranged from 30 to 150 μm. The catalyst was kept suspended by gas bubbling through the liquid. The gas was a mixture of H 2 , CO and N 2 of varying composition, and was fed with a superficial gas velocity of 4 cm/s. The temperature in the reactor was 230° C., and the pressure was 30 bar (3×10 6 Pa).
The filtrate level inside the slurry was set approximately half way up in the valve.
The liquid formed by the Fischer-Tropsch reaction in the reactor was withdrawn through the filter unit. In addition, a poly α-olef in liquid fed to the reactor was also withdrawn through the filter unit. The liquid withdrawal varied from 320 to 2.5 g/h depending on the formation rate of the liquid product, and the feeding rate of the hydrocarbon liquid. The experiment lasted approximately 400 hours, and a total amount of liquid of 30 liters was withdrawn through the filter unit.
The liquid level in the reactor was constant during the experiment, and no colour indicating presence of solid particles could be observed in the liquid.
EXAMPLE II
A glass tube, with a diameter of 22 cm and a height of 2.5 meters was filled with hydrocarbon liquid (Monsanto heat transfer fluid, MCS 2313) and a fine alumina powder (average particle diameter approximately 75 μm). The content of alumina was approximately 15% by weight. The tube was operated as a slurry bubble column (SBC) by bubbling gas through the slurry. A filter member without a connection tube between the gas volume above the slurry phase and the gas volume above the product phase was placed in the upper part of the SBC. The filter member was made of a Sika fill 10 stainless steel sintered metal cylinder produced by Sintermetallwerk Krebsoge GmbH. The sinter cylinder had an outer diameter of 2.5 cm, a height of 20 cm, and an average pore size of 10 m.
In this particular experiment the slurry level was set to be at the top of the sinter cylinder. The pressure amplitude in the SBC was measured to be 6 mBar, the pressure drop across the sinter metal wall was approximately 3-4 mBar (300-400 Pa). The temperature in the slurry was 20° C., the pressure was 1 Bar (10 5 Pa) and the gas velocity was approximately 6 cm/s.
At the start of the experiment, the flow of the filtrate through the sinter metal cylinder was about 1000 ml per minute. After 4 hours the flow was reduced to zero due to clogging of the sinter metal wall on the slurry side.
When a similar experiment was carried out in an apparatus in which communication between the gas volumes was provided by a piece of pipe acting as a connection tube, the initial flow rate was maintained essentially at the same level throughout the experiment. It was therefore concluded that the absence of a connection tube between the gas volume above the slurry and the gas volume above the product phase resulted in clogging in the first experiment. | A method of conducting a continuous multi-phase catalytic reaction such as the conversion of syngas to higher hydrocarbon fuels. Gaseous reactants are introduced via a gas permeable plate into a slurry which includes the product and a finely divided catalyst. The liquid product is separated from the remainder of the slurry by means of a filter unit including a filter member. A pressure differential is established across the filter member by means of a constant level device within the filter unit which maintains a level of filtrate within the filter unit below the level of the slurry. The slurry is maintained in a constant state of agitation by the introduction of the gaseous components as a steam of bubbles. Fluctuations in the pressure differential across the filter member prevent the filter member from clogging, and the gas space is above the filtrate and the slurry are in communication. | 1 |
[0001] Priority is claimed from U.S. Provisional Application Ser. No. 60/897,836, filed Jan. 29, 2007.
BACKGROUND OF THE INVENTION
[0002] This invention generally relates to irrigation sprinklers, and more specifically, to an automatic arc adjustment device for a high-volume sprinkler.
[0003] High-volume sprinklers are often used to irrigate large fields, and they are typically attached to a hose reel stationed at one end of the field. In use, the hose is extended to its full length by means of a traveling cart with a high-volume sprinkler located on the cart. When the water supply valve is opened, water under pressure travels from the hose reel through the hose, into the cart and is dispensed through the sprinkler nozzle. As the water is applied over the area to be irrigated, the hose is slowly rolled back onto the reel, pulling the cart and the sprinkler towards the reel. When the cart and sprinkler reach the hose reel, the irrigation cycle is complete. The reel is then moved to another site where the cycle is repeated.
[0004] Where possible, and for optimum irrigation efficiency, a 270-degree arc is set for the sprinkler. This is set such that, when viewed from overhead, the 90-degree dry spot of the sprinkler is centered upon the hose being pulled towards the hose reel. This arrangement provides the best results in terms of applying water uniformly, and is the most forgiving with respect to countering the effects of wind.
[0005] Oftentimes, however, the farmer starts his cart or traveler with the sprinkler located adjacent a road, fence, or other boundary where a 270-degree arc is not feasible. Accordingly, the farmer manually sets the sprinkler pattern stops initially to provide an arc of 180 degrees, with the boundary of the area to be wetted defined by the fence, road, etc. He starts the sprinkler and operates the hose reel until the cart is pulled into the field far enough that a 270-degree operating arc will be acceptable, and then manually resets the stops on the sprinkler to provide the desired 270-degree arc. This procedure is workable, but requires the farmer or irrigator to be on site to make the required manual stop adjustments.
BRIEF DESCRIPTION OF THE INVENTION
[0006] The exemplary but nonlimiting implementation of the invention described herein performs the above adjustment procedure automatically through the use of an electro/hydraulic device or mechanism. In the exemplary embodiment, the device is initially adjusted for the 180-degree arc at the field boundary; a timer value is input into a countdown timer attached to a solenoid valve, and the system is started. When the predetermined time value is reached, a solenoid valve is opened, extending a hydraulic cylinder piston operating on system water pressure. The extending piston causes rotation of the adjustment stops of the sprinkler to obtain the desired 270-degree arc. The arc adjustment stops always remain in the correct orientation relative to an associated tripping mechanism that reverses the direction of arcuate movement of the sprinkler head.
[0007] An advantage of the disclosed device is that it can be easily installed in the field. In addition, it is simple in construction, allowing effective trouble-shooting of any mechanical malfunction.
[0008] Accordingly, in one aspect, the invention relates to an adjustable sprinkler comprising: a sprinkler head having a bearing mounted on a support, the sprinkler head rotatable on the bearing about a vertical axis; an arc adjustment plate mounted on the support for rotation about the axis relative to the support and to the bearing; first and second stops supported on the plate for arcuate movement about the axis, at least one of the stops movable relative to the plate, wherein the first and second stops define limits of rotational movement of the sprinkler head about the axis; and an actuator for moving one of the stops relative to the other of the stops for varying the limits of rotational movement of the sprinkler head.
[0009] In another aspect, the invention relates to a sprinkler head having a bearing mounted on a support, the sprinkler head rotatable on the bearing about a vertical axis; an arc adjustment plate mounted on the support for rotation about the axis relative to the support and to the bearing; first and second stops supported on the plate for arcuate movement about the axis, the stops movable relative to the plate and to the support, wherein the first and second stops define limits of rotational movement of the sprinkler head about the axis; and means for automatically moving the arc adjustment plate and the first and second stops relative to the support to vary the limits as a function of time.
[0010] In still another aspect, the invention relates to a method of operating a sprinkler to irrigate a field having at least one end defined by a boundary and a second real or imaginary opposite end comprising: providing a sprinkler cart having a sprinkler head mounted thereon, the cart connected to a hose windable on a hose reel; locating the cart adjacent the boundary at the one end, with the hose reel located at the opposite end; setting the sprinkler head to achieve a 180-degree arc of rotation at the one end, such that water emitted from the sprinkler head does not cross the boundary; winding the hose onto the hose reel to thereby pull the cart away from the boundary at the one end in a direction toward the opposite end; and employing an actuator to automatically set the sprinkler head to achieve a 270-degree arc of rotation, with a remaining 90-degree dry area centered on the hose, when the cart is a sufficient distance away from the boundary at the one end that water emitted from the sprinkler head does not cross the boundary.
[0011] The invention will now be described in connection with the drawings identified below.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] FIG. 1 is a schematic plan view of a cart-mounted high-volume sprinkler located at one end of a field to be irrigated;
[0013] FIG. 2 is a schematic view similar to FIG. 1 , but with the cart drawn further into the field by a hose reel;
[0014] FIG. 3 is a side elevation of the high-volume sprinkler removed from the cart;
[0015] FIG. 4 is a partial enlargement of FIG. 3 ;
[0016] FIG. 5 is a top perspective view of the high-volume sprinkler shown in FIG. 3 , with a water deflector in a first operative position;
[0017] FIG. 6 is a partial enlargement of FIG. 5 ;
[0018] FIG. 7 is a top perspective view similar to FIG. 5 , but with the water deflector in a second operative position;
[0019] FIG. 8 is a partial enlargement of FIG. 7 ;
[0020] FIG. 9 is a plan view of the high-volume sprinkler, showing the automatic arc adjustment mechanism;
[0021] FIG. 10 is a plan view similar to FIG. 9 , but with parts removed to show additional details of the arc adjustment mechanism;
[0022] FIG. 11 is a partial enlargement of FIG. 10 ;
[0023] FIG. 12 is a side elevation similar to FIG. 3 but with parts removed;
[0024] FIG. 13 is a view similar to FIG. 9 , but with the sprinkler rotated clockwise through about 225 degrees;
[0025] FIG. 14 is a view similar to FIG. 13 but with parts removed; and
[0026] FIG. 15 is a partial enlargement of FIG. 14 .
DETAILED DESCRIPTION
[0027] FIG. 1 shows a schematic aerial or plan view of a field 10 irrigated with a traveler cart (or, simply, “cart”) 12 at the start of the irrigation cycle. The field boundary 14 is the area to be irrigated with all water coming from a high-volume sprinkler 16 , mounted on the cart, to fall within that boundary. The sprinkler 16 may be of the type available from the assignee, Nelson Irrigation Corporation of Walla Walla, Wash., known as the Big Gun® series sprinklers, or any other suitable high-volume sprinkler.
[0028] The end boundary 18 of the field is the boundary to which the cart 12 is initially pulled. A cart hose reel 20 is located at the other end of the field and is connected to the cart 12 by a hose 22 wound on the reel 20 . The “other” end of the field could be a real or imaginary end depending on the length of the field vis-a-vis the length of the hose. An automatic sprinkler arc changer or adjustment mechanism 24 (sometimes referred to herein as “the arc adjustor 24”) is also located on the cart 12 , at the base of the sprinkler 16 . Initially, because of the presence of the end boundary 18 , sprinkler pattern or arc adjustment stops (discussed in detail further below) are set to achieve a 180-degree arc 26 . The sprinkler 16 thus rotates back and forth to irrigate the area described by the arc 26 and end boundary 18 .
[0029] FIG. 2 shows a schematic aerial view of the same irrigated field 10 as in FIG. 1 but after the cart hose 22 has been wound onto the hose reel 20 , pulling the cart 12 away from the end boundary 18 to a point where a 270-degree operating arc 28 can be safely run without the sprinkler stream extending beyond or outside the end boundary. It is the arc adjustor 24 described in further detail below that implements the arc change from 180 degrees to 270 degrees.
[0030] FIG. 3 is a side view of the high-volume sprinkler 16 . The sprinkler 16 rotates under the power of the water exiting the sprinkler nozzle 30 . Specifically, a drive arm 32 moves up and down as water strikes a drive vane 34 fixed to a remote end of the arm. The drive arm 32 is constructed such that the water, as it leaves the drive vane, causes the drive arm to pivot about a horizontal axis defined by drive arm shaft 36 fixed to the sprinkler body 38 . The sprinkler body 38 , and hence nozzle 30 , also rotate about a vertical axis in the form of a lower bearing unit (or simply lower bearing) 40 , which, in turn, is mounted to the cart 12 via a mounting flange 42 .
[0031] FIG. 4 is a close-up of the lower bearing unit 40 , showing a trip lever 44 and associated arc adjustment components of the sprinkler 16 described further herein. FIGS. 5-8 illustrate reversal of direction sequence of the sprinkler. For ease of understanding, the description of the structure of the various arc adjustment components is tied to their function in use. As already noted, as the water exits the nozzle 30 at pressure, the drive arm 32 swings upwardly about the shaft 36 and contacts the water stream, a portion of which is deflected (see FIG. 5 ) by the drive vane 34 causing the sprinkler to rotate in a clockwise direction about the lower bearing 40 . The trip lever 44 is mounted to the sprinkler body 38 and thus rotates with the sprinkler body, but the lever is also free to pivot about the rod or pin 45 (which forms a pivot axis for the lever) on which it is seated. As the sprinkler rotates in the clockwise direction, a trip lever roller 46 mounted to the lower end of the lever 44 will contact a trip face 48 of a clockwise stop 50 . The water will continue driving the sprinkler in a clockwise direction causing the trip lever 44 to rotate about the trip lever pivoting axis 45 in a counterclockwise direction. At an over-center point, an over-center “spring” 52 pivotally attached to a shift lever 56 via pin 53 , as well as to the trip lever 44 via pin 55 , will shift to the other side of a stop bracket 54 (compare FIGS. 6 and 7 ), rotating the shift lever 56 in a counterclockwise direction about a shift lever pivot axis or bushing 57 that is integrated with a bushing 59 that receives the drive arm shaft 36 . Thus, the counterclockwise rotation of the shift lever also causes counterclockwise rotation of the drive arm (compare FIGS. 5 and 7 ). Now the water stream impinges on the other side of the vane 34 , causing the sprinkler 16 to rotate in a counterclockwise direction as shown in FIG. 7 until the trip lever roller 46 contacts a counterclockwise stop 58 , reversing the sprinkler direction through reverse action of the components as described above. The direction-reversal mechanism per se as described above is known in the art.
[0032] With reference now to FIGS. 9-12 (but with continuing reference to FIGS. 5-8 ), the pattern or arc adjustment stops 50 and 58 are positioned in FIGS. 8-11 to provide a 180-degree arc of coverage about an arc “A” ( FIG. 9 ). The arc adjustment mechanism includes a base plate 60 secured to the lower end of the sprinkler, e.g., to the mounting flange 42 . A countdown timer 62 is electrically connected to two latching, three-way solenoids 64 and 66 . The electrical components 62 , 64 and 66 may be mounted on the base plate 60 or on any convenient support on the sprinkler cart 12 . As shown, solenoid 64 is normally open and effects the 180-degree arc, while solenoid 66 , normally closed, is used to effect the 270-degree arc. The solenoids are connected to a double-acting cylinder 68 , also mounted on the base plate 60 . As explained in greater detail below, in “position one” (for a 180-degree arc) the cylinder piston 70 is retracted, and in “position two” (for a 270 degree arc) the cylinder piston 70 is extended. The cylinder 68 is mounted to the base plate 60 by a cylinder mounting bracket 71 , or any other suitable securement mechanism.
[0033] The piston 70 of the cylinder 68 is attached to a linearly movable rack 72 which drives a drive gear 74 ( FIG. 10 ) about a shaft (or axis) 76 secured to the base plate 60 . The drive gear 74 is attached to a larger diameter multiplier gear 78 , also secured to the base plate. This gear assembly, when driven, rotates an arc adjustment plate/gear housing 80 (also referred to herein as the “arc adjustment plate”, or, simply, “the plate”) via engagement with a gear component 82 of the housing 80 , best seen in FIG. 12 , and as described in further detail below.
[0034] As best seen in FIGS. 9 and 10 , the clockwise stop 50 is fixed in the clockwise stop adjustment groove 84 formed in the plate 80 . This groove, extending only about 45 degrees, allows for fine field adjustment of the clockwise sprinkler rotation for the initial 180-degree operation. The counterclockwise stop 58 floats in the counterclockwise stop adjustment groove 86 , also formed in the plate 80 , and is free to move around the centerline axis of the arc adjustment plate, as permitted by the groove 86 , and as limited by external stop posts described below. Thus, the stop 58 is constrained by a first stop post 88 for 180-degree movement (post 88 is adjustably attached to the base plate 60 via groove 89 ), and a 180-degree stop spring 90 which is attached to the arc adjustment plate 80 . In this regard, a stop pin 92 projects from the stop 58 such that it will engage the stop post 88 during counterclockwise rotation of the plate 80 (i.e., when the arc is reset to 180 degrees from 270 degrees), and is then held against the post by the counterclockwise compression spring 90 .
[0035] After a time value entered in the timer 62 has expired, the solenoid 66 will open, causing the piston 70 to move from retracted position one to extended position two as shown in FIG. 13 . During extension of the piston 70 , the rack 72 rotates the drive gear 74 and multiplier gear 78 which, in turn, rotates the plate 80 via gear component 82 (seen more clearly in FIG. 12 , and which could be in the form of a simple chain wrapped about the lower housing portion of the plate 80 ) through 225 degrees, thus placing the stops 50 and 58 in their final positions for 270 degrees of sprinkler rotation. More specifically, and with additional reference to FIGS. 14 and 15 , as the arc adjustment plate 80 rotates from its FIG. 9 position, i.e., position one, the counterclockwise stop 58 also rotates through approximately 135 degrees until the stop pin 92 contacts a second stop post 96 . Post 96 is also adjustable within a groove 97 and is attached to the base plate 60 . The post 96 “holds” the clockwise stop 58 in this rotational location while the plate 80 continues to rotate. The counterclockwise stop 58 thus “floats” in the counterclockwise stop adjustment groove 86 as the arc adjustment plate 80 continues its rotation through the full 225 degrees. The clockwise rotation of the plate 80 ends with full extension of the piston 70 , prior to when the stop 58 would otherwise be engaged by the end of the groove 86 . Note that the groove 86 may itself extend about 160 degrees, with two adjustable rubber (or similar) stops attached to plate 80 and located within the grove 86 , thus defining the rotation limits of the stop 58 relative to the plate 80 . These rubber or similar stops simply serve to protect the plate by preventing engagement of the stop with the ends of the groove 86 .
[0036] Note that the stop pin 92 will be pressed against the post 96 by the clockwise compression spring 94 as the plate 80 and spring 90 continue rotation relative to the now stationary stop 58 and pin 92 . At the same time, stop 50 has also been rotated to the position shown in FIG. 14 , so that the sprinkler is now rotatable through a 270-degree arc “B” ( FIG. 15 ), generally between the arrowheads 98 , 100 on the stops 50 , 58 , respectively. While the springs 90 and 94 are arranged to compress upon engagement of pin 92 with posts 88 or 96 (and thus push the pin 92 against the posts 88 and 96 ), depending on the direction of rotation of the plate 80 , it will be appreciated that similar springs could be relocated to extend in tension so as to pull the pin 92 into engagement with posts 88 and 96 without departing from the scope of this invention.
[0037] As noted above, rotation of the arc adjustment plate 80 is initiated by the timer 62 and associated solenoids 64 , 66 that control movement of the piston 70 between retracted and extended positions. The timer 62 is set to cause the piston to extend when the set time period has expired. The time value input to the timer 62 is based on field conditions and cart movement such that sufficient time is allotted to allow the sprinkler cart to move a distance away from the end boundary 18 which will permit a 270-degree arc of coverage that does not project beyond the end boundary 18 behind the sprinkler (see FIGS. 1 and 2 ).
[0038] In a subsequent cycle, retraction of the piston 70 will rotate the plate 80 , along with stops 50 and 58 to the first position shown in FIGS. 9-11 for a 180-degree pattern.
[0039] Note that a projection 102 on the sprinkler head will engage upstanding tabs 104 , 106 , on the stops 50 , 58 , respectively, insuring that the sprinkler head rotation is confined to arcuate movement between the stops 50 and 58 . It should also be noted that adjustment of the stops 50 and 58 does no harm to the direction reversal mechanism. The sprinkler head necessarily rotates during the change from a 180-degree arc to a 270-degree arc, such that the trip lever will be engaged by the stop 50 and will cause the over-center spring 52 to shift as described above in connection with FIGS. 6 and 7 . Absent water under pressure flowing through the sprinkler head, this shift is of no consequence.
[0040] While the invention has been described in connection with what is presently considered to be the most practical and preferred embodiment, it is to be understood that the invention is not to be limited to the disclosed embodiment, but on the contrary, is intended to cover various modifications and equivalent arrangements included within the spirit and scope of the appended claims. | An adjustable sprinkler including: a sprinkler head having a bearing mounted on a support, the sprinkler head rotatable on the bearing about a vertical axis; an arc adjustment plate mounted on the support for rotation about the axis relative to the support and to the bearing; first and second stops supported on the plate for arcuate movement about the axis, at least one of the stops movable relative to the plate, wherein the first and second stops define limits of rotational movement of the sprinkler head about the axis; and a fluid actuator for moving one of the stops relative to the other of the stops for varying the limits of rotational movement of the sprinkler head. | 1 |
FIELD OF THE INVENTION
[0001] The invention relates to a domestic appliance, provided with a surface layer comprising an antimicrobial agent. The invention in particular relates to an iron, a soleplate, a steam ironing device, and a method of manufacturing an iron and a method of manufacturing a soleplate.
BACKGROUND OF THE INVENTION
[0002] Domestic appliances such as grills, (rice) cookers, pots and (frying) pans, hair rollers, hair straighteners, irons and the like increasingly have to meet higher hygienic demands. For this reason, domestic appliances are provided with antimicrobial properties. For instance, an iron provided with antimicrobial properties is known from WO 2008/044166A1. WO 2008/044166A1 discloses an iron comprising a soleplate having means for accommodating an antimicrobial agent. The soleplate contacts a garment during ironing through its garment-contact surface. The garment-contact surface of the iron of WO 2008/044166A1 is arranged for transferring the antimicrobial agent to a piece of garment during ironing thereof. By contacting the garment-contact surface with the piece of garment, as is being done during ironing, the antibacterial agent is automatically transferred to the garment. This prevents having to provide antimicrobial agent by separate means, such as by adding it to a water feed tank of the iron.
[0003] Although the anti-microbial soleplate of WO 2008/044166A1 is quite satisfactory, its functioning is based on the easy transfer of antimicrobial agent to a garment. When appliances such as an iron are not in use or being stored after use however, growth of microbes on the surface of the appliances may happen, which can lead to foul or unpleasant odours and formation of bio-films. In some cases, the attached microbes may even degrade or corrode the surface material. Since the known iron transfers antimicrobial agent onto garments, the soleplate surface thereof may lose its antimicrobial protection in time.
SUMMARY OF THE INVENTION
[0004] It is an object of the present invention to provide an appliance, such as an iron, that is capable of retaining its antimicrobial activity for a prolonged usage period, in particular for a period extending 100 hours of use at elevated temperature and/or humidity, as is typically encountered in steam irons, pots and pans, and other domestic appliances.
[0005] This and other objects are achieved by an appliance according to claim 1 . An appliance according to the invention is provided with a surface layer comprising an antimicrobial agent associated with a carrier, wherein the carrier is inorganic and selected such that the antimicrobial activity of the surface layer according to JIS Z2801:2000 has a value of at least 2 after 100 hours of continuous use at a temperature of at least 230° C. The inventors have found out that by providing a surface layer comprising an antimicrobial agent associated with an inorganic carrier, certain carriers in particular provide the desired combination of a minimal release of the antimicrobial agent for a prolonged usage period at elevated temperature. Providing antimicrobial activity for at least 100 hours in continuous use at temperatures in the range of 210 to 230° C. and higher, and in moist and abrasive conditions, is unprecedented in the art. The temperature at which the antimicrobial activity of the surface layer is measured is stipulated in the JIS Z2801:2000 norm, and is generally room temperature.
[0006] A preferred embodiment of the appliance according to the invention comprises a carrier, selected such that the antimicrobial activity of the surface layer according to JIS Z2801:2000 has a value of at least 2 after 100 hours of continuous use at a temperature of at least 240° C., more preferred at least 250° C., and most preferred at least 260° C.
[0007] In another preferred embodiment of the appliance according to the invention, the carrier is selected such that the antimicrobial activity of the surface layer according to JIS Z2801:2000 has a value of at least 3 after 100 hours of continuous use at a temperature of at least 230° C., more preferably a value of at least 4, even more preferably a value of at least 5, and most preferably a value of at least 6.
[0008] Preferably, to produce antimicrobial coating layers which are able to withstand at least 100 hours in continuous use at temperatures exceeding 230° C. and preferably are also non-yellowing, whereby the coordinate b* of CIELAB color space is smaller than 3.5, the coating is cured at a temperature ranging from about 250° C. to about 450° C.
[0009] The antimicrobial agent has antimicrobial properties, which means that it kills, or slows the growth of, microbes like bacteria (antibacterial activity) and/or fungi (antifungal activity for instance against fungi known as mold).
[0010] The appliance according to the invention preferably comprises an iron or a soleplate thereof. After ironing using an iron according to the invention, the ironed surface of the piece of garment may be provided with a small quantity of the antimicrobial agent. By ironing a piece of garment with the iron according to the invention the resistance against bacteria, fungi and the like may be enhanced. According to the invention, sufficient antibacterial agent remains in the surface layer of the appliance during use, thereby offering antibacterial protection to the appliance for a prolonged usage period.
[0011] The soleplate of an iron is usually heated by an electric heating element. The temperature of the soleplate is usually kept at a desired value by means of a thermostat and a temperature dial. The number of dots on the temperature dial indicates the temperature of the soleplate's surface, which typically corresponds to, for a 1 dot setting (the Low setting on most irons) on average 110° C., for a 2 dot setting (the Medium setting on most irons) on average 150° C., and for a 3 dot setting (the High setting on most irons) on average 200° C.
[0012] The appliance, and in particular the iron according to the invention may be used at any point in the temperature range provided by the appliance, whereby the temperature of the surface of the appliance may occasionally be as high as 260° C., and even more. Especially for an iron, the soleplate thereof is moreover subject to high abrasive forces during ironing. Indeed, the fibers of a garment tend to abrade the surface of a soleplate, in particular at the typical temperatures and moisture levels encountered when ironing.
[0013] A preferred embodiment of the appliance according to the invention comprises a carrier selected such that the antimicrobial agent does not show visible degradation after exposure to a temperature of at least 230° C. for at least 100 hours, more preferred at least 240° C., even more preferred at least 250° C. and most preferred at least 260° C.
[0014] Preferably the appliance according to the invention is characterized in that the antimicrobial agent is selected from the group of antimicrobial metal ions, and even more preferred from the group comprising ions of silver, zinc, copper, selenium, platinum or a combination thereof. Antimicrobial metal ions are metal ions having antimicrobial properties and when accommodated in the iron known from WO 2008/044166A1 show no degradation after exposure to a temperature of 250° C. for at least 4 hours. An additional advantage of the present invention is that the purposive selection of carriers provides an increased temperature stability to the antimicrobial agent, and the metal ions in particular, beyond what was known hitherto. The absence of appreciable degradation can easily be observed by visual inspection in that yellowing of the surface layer does not occur to any appreciable extent within the indicated time frame and temperature of exposure.
[0015] During storage of the iron, bacteria start to grow. An iron according to the invention, stays fresher for a longer period of time than known hitherto. The ironing soleplate itself tends to be cleaner and show a reduced growth of bacteria/fungi on its surface for a longer period of time than known hitherto.
[0016] In order to further improve the long lasting antimicrobial activity of an appliance according to the invention, the appliance may be made from a material, preferably aluminum, aluminum alloy or stainless steel, comprising metal ions of silver, copper, zinc, platinum or selenium or a combination thereof. In a practical embodiment, metal particles such as silver, copper or zinc particles or a combination thereof are incorporated in the appliance material itself. When these metal particles are exposed to oxygen, as is present in the air, conversion of metal to metal oxide occurs spontaneously at the surface of these particles, resulting in the presence of antimicrobial metal ions (in this case silver, copper or zinc ions or a combination thereof) in the appliance.
[0017] Conversion of Ag to Ag 2 O occurs spontaneously when Ag is exposed to oxygen present in the air. This conversion occurs slowly. Increasing the temperature increases the speed at which the conversion of the metal to the metal oxide occurs. The typical ironing temperatures are thus very suitable for generating an Ag to Ag 2 O conversion and hence for generating Ag+ ions. However, this may also result in degradation and yellowing of the appliance material. The purposively selected carriers according to the invention at least retard such degradation.
[0018] It has turned out that an appliance according to a preferred embodiment comprises a carrier selected from the group consisting of a phosphate and a soluble silicate. These carriers in particular have shown to yield the desired combination of slow and/or very limited release of antimicrobial agent and prolonged appliance protection. The preferred carrier associated with the antimicrobial agent, and a silver ion in particular, is one which protects the antimicrobial agent from discoloration when exposed to heat, humidity and/or light. In one particular preferred embodiment, the antimicrobial agent carrier is a zirconium phosphate, such as but not limited to Alphasan® RC 2000 (Milliken and Co., Spartanburg, S.C.). In another preferred embodiment, the antimicrobial agent carrier is a soluble silicate, preferably one that is soluble in water, such as, but not limited to, IonPure® IZA<40 μm, and more preferably IonPure® IZA<10 μm (Ishizuka Glass Co., Naguya, Japan). The soluble silicate may be a glass powder, such as sodium silicate, but may also be another form of silicate such as, but not limited to, a potassium silicate. In some embodiments, the soluble silicate is soluble in an aqueous environment. The antimicrobial agent may be associated with the carrier by one or more of many well-known physical and chemical means. In some embodiments, the association of the silver with the carrier is by ionic bonds, covalent bonds, and/or physical sequestration. The inventors have also found that carriers such as a zeolite do not have the desired structure and therefore do not yield the desired results. A zeolite carrier therefore is not preferred, and is preferably excluded from the group of suitable carriers.
[0019] It has also turned out that the amount of antimicrobial agent in the surface layer of the appliance according to the invention is not particularly critical. However, a particularly preferred embodiment has a surface layer comprising a phosphate and at least 0.05 vol.-% of antimicrobial agent, more preferred at least 0.10 vol.-%, and most preferred at least 0.15 vol.-% of antimicrobial agent.
[0020] In another particularly preferred embodiment, the appliance according to the invention has a surface layer comprising a soluble silicate and at most 0.10 vol.-% of antimicrobial agent, more preferably at most 0.05 vol.-%, and most preferably at most 0.02 vol.-% of antimicrobial agent. The antimicrobial agent may be present as particles, the particles preferably having an average size in the range of 1 nm-100 μm, more preferably in the range of 1-30 μm, and most preferably in the range of 5-15 μm.
[0021] According to the invention, the appliance comprises a surface layer having an antimicrobial agent. In an embodiment, the appliance is provided with the surface layer comprising the antimicrobial agent. Layers having a thickness in a range of 0.5-250 μm have been found suitable.
[0022] Alternatively, the layer comprises a thermoplastic polymer, a sol-gel or an enamel material comprising the antimicrobial agent, a sol-gel material being the preferred material.
[0023] Suitable thermoplastic polymers are thermally stable polymers such as silicones, polyimides, polyamide imide, polyether amide, polyether sulfone, polyether ether ketone, polyphenyl sulfide polysulfone and polytetra fluoro ethylene. The layer may be a sol-gel coating comprising the antimicrobial agent and having a thickness in the range of 5-100 μm.
[0024] The invention also relates to a steam ironing device. The steam ironing device according to the invention comprises a steam-generating means and an iron according to the invention, i.e. provided with a surface layer comprising an antimicrobial agent associated with a carrier, wherein the carrier is inorganic and selected such that the antimicrobial activity of the surface layer according to JIS Z2801:2000 has a value of at least 2 after 100 hours of continuous use at a temperature of at least 230° C., wherein the soleplate comprises at least one opening and the steam-generating means is arranged for delivering steam to the opening.
[0025] In a conventional steam iron, steam is generated by a steam generating means, which comprises a water reservoir and a steam chamber. Usually, a water-dosing pump is provided to pump the water from the water reservoir to the steam chamber (as drops rather than a large flow of water). The water may be pumped via a hose under command of a pump signal from an electric control device. The rate at which water is supplied dictates the amount of steam being produced, and the amount of steam is sufficiently small that the temperature of the sole plate is not significantly affected. Instead of a pumped system, water can be dosed to the steam chamber under gravity.
[0026] The steam chamber is typically heated by the sole plate, but an auxiliary heating element may instead be provided. The steam from the steam chamber reaches a steam outlet opening or openings provided in the sole plate of the iron. While being ironed using the steam function on the iron, the garment surface is moistened by the steam and contacted by the garment-contact surface comprising the antimicrobial agent of the iron at the same time.
[0027] The steam ironing device as such is well-known in practice. The steam ironing device may be a steam iron or a so-called boiler ironing system. The boiler ironing system comprises a steam iron having a soleplate with a soleplate surface and a boiler for heating water which is arranged separately from the steam iron, wherein the water tank is attached to a stand comprising the boiler. In many cases, the water tank is removably arranged, so that a user of the device comprising the water tank is capable of taking the water tank to a tap or the like in order to fill the water tank, without having to move the entire device.
[0028] In an embodiment of the steam ironing device according to the invention, the steam generating means comprises a steam chamber.
[0029] In another embodiment of the steam ironing device according to the invention, the steam generating means comprises a boiler. The steam generating means may be housed by an ironing board.
[0030] The invention also relates to a method of manufacturing an appliance according to the invention. The invented method comprising preparing a layer material containing a suitable amount of antimicrobial agent and carrier associated therewith, the carrier being selected such that the antimicrobial activity of the surface layer according to JIS Z2801:2000 has a value of at least 2 after 100 hours in continuous use at a temperature of at least 230° C., more preferably at least 240° C., even more preferably at least 250° C., and most preferably at least 260° C., and providing the layer material onto a surface of the appliance. In another preferred method the carrier is selected such that the antimicrobial activity of the surface layer according to JIS Z2801:2000 has a value of at least 3 after 100 hours of continuous use at a temperature of at least 230° C., more preferably a value of at least 4, even more preferably a value of at least 5, and most preferably a value of at least 6.
[0031] A way to execute one of the methods according to the invention as described above is to apply a polymer layer comprising the antimicrobial agent to the soleplate. More preferred is to apply a sol-gel coating and/or enamel coating comprising the antimicrobial agent to the soleplate and cure the soleplate thus obtained. Both coatings in particular are wear resistant and provide a long-lasting antimicrobial effect. Applying a sol-gel coating as such is known per se, but for the manufacture of an appliance according to the invention, and a soleplate in particular, a very suitable method comprises the steps of providing a sol-gel solution, spraying the sol-gel solution onto the surface of the appliance, drying the sol-gel layer thus obtained, for instance by heating the appliance at least partially, such that solvent for instance is evaporated and a gel network results, and finally curing the gel by additional heating. Drying and subsequent curing may be combined in one curing step. The antimicrobial agent is generally admixed to the sol-gel solution before applying it to the surface of the appliance.
[0032] Although it is possible to apply a sol-gel solution to the surface of the appliance and on top of that apply antimicrobial agent e.g. by spraying a solution comprising the antimicrobial agent, this method is not preferred, since the long-lasting effect may not occur to the desired extent.
[0033] The invention also includes any possible combination of features or subject matter as claimed in any one of the claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0034] The invention will now be described, by way of example, with reference to the accompanying drawings. In principle, aspects can be combined.
[0035] FIG. 1 schematically depicts an embodiment of an iron according to the invention.
[0036] FIG. 2 schematically depicts an embodiment of a steam ironing device according to the invention.
[0037] FIG. 3 schematically depicts another embodiment of the steam ironing device according to the invention.
DETAILED DESCRIPTION OF THE EMBODIMENTS
[0038] In FIG. 1 a preferred embodiment of the iron according to the invention is schematically depicted. The iron 10 comprises a soleplate 13 provided with an antimicrobial layer 17 comprising an antimicrobial agent. The layer 17 has a garment-contact surface 15 . The iron further comprises a means for supplying water to the fabric to be ironed. This water-supply means comprises a depressable water trigger 19 and a water sprayer 18 connected to a water reservoir (not shown).
[0039] In FIG. 2 an embodiment of the steam ironing device according to the invention is schematically depicted. This device is provided with a steam iron 40 comprising a soleplate 42 provided with a layer 43 comprising an antimicrobial agent and having the steam outlet opening 47 . The layer 43 comprises the garment-contact surface 45 . The steam iron 40 further comprises a means for generating steam. The steam generating means comprises a steam chamber 49 and a water reservoir (not shown). The steam-generating means is arranged for providing steam via the opening 47 to the piece of garment to be ironed. A water sprayer (not shown) may be provided to moisten the garment.
[0040] In FIG. 3 another embodiment of the steam ironing device according to the invention is depicted. The steam ironing device 50 in this embodiment is the so-called boiler ironing system. In such a system a steam-generating means 59 comprises a boiler 332 for heating water, which is arranged separately from a steam iron 51 according to the invention, and a water tank 334 . The boiler 332 comprises a heating plate 338 connected to a heating element 340 . An electro valve 350 is arranged that opens to let steam pass via a steam delivery hose 352 to the iron 51 . The boiler usually further comprises a pressure sensor 342 to measure the pressure inside the boiler, a water-level sensor 344 and a safety valve 346 that opens if the pressure inside the boiler 332 is too high, i.e. above a certain set value. To fill the boiler, water is pumped by a water pump 336 from the water tank 334 to the boiler 332 . A de-airing valve 348 may be present to let air out of the water.
[0041] The steam ironing device 50 comprises the iron 51 according to the invention having a soleplate 52 . An antimicrobial layer 53 according to the invention is provided onto the sole plate 52 of the iron 51 . The antimicrobial layer 53 comprises a garment-contact surface 55 . The sole plate 52 of the iron comprises a steam-outlet opening 57 .
[0042] To illustrate the effect of the purposively selected carrier/antimicrobial agent combination, the following examples are given hereinafter.
Example 1
[0043] In a reaction vessel 5.5 g of maleic acid was dissolved in 380 g of LudoxAS40, a colloidal silica 40 wt. % suspension in water. An amount of 0.95 g of methyltrimethoxysilane (MTMS) was then added and the mixture was stirred for 45 minutes. Subsequently, 391 g of MTMS was stirred into the acidified silica sol. Sixty minutes later the mixture was diluted with 196 g of water before the gradual addition of 315 g of 30% polytetrafluoroethylene (PTFE) dispersion in water stabilized with a polysiloxane polyoxyalkylene copolymer (SIL WET L77) together with a suitable defoaming agent. After the addition of the PTFE had been completed, 30 g of a mica-based pigment was added followed by 12 g of Ionpure IZA (particle size <10 μm), a soluble phosphate glass.
[0044] Coatings were sprayed on previously dried sol-gel layers applied on anodized aluminium plates and cured at 300° C. The amount of Ionpure IZA particles in the cured coating was approximately 1.7% by volume (the amount of Ag being approximately 0.01% by volume).
Example 2
[0045] In a reaction vessel 5.5 g of maleic acid was dissolved in 380 g of LudoxAS40. An amount of 0.95 g of MTMS was then added and the mixture was stirred for 45 minutes. Subsequently 391 g of MTMS was stirred into the acidified silica sol. 60 minutes later the mixture was diluted with 196 g of water before the gradual addition of 315 g of 30% PTFE dispersion in water stabilized with SIL WET L77 together with a suitable defoaming agent. After the addition of the PTFE had been completed, 30 g of a mica-based pigment was added followed by 46 g of AlphaSan RC2000, a zirconium phosphate.
[0046] Coatings were sprayed on previously dried sol-gel layers applied on anodized aluminum plates and cured at 300° C. The amount of AlphaSan RC2000 particles in the cured coating was approximately 6.0% by volume (the amount of Ag was approximately 0.17% by volume).
Comparative Experiment A
[0047] In a reaction vessel 5.5 g of maleic acid was dissolved in 380 g of LudoxAS40. An amount of 0.95 g of MTMS was then added and the mixture was stirred for 45 minutes. Subsequently 391 g of MTMS was stirred into the acidified silica sol. 60 minutes later the mixture was diluted with 196 g of water before the gradual addition of 315 g of 30% PTFE dispersion in water stabilized with SIL WET L77 together with a suitable defoaming agent. After the addition of the PTFE had been completed, 30 g of a mica-based pigment was added followed by 11.8 g of AlphaSan RC2000, a zirconium phosphate.
[0048] Coatings were sprayed on previously dried sol-gel layers applied on anodized aluminum plates and cured at 300° C. The amount of AlphaSan RC2000 particles in the cured coating was approximately 1.5% by volume (the amount of Ag was approximately 0.04% by volume).
Comparative Experiment B
[0049] In a reaction vessel 5.5 g of maleic acid was dissolved in 380 g of LudoxAS40. An amount of 0.95 g of MTMS was then added and the mixture was stirred for 45 minutes. Subsequently 391 g of MTMS was stirred into the acidified silica sol. 60 minutes later the mixture was diluted with 196 g of water before the gradual addition of 315 g of 30% PTFE dispersion in water stabilized with SIL WET L77 together with a suitable defoaming agent. After the addition of the PTFE had been completed, 30 g of a mica-based pigment was added followed by 3.0 g of AlphaSan RC2000, a zirconium phosphate.
[0050] Coatings were sprayed on previously dried sol-gel layers applied on anodized aluminum plates and cured at 300° C. The amount of AlphaSan RC2000 particles in the cured coating was approximately 0.37% by volume (the amount of Ag was approximately 0.01% by volume).
Comparative Experiment C
[0051] In a reaction vessel 5.5 g of maleic acid was dissolved in 380 g of LudoxAS40. An amount of 0.95 g of MTMS was then added and the mixture was stirred for 45 minutes. Subsequently 391 g of MTMS was stirred into the acidified silica sol. 60 minutes later the mixture was diluted with 196 g of water before the gradual addition of 315 g of 30% PTFE dispersion in water stabilized with SIL WET L77 together with a suitable defoaming agent. After the addition of the PTFE had been completed, 30 g of a mica-based pigment was added followed by 2.5 g of AgIon® (WAJ), a zeolite based slurry with 20 wt % solid containing Ag + . Coatings were sprayed on previously dried sol-gel layers applied on anodized aluminum plates and cured at 300° C. The amount of AgIon® particles in the cured coating was approximately 0.3% by volume.
[0052] The anti-microbial activity of the produced surface coating layers was measured by quantifying the survival of bacterial cells which have been held in intimate contact for 24 hours at 35° C. with the surface of the surface layer. The anti-microbial effect is measured by comparing the survival of bacteria on a treated material with that achieved on an untreated material. The anti-microbial tests were carried out according to Japan Industrial Standard (JIS), JIS Z 2801: 2000 “Antimicrobial products—Tests for antimicrobial activity and efficacy”.
[0053] The results obtained are summarized in Table 1 below.
[0000]
TABLE 1
Anti-microbial activity of coating layers
Value of Anti-microbial Activity{circumflex over ( )}
(JIS Z2801: 2000)
Coating after 100 h of continuous
Example/Comparative
Coating
wearing on fabric under steam
Experiment
at 0 h
condition and 2 kg load
Example 1: IonPure IZA
5.2
>6.0
(Ag 0.01 vol %)
Example 2: Alphasan RC
4.9
>6.0
2000
(Ag 0.17 vol %)
Comp. Exp. A: Alphasan
5.3
0.3
RC 2000
(Ag 0.04 vol %)
Comp. Exp. B: Alphasan
2.5
0.5
RC 2000
(Ag 0.01 vol %)
Comp. Exp. C: Zeolite
>6.0
0.3
AgION ® WAJ slurry
(Ag 0.06 vol %)*
*Lumps formation (incompatibility) observed, higher loading not feasible.
{circumflex over ( )}This is the log reduction of the living bacteria population on the treated sample and that on the control surface. It should be not less than 2.0 for antibacterial finish, i.e. over 99% of the micro-organisms must be killed in excess to the untreated material or article.
[0054] The release mechanisms of silver ions and its concentration in the coating influence the ability for the anti-microbial function to be wear resistant. As shown in Table 1, the preferred concentration of soluble glass additives such as IonPure IZA is low (as low as 0.01% by Ag volume in coating) to maintain its anti-microbial function for more than 100 hours of wearing. The preferred concentration however of additives that release silver ions by ion exchange, such as Alphasan RC 2000, is higher. Indeed Alphasan RC 2000 shows a relatively poor anti-microbial function after 100 hours of wearing if the amount of additive is too low (lower than 0.1% by Ag volume in coating). For such additive, a long lasting anti-microbial function is preferably achieved with a higher loading (higher than 0.1% by Ag volume in coating).
[0055] A coating according to the disclosure of WO 2008/044166A1 shows a very poor anti-microbial function after 100 hours of wearing, as is clear from the results of Comparative Experiment C. Higher loadings of AgION (WAJ) result in incompatibility with the coating.
[0056] The present invention offers a unique wear resistant inorganic coating with anti-microbial agent incorporated. This coating retains excellent anti-microbial properties for at least 100 hours of mechanical wearing, without discoloration or yellowing.
[0057] The coating has anti-microbial function on bacteria like Staphylococcus aureus and Escherichia Coli . For example, using the coating on a soleplate of a steam iron, it has excellent wear resistance and has a long lasting anti-microbial effect upon continuous use at 230° C. at least. It is crack-free with a layer thickness of 10-40 μm being preferred. The coating does not show any visible color change after 600 cycles of heating with steam and cooling process. Scratch resistance of the coatings according to the invention is excellent. | The invention relates to a domestic appliance, such as an iron, provided with a surface layer. The surface layer comprises an antimicrobial agent associated with a carrier, the carrier being inorganic and selected such that the antimicrobial activity of the surface layer according to JIS Z2801:2000 has a value of at least 2 after 100 hours of continuous use at a temperature of at least 230° C. In a preferred embodiment, the carrier is selected from the group consisting of a phosphate and a soluble silicate, while the antimicrobial agent is preferably selected from a group comprising ions of silver, zinc, copper, selenium, platinum or a combination thereof. The appliance stays fresher for a longer period of time than known hitherto. The invention further relates to an iron, a steam ironing device and a method of manufacturing the appliance. | 3 |
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application claims the benefit of Great Britain provisional application no. GB1416475.0 titled, “Impeller Cavitation System,” filed on Sep. 17, 2014.
FIELD
[0002] This invention relates to the field of law enforcement and more particularly to a system for creating floating security barriers against vessels propelled by water jet or impeller drives.
BACKGROUND
[0003] There exists a need for law enforcement to be able to stop watercraft for boarding, inspection, and possible arrests and confiscation of contraband. In many jurisdictions, probable cause is not sufficient reason for opening fire on a watercraft and/or an operator of that watercraft. Often, well equipped law enforcement watercrafts are able to go faster than a suspect's watercraft, but without firing of a weapon, it is difficult to force the suspect to slow down and stop for boarding. The issue is further complicated by potential risk to the public should the suspect lose consciousness and the watercraft continues to move as well as the environmental concerns should fluids escape from the watercraft after being shot.
[0004] Certain vessels can be stopped by use of prop entanglement systems such as US Coast Guard SNARE as described in U.S. Pat. No. 8,402,894 or US Coast Guard RGES as described in U.S. Pat. No. 7,975,639. Some law enforcement agencies run alongside the suspect's watercraft and shoot the engines of such vessels with specially designed rounds of ammunition that are designed to disable the engine of a vessel. These existing systems and techniques do not work on small personal watercraft such as jet skis with jet drives consisting of an impeller in a tubular housing. Any watercraft lacking an exposed propeller is unaffected by running over existing entanglement systems. Furthermore, in many such watercrafts, the engine is located close to the driver or possibly between the driver's legs making it impossible to shoot at the engine without risking life and limb of the driver or any passengers. There are situations where the operator is unconscious or otherwise incapacitated and the watercraft needs to be stopped without hurting the operator.
[0005] With respect to maritime and riverine law enforcement, there exists a problem in not being able to stop certain classes of watercraft such as small personal watercraft, often referred to as jet skis.
[0006] What is needed is a system that will stop or slow watercraft that utilize internal impellers for propulsion.
SUMMARY
[0007] One aspect of the present invention provides a floating submunition that, after being sucked into the inlet of a jet drive and hit by the impeller, causes the impeller to cavitate. The submunition is hit by the advancing impeller blade, deforms around the leading edge of the impeller blade and creates cavitation as it is swept around the jet drive unit.
[0008] In order to be sucked into the inlet of the jet drive, the submunition is designed to float, preferably in a vertically orientation. The submunition includes a buoyant body and a weight at one end to maintain an upright posture.
[0009] In some embodiments, multiple submunitions are placed in a cartridge that is fired in advance of the suspect's watercraft, for example, by a pneumatic launcher, a rocket, firearm, or a spigot mortar, sending the multiple submunitions into the water in front of the suspect's watercraft so that one or more of the submunitions are sucked into the inlet of the jet drive of the suspect's watercraft.
[0010] In some embodiments, the buoyant portion of the submunitions is made of closed cell foam or other highly buoyant material, or, in some embodiments, the buoyant portion is a sealed container or tube having a gas or air within the container to provide buoyancy.
[0011] In some embodiments, multiple submunitions are placed in a grenade or bomb that is detonated in advance of the suspect's watercraft. In some embodiments, the submunitions are deployed using a sabot that opens once the round has left the barrel of the launcher.
[0012] In some embodiments, the materials used to produce the submunitions are selected to biodegrade over relatively short time periods.
[0013] In one embodiment, the submunition consists of a buoyant float with a weight at one end and a retaining element such a disc at the other end. A cord, line or wire runs through the buoyant float, joining the weight and the retaining element. It is anticipated that the weight be metal or ceramic with a central hole through which the cord/line/wire runs and is attached.
[0014] In some embodiments, the submunitions are between 0.25 inches and 1.5 inches in diameter to facilitate passing through input grates of target watercraft. In some embodiments, the submunitions are less than 1.0 inch in diameter to facilitate passing through input grates of target watercraft. In some embodiments, the submunitions are less than 4.0 inches long to facilitate passing through input grates of target watercraft.
[0015] In some embodiments, the submunitions are provided with a range or mix of diameters and lengths to facilitate passing through input grates of target watercraft.
[0016] In some embodiments, the submunitions have a proportion of their length above the water when floating vertically, and in some such embodiments between one tenth and one third of the submunitions length is above the water when floating vertically, assuming distilled water.
[0017] In one embodiment, a submunition is disclosed including a buoyant member, a first end cap and a second end cap. A lanyard (or other connecting member) connects the first end cap to the second end cap, in some examples, passing through the buoyant member. The second end cap is heavier than the first end cap promoting an upright orientation when suspended in a fluid such as water.
[0018] In another embodiment, a method of stopping an impeller-driven watercraft is disclosed including distributing a plurality of submunitions in advance of a path of the impeller-driven watercraft, each of the submunitions includes a buoyant member, a first end cap, and a second end cap; the second end cap is heavier than the first end cap. A lanyard (or other connecting member) connects the first end cap to the second end cap. At least one of the submunitions enters an intake vent of the impeller-driven watercraft and attaches to a blade of an impeller of the impeller-driven watercraft, causing cavitation and imbalance, thereby slowing the impeller-driven watercraft.
[0019] In another embodiment, a submunition is disclosed including a buoyant member made of low-density polyethylene foam, a first end cap made of steel and a second end cap also made of steel, the second end cap being heavier than the first end cap. A lanyard (or other connecting member) connects the first end cap to the second end cap, passing through the buoyant member.
BRIEF DESCRIPTION OF THE DRAWINGS
[0020] The invention can be best understood by those having ordinary skill in the art by reference to the following detailed description when considered in conjunction with the accompanying drawings in which:
[0021] FIG. 1 illustrates a cross sectional view of a submunition.
[0022] FIG. 2 illustrates a cross sectional view of a submunition.
[0023] FIG. 3 illustrates a cross sectional view of a submunition.
[0024] FIG. 4 illustrates a plan view of a first end of the submunition.
[0025] FIG. 5 illustrates a plan view of a second end of the submunition.
[0026] FIG. 6 illustrates multiple submunitions in a pack ready for deployment.
[0027] FIG. 7 illustrates the deployment of one or more submunitions in advance of a watercraft.
[0028] FIG. 8 illustrates one of the submunitions entering the intake of a watercraft.
[0029] FIG. 9 illustrates one of the submunitions adhering to a blade of an impeller of a watercraft.
DETAILED DESCRIPTION
[0030] Reference will now be made in detail to the presently preferred embodiments of the invention, examples of which are illustrated in the accompanying drawings. Throughout the following detailed description, the same reference numerals refer to the same elements in all figures.
[0031] Referring to FIGS. 1-5 , cross sectional views and end views of a submunition 10 are described. The submunition 10 is an impeller jamming system. As shown in FIGS. 7-9 , one or more of the submunitions 10 is launched into the water in front of a watercraft 20 (any impeller-propelled watercraft 20 such as a jet ski, etc.). The intent is for one or more of the submunitions 10 to clamp onto a blade 27 of the impeller 26 (see FIG. 8 ) of the watercraft 20 . Once one or more submunitions 10 clamp onto the blade 27 of the impeller 26 , the submunition(s) 10 move with the blade 27 of the impeller 26 as it rotates, causing cavitation within the impeller cavity 30 , reducing the thrust 28 / 28 ′ and slowing the watercraft 20 for boarding by, for example, a law enforcement personnel.
[0032] It is desired that the submunition 10 float on the water in front of the watercraft 20 so that the submunition 10 submerges slightly when hit by the bow of the watercraft 20 , then by way of the buoyancy of the submunition 10 , the submunition 10 quickly recovers and is sucked into the intake 21 (see FIGS. 8 and 9 ) of the watercraft 20 . The submunition 10 is then hit by the impeller 26 and bends around the leading edge of a blade of the impeller 26 and remains on the blade 27 of the impeller 26 by way of memory of the lanyard 4 and/or by way of an optional adhesive applied to the submunition 10 . In some embodiments, once the engine of the watercraft 20 is stopped, the submunition 10 falls off of the blade 27 of the impeller 26 , allowing future use of the watercraft 20 with no or minimal damage to the watercraft 20 and the impeller 26 .
[0033] The submunition 10 comprises a buoyant body 7 with two endcaps 3 / 5 at each end. The endcaps 3 / 5 are connected to each other by a lanyard 4 (or other connecting member) that in some embodiments passes through the buoyant body 7 . Each endcap 3 / 5 is affixed to respective ends of the lanyard 4 by any way known for affixing, including, but not limited to welding, soldering, adhesive, a knot, crimping, etc. For example, in FIGS. 4 and 5 , the lanyard 4 is shown affixed to the endcaps 3 / 5 by a weld 9 .
[0034] So that the submunition 10 floats in an upright fashion, the upper endcap 3 is of less mass than the lower endcap 5 and, therefore, when placed in water, the upper endcap 3 remains at or above the surface of the water and the lower endcap 5 sinks below the surface of the water. By providing this upright orientation, the probability of being sucked into the intake 21 of the watercraft 20 is greatly enhanced.
[0035] The buoyant body 7 is made of a material or has a structure that makes the buoyant body 7 lighter than water (e.g., sea water, river water, lake water), providing sufficient buoyancy as to keep the submunition 10 and endcaps 3 / 5 afloat until external forces are applied (e.g., until hit by the leading edge of a hull of the watercraft 20 ). In the example shown in FIG. 2 , the buoyant body 7 is made of a material 1 that has a specific gravity relative to water that is less than 1.0. It is further desired that the overall specific gravity relative to water of the entire submunition 10 is less than 1.0, allowing the submunition 10 to partially float with the upper endcap 3 at or above the surface of the water. It is understood that the specific gravity with respect to water depends upon the type of water (e.g., salt water or fresh water) as well as the temperature and air pressure. To this, the submunition 10 is designed to operate in one or more types of target water (e.g. a submunition 10 designed for fresh water or a submunition 10 designed for salt water, etc.).
[0036] In some embodiments, the buoyant body 7 is made of a material 1 that is a foam material such as low-density polyethylene foam that is often used in packing materials. In some embodiments, the buoyant body 7 is made of a buoyant material 1 that is starch-based or starch-based foam that biodegrades relatively quickly when exposed to water. In some embodiments, the buoyant body 7 is made of a buoyant material 1 that is edible by marine life. In this embodiment, it is anticipated that when the blade 27 of the impeller 26 hits the submunition 10 , the buoyant body 7 deforms or exits the submunition 10 .
[0037] In some embodiments, as shown in FIG. 3 , the buoyant body 7 is made as an enclosed tube 12 having seals 13 at each end, providing buoyancy due to air, gas, or, even by being evacuated within the cavity contained by the tube 12 and seals 13 . In this embodiment, it is anticipated that when the blade 27 of the impeller 26 hits the submunition 10 , the tube 12 fractures. In some embodiments, the enclosed tube 12 is the connecting member, connecting the end caps 3 / 5 .
[0038] In some embodiments, as shown in FIG. 1 , the buoyant body 7 is coated with an outer layer 15 . In some such embodiments, the outer layer is made of paper or a water-soluble film that slows water ingress into the buoyant material 1 , thereby slowing the decomposition of the buoyant material 1 . In some embodiments, the outer layer 15 includes an adhesive that, when struck by a blade 27 of the impeller 26 of a watercraft 20 , the adhesive of the outer layer 15 aids in adherence of the submunition 10 to the blade 27 of the impeller 26 . In some embodiments, the adhesive is water activated or micro encapsulated to prevent the submunitions 10 from bonding to each other in the launch cartridge but then the submunitions 10 become sticky when exposed to water or when the submunitions 10 are hit by the impeller blade 27 .
[0039] Although there is no limitation on size, it is preferred that the submunition be longer (the distance between the endcaps 3 / 5 ) than wider. In some embodiments, the submunitions are between 0.25 inches and 1.5 inches in diameter to facilitate passing through intake grates of target watercraft 20 . In some embodiments, the submunitions 10 are less than 1.0 inch in diameter to facilitate passing through intake grates of target watercraft 20 . In some embodiments, the submunitions 10 are less than 4.0 inches long (the distance between the endcaps 3 / 5 ) to facilitate passing through intake grates of target watercraft 20 .
[0040] It is fully anticipated that the submunitions 10 are provided with a range or mix of shapes, diameters, and lengths to facilitate passing through intake grates of a variety of target watercrafts 20 .
[0041] In some embodiments, the submunitions 10 have a proportion of their length above the water when floating vertically (endcap 5 submerged and endcap 3 at or above the surface), and in some such embodiments between one tenth and one third of the submunitions length is above the water when floating vertically, assuming a specific type of water such as fresh water, salt water, etc.
[0042] The lanyard 4 is made of a material that is sufficiently strong as to not break under the initial force of a hit by the blade 27 of the impeller 26 . Suitable materials are fishing line, braided fishing line, annealed wire (e.g., baling wire), etc. Although not required, it is preferred to use a material that has plastic properties, in that, when bent, the material remains bent. For example, annealed wire will remain bent after the submunition 10 bends around the leading edge of the blade 27 of the impeller 26 .
[0043] It is anticipated that in some embodiments the endcaps 3 / 5 are made of metal or ceramic with a central hole through which the lanyard 4 runs and is attached. To achieve an upright posture when in the water, the upper endcap 3 has less mass than the lower endcap 5 . For example, the upper endcap 3 is a 24 gauge steel washer and the lower endcap 5 is a 12 gauge steel washer. In some embodiments, the endcaps 3 / 5 are made from a material that is not harmful to the environment and will eventually biodegrade such as steel or iron. In some embodiments, the lower endcap 5 is made from a formed piece of metal, shaped so as to create cavitation bubbles when the submunition 10 is situated on the leading edge of a rotating blade 27 of an impeller 26 .
[0044] Referring to FIG. 6 illustrates multiple submunitions 10 in a pack 50 ready for deployment. In this example, the pack 50 is launched from a weapon by way of pneumatic pressure or an explosive charge, sending the multiple submunitions 10 into the air and, eventually, into the water preceding the path of the watercraft 20 .
[0045] Referring to FIG. 7 illustrates the deployment of one or more submunitions 10 in advance of a watercraft 20 . One or more of the submunitions 10 is launched into the water in front of a watercraft 20 (any impeller-propelled watercraft 20 such as a Jet Ski, etc.) by a propulsion mechanism 32 from, for example, a law enforcement vehicle (e.g. boat 30 , helicopter, airplane, from land, etc.).
[0046] Referring to FIGS. 8 and 9 , one of the submunitions 10 entering the intake 21 of a watercraft 20 (in FIG. 8 ) then adhering to a blade 27 of an impeller 26 of a watercraft (in FIG. 9 ) is shown. The intent is for one or more of the submunitions 10 to clamp onto the blade 27 of the impeller 26 (see FIG. 9 ) of the watercraft 20 . Once one or more submunitions 10 clamps onto the blade 27 of the impeller 26 ; the submunition(s) 10 move with the blade 27 of the impeller 26 as it rotates, causing imbalance and cavitation within the impeller cavity 30 . In FIG. 8 , the watercraft 20 driven by a person 25 (perhaps a criminal or a person with a medical condition) is moving at a high rate of speed and the submunition 10 is floating in the path of the watercraft 20 , then the submunition 10 is hit by the hull of the watercraft 20 and submerges, recovering to enter the intake 21 of the watercraft 20 within the propulsion shroud 30 where, as in FIG. 9 , the submunition after being hit by the blade 27 of the impeller 26 holds onto the blade 27 of the impeller 26 causing cavitation within the propulsion shroud 30 . The cavitation and imbalance reduces the output thrust 28 / 28 ′ from a high output thrust 28 (see FIG. 8 ) to a low output thrust 28 ′ (see FIG. 9 ). The low output thrust 28 ′ allows a small amount of maneuverability and low speed so that the watercraft 20 has difficulty escaping the law enforcement vehicle (e.g. boat 32 ).
[0047] Equivalent elements can be substituted for the ones set forth above such that they perform in substantially the same manner in substantially the same way for achieving substantially the same result.
[0048] It is believed that the system and method as described and many of its attendant advantages will be understood by the foregoing description. It is also believed that it will be apparent that various changes may be made in the form, construction and arrangement of the components thereof without departing from the scope and spirit of the invention or without sacrificing all of its material advantages. The form herein before described being merely exemplary and explanatory embodiment thereof. It is the intention of the following claims to encompass and include such changes. | A method and apparatus for stopping an impeller-driven watercraft is includes distributing a plurality of submunitions in advance of a path of the impeller-driven watercraft. Each of the submunitions includes a buoyant member, a first end cap, and a second end cap; the second end cap is heavier than the first end cap. A lanyard connects the first end cap to the second end cap, optionally passing through the buoyant member. At least one of the submunitions enters an intake vent of the impeller-driven watercraft and attaches to a blade of an impeller of the impeller-driven watercraft, causing cavitation and imbalance, thereby slowing the impeller-driven watercraft | 5 |
FIELD OF THE INVENTION
The present invention relates to an improvement in the structure of a housing component of thermal apparatus and fluid flow machines and particularly a steam turbine, comprising an inner and an outer housing as well as pipes to supply and discharge the operating fluid medium.
BACKGROUND OF THE INVENTION
In order to keep the time periods for inspection of thermal apparatus and particularly a steam turbine to a minimum, i.e., to ensure brief shutdown times for a plant, it becomes necessary to design individual parts especially housing parts of the turbines in such manner that they will specifically facilitate any servicing. Heretofore, mounting platforms or cover grills were used for inspection and repairs of the turbine at the plant location and assembled in accordance with the structural conditions at the working site or of the plant. In different cases an access plate or grill was supplied by the manufacturer to be utilized when needed, that is for the original assembly or inspection after the removal of the outer turbine housing. Such mounting platforms had again to be removed from the turbine upon the completion of the inspection or repair.
SUMMARY OF THE INVENTION
It is the principal object of this invention to provide a housing containing devices which will make unnecessary the erection of a mounting platform, which need not be dismantled upon the completion of the inspection or repair and which will help to reduce substantially the shutdown time periods of a plant.
The invention solves this problem in that manner that one portion of the housing is hinged and can be lowered or raised into the horizontal plane and forms a working platform.
In accordance with a preferred embodiment of the invention one portion of the inner housing, as well as one portion of the outer housing, of a steam turbine can be lowered or raised into the above defined position.
The construction proposed by the invention has the advantage that the hinged housing portions become structurally integrated with the inner or outer housing of the turbine. During normal operation these coverings, for example, the outer coverings, are hinged at the inner walls of the turbine housing and will thus not interfere with fluid flow. When inspections or repairs become necessary, the bolts holding the coverings in place can be detached, and the covering portions can be lowered or raised into a horizontal position. It will be advantageous for this purpose to provide these portions with a hinge at one end while they are being held at their other end in the horizontal position by means of chains, to give an example. Since these hinged portions are relatively large and heavy, they are lowered, or raised respectively, by means of pulleys which are available and in fixed position at practically all turbine plants. The hinged portions, serving as working platforms, are immediately accessible to service personnel when brought into the horizontal position. Furthermore, when the portions are restored to their original vertical or nearly vertical position, the turbine is then immediately in running order again, with no need to remove auxiliary components from the turbine. This is particularly advantageous when turbines are installed in systems employing boiling water reactors because there will be no need for any decontamination measures.
In a further development of the invention, the hinged housing portions are limited by a rim and means are provided to accommodate a guard rail.
The placement of an upwardly directed rim, bordering the hinged housing portions, and the arrangement of receptacles for the placement of a guard rail will prevent tools or materials from falling into the condenser, located a few meters below, by sliding off the working platform, and the insertion of a guard rail into receptacles, for example, pipe stubs welded to the rim, will reduce substantially the danger of accidents involving personnel working at the platform. It is also feasible to design the guard rail in such manner that it will become an integral part of the covering, i.e., by folding this rail prior to restoring the platform to the initial position in such manner that it becomes located inside the upwardly directed rim.
It is also possible and expedient to design the hinged housing portion as a covering for an access hatch and to utilize its rim as a seal support.
This specific arrangement will be advantageous in all instances where a hinged portion of the outer housing of the turbine can be lowered or raised so that a wide opening can be provided at the turbine, thereby improving substantially the accessibility to the inner jacket and to the blading of a fully assembled turbine. In this case it is also possible to make the area of the hatch opening smaller than the area of the hinged portion of the outer housing.
BRIEF DESCRIPTION OF THE DRAWINGS
In the accompanying drawings which illustrate, in a simplified manner, preferred embodiments of the invention:
FIG. 1 shows a longitudinal axial vertical section of a dual flow type steam turbine with portions of the inner housing that can be lowered or raised,
FIG. 2 is a plan view of the turbine shown by FIG. 1,
FIG. 3 is a vertical transverse sectional view of a portion of the turbine shown by FIG. 1,
FIG. 4 is a detail of the cover with fold-down guard rail,
FIG. 5 shows in perspective the working platform with the guard rail inserted,
FIG. 6 shows in elevation one construction of a turbine's outer housing with access hatches and lowerable covering,
FIG. 7 is a side view of the turbine housing illustrated by FIG. 6, and
FIG. 8 shows a sealing arrangement at an enlarged scale where the hinged housing portion forms a seal with the outer housing.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
Numeral 1 in FIGS. 1, 2, and 3 denotes a dual flow, i.e., a center intake turbine which is surrounded by a housing 2. Housing parts 3 and 3' of housing 2 are designed in such manner that they can be lowered or raised along a hinge line from a vertical closed position into a horizontal open position so that they can be utilized as working platforms for inspections and repairs. FIG. 1 shows the housing part 3' lowered from its upper vertical position into its lower horizontal position (heavy lines), with the initial, upright position indicated by dots and dashes. The housing part 3 is raised from its initial lower vertical position to its upper horizontal position and properly secured in the working-platform position. The housing parts 3, 3' are held in place at their working-platform positions by suspension means, for example, by chains 4 or struts 4'. When the housing parts 3, 3' are moved back, the suspension means can either be removed or be secured within the associated housing part 3 or 3' as illustrated in FIG. 1 so that they will not impede the turbine flow.
FIG. 4 provides a detailed view of the housing part 3, with railings 5 arranged at the outer contours in such manner that they can be folded inwardly. The broken lines indicate the position of the railing 5 in the folded-down state.
The perspective view of the housing part 3 in FIG. 5 illustrates the rim 6 which closes off this part for reasons of safety as well as the receptacles 7, for example, in the form of pipe stubs which are welded on and into which the railings 5 can be inserted.
In the case of the embodiment shown by FIG. 6 the housing 2 forms one part of the outer turbine housing and is provided with two access spaced hatches 8 which are covered toward the outside by means of the hinge-mounted housing parts 3. This figure shows the access hatch 8 at the left in the open position, i.e., the housing part 3 is lowered inwardly and down and held in place by the suspension chains 4 while the access hatch at the right is covered over by the housing part 3.
FIG. 7 provides a partial view of the housing structure depicted in FIG. 6, this view showing one of the access hatches 8 in the housing 2, and the hinge-mounted housing part 3 which has an arcuate surface matching that of housing 2 and which is lowered inwardly and downwardly about its hinge axis in the direction of the arrow to its horizontal position providing the desired working platform. The housing part 3 is held in that position by chains 4 and includes a planar plate 12 to be walked on by servicing personnel.
FIG. 8 is a detail, depicted at a larger scale of a portion of the hinged housing part 3 at the side opposite its hinge axis showing the manner in which it is secured in its raised position, i.e. as a cover over the hatch opening 8. A generally rectangular flange 10 matching that of the periphery of the housing part 3 is welded to the housing 2 and projects over the border of the hatch opening 8 so as to be engaged by the border portion of the housing part 3 when moved into the hatch-closing position as indicated in the drawing. A peripherally extending sealing strip 9 set into a recess in the outer surface of the housing part 3 is pressed into contact with the inner face of flange 10 and establishes a desired seal for the hatch as a peripherally extending series of bolts 11 which pass through openings in the flange 10 and thread into the housing part 3 are tightened.
The arrangement of the access hatch(es) 8 at the outer wall of the turbine housing structure greatly facilitates access to the inner housing and to the turbine blading with the turbine fully assembled and therefore there will be no need to remove large-sized sections of the outer housing. Obviously, if the housing parts 3 for covering the hatches 8 are lowered outwardly from the housing 2 to form the desired horizontal working platform rather than inwardly as depicted in FIG. 6-8, the seal 9 and flange 10 will have to be located at the inner surface of the housing part 3. | A housing structure for a steam turbine includes inner and outer housings and a hinged portion of one of those housings is structured for being lowered or raised into a horizontal plane to serve as a working platform to facilitate servicing. The hinged housing portion includes a hinged upstanding rim to prevent tools from sliding off and a protective railing is secured to the rim. | 5 |
CROSS REFERENCE TO RELATED APPLICATION
This application is a continuation of U.S. patent application Ser. No. 12/847,874, which is a divisional application of U.S. patent application Ser. No. 11/823,214 filed Jun. 27, 2007, now U.S. Pat. No. 7,796,492.
FIELD
The present invention relates to MEMS memory devices, and more particularly, to seek-scan-probe memory storage devices.
BACKGROUND
FIG. 1 illustrates a prior art, conventional MEMS (Micro-Electro-Mechanical System) seek-scan-probe (SSP) memory device, where various components are labeled by their typical names. For simplicity, only two cantilevers are shown in FIG. 1 , but in practice there is an array of cantilevers. The storage media comprises a Chalcogenide. However, other media may be used for storage, such as ferroelectric material. Electrical energy (heat) converts a Chalcogenide between its crystalline (conductive) and amorphous (resistive) phases, so that information may be stored, and read by sensing current through the storage media. The cantilever array is on a stage mover. The cantilever array may be moved laterally so that a data bit may be stored or read spatially. Each cantilever covers a specific region of the storage media to perform read, write, and erase operations over the specific region.
To perform a read, write, or erase operation, the tip of the active cantilever needs to contact the storage media so that current can flow between the tip and the media electrode underneath the storage media for resistance sensing (read operation) or electrical current passing (write and erase operations). The read, write, or erase action is performed with a pulse voltage, e.g., ground to 8 volts, applied on the media electrode with a typical duration of about 20 nano-seconds (ns). The cantilever mechanical response is insensitive to such a fast electrical pulse. The tip contact with the storage media is mainly achieved by the cantilever's bending from internal stress.
Due to process variation on the wafer, the stress-induced bending may vary significantly from cantilever to cantilever, resulting in situations in which some cantilevers are in contact with the storage media while some have inadequate bending to reach the storage media surface. In order to make sure that all cantilevers are contacting the storage media, the gap between the mover and storage media surface is usually reduced to obtain adequate contact force on the least-bent cantilevers. However, this may damage the cantilever tips.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 illustrates a prior art scan-seek-probe memory device.
FIG. 2 illustrates a scan-seek-probe memory device according to an embodiment of the present invention.
DESCRIPTION OF EMBODIMENTS
In the description that follows, the scope of the term “some embodiments” is not to be so limited as to mean more than one embodiment, but rather, the scope may include one embodiment, more than one embodiment, or perhaps all embodiments.
FIG. 2 illustrates in simplified form a side-view of an embodiment. For simplicity, only two cantilevers are shown, but in practice an array of cantilevers are used to store, read, and erase bits on the storage media. Each cantilever is sandwiched by two actuation electrodes, a media electrode and another electrode on the mover, which is referred to as a pull electrode in FIG. 2 . Each media electrode and its corresponding pull electrode are separated by an air gap. A pull electrode is located at the backside of its corresponding cantilever, and allows the cantilever to be actuated upwards. The media electrode serves as the front actuation electrode of its corresponding cantilever to increase contact force with the storage media. For some embodiments, when the electrodes are powered off (no actuation), the cantilevers contact the storage media with forces ranging from about 0 to 25 nN.
For some embodiments, the cantilevers comprise a relatively compliant beam to allow acceptable force variation caused by process variation. For example, for a cantilever beam of compliance (spring constant) k=0.05N and for a variation in the vertical dimension of Δz=0.5 μm, the force variation is ΔF=kΔz=25 nN. For such embodiments, this relatively small force range is not expected to damage the cantilever tips after a wafer is bonded.
When powered up, the cantilevers are actuated into two groups: a non-active group and an active group. Cantilevers in the non-active group do not perform R/W/E (Read/Write/Erase) actions. The cantilevers in the active group have their tips in contact with the storage media for data access. For a non-active cantilever, a high voltage may be applied on the pull electrode. For example, for some embodiments a voltage of 30V may be applied on the pull electrode, resulting in a pulling force of between 0.1 to 0.2 μN for an assumed gap of 4 μm to 5 μm. For such embodiments, the force is expected to move the tip of a cantilever upwards by 0.5 μm to 1 μm, slightly above the storage media surface, and the applied voltage is expected to produce an electrostatic force in balance with the cantilever spring, but not so large as to cause pull-in of the cantilever onto the pull electrode. In this way, the cantilever is suspended between the over and media wafer. Because the tips are only slightly above the storage media, the non-active cantilevers may be made active and contact the storage media surface when the pull voltage is removed.
For active cantilevers, no voltage need be applied on the pull electrode. For some embodiments, the active cantilevers contact the storage media surface with a force in the range of 0 nN to 25 nN, depending on the initial bending due to process variation. For cantilevers with close to zero spring contact force, an additional actuation may be used to boost the contact force. For example, a low voltage may be applied on the media electrode to produce an additional attracting force between the cantilever tip and the storage media. For example, for a 0.3 μm tip height, an electrostatic force of about 50 nN to 100 nN may be produced by applying 2V on the media electrode. This low voltage on the media electrode is essentially invisible to the phase change storage media, which usually requires a voltage larger than 7V to cause a phase change. Typically, the storage media has a very high resistance, in the neighborhood of 100 kΩ between the tip and media electrode, so that a low actuation voltage may be maintained if needed.
The total contact force is the sum of the spring force and electrostatic force from the media electrode. By adjusting the voltage on the media electrode, the tip contact force may be modulated, for example, from 25 nN to more than 100 nN. The R/W/E action with a short electrical pulse (V S >7V and less than 100 ns in duration) may be performed when the desired contact force is achieved. The very short pulse from the R/W/E action should have minimum effect on the cantilever. When a cantilever completes a data access, the media electrode voltage is removed and a high voltage is applied on the pull electrode to open the cantilevers, that is, pull the tip upwards so that the cantilever is in a non-active mode.
Because only the active cantilevers are contacting with the storage media during data access, it is expected that tip and storage media wear should be reduced for the non-active cantilevers. It is also expected that this may improve reliability and lifetime of the device.
Various modifications may be made to the described embodiments without departing from the scope of the invention as claimed below. For example, the spring constant need not be uniform throughout a cantilever. For example, some embodiments may have cantilevers such that over their length closest to the mover, the spring constant is higher than for a portion of their length closest to the storage media. | A seek-scan-probe memory device, utilizing a media electrode to allow active cantilevers to contact the storage media, and a pull electrode to pull up cantilevers away from the storage media when in an inactive mode. Other embodiments are described and claimed. | 6 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of and claims priority to U.S. patent application Ser. No. 10/778,338 filed on Feb. 17, 2004, which in turn claims priority to U.S. Provisional Application No. 60/519,629 filed Nov. 14, 2003.
FIELD OF THE INVENTION
[0002] This invention relates to distributing and activating communication devices, such as wireless phones. More particularly, the invention relates to distributing wireless communication devices at point-of-sale merchant terminals wherein the communication devices may be used for wireless communication service.
BACKGROUND OF THE INVENTION
[0003] Merchant stores receive wireless phones from distributors and sell the phones and other communication devices to customers. These phones may be pay-as-you-go wireless phones. Typically, the phones are inactive when the stores receive the phones from distributors. Thus, in order for a customer to use a phone after purchase, the phone must be activated through a communication service provider, i.e., a carrier. For instance, a customer may purchase at a merchant store a phone pre-associated with a specific wireless telecommunication provider. To activate the phone, the customer must later call the provider, at which point the provider determines whether to activate the phone. Typically, providers will automatically activate any phone at a customer's request. Once activated, the phone can be used for its intended purpose, such as wireless communication service.
[0004] The traditional method does not allow the carrier to know the status of the phone prior to activation. In other words, at the time of activation, but not prior, the carrier will know that the phone is in the hands of a user and no longer in the chain of distribution. However, the carrier will not know whether the phone was ever legitimately purchased at an authorized retailer. For instance, the carrier will not know whether the person calling to activate the phone is requesting to activate a stolen phone or a legitimately purchased phone.
[0005] What is desired is a method of distributing the phone to customers so that a carrier can verify that a phone was validly purchased prior to activation.
SUMMARY OF THE INVENTION
[0006] Systems and methods of authorizing the activation of a previously functioning by subsequently deactivated or disabled communication device are disclosed. The method comprises receiving at a central processor an authorization request from a merchant terminal at the merchant store to authorize activation of a communication device, the central processor being in selective communication with the merchant terminal and a communications service provider; determining at the central processor whether the communication device was validly sold from the merchant store in a purchase transaction; authorizing at the central processor activation of the communication device, responsive to a determination that the communication device was validly sold from the merchant store in a purchase transaction; and sending a notification from the central processor to the communications service provider that the communication device is authorized and ready for activation.
DESCRIPTION OF THE DRAWINGS
[0007] FIG. 1 illustrates a system for authorizing the activation of a communication device according to an embodiment of the invention.
[0008] FIG. 2 illustrates an exemplary communication device and package.
[0009] FIG. 3 illustrates a flowchart showing a method of distributing a communication device according to an embodiment of the invention.
[0010] FIG. 4 illustrates a flowchart showing a method of authorizing the activation of a communication device according to another embodiment of the invention.
[0011] FIG. 5 illustrates a flowchart showing a method of authorizing the activation of a communication device according to yet another embodiment of the invention.
DETAILED DESCRIPTION OF THE EMBODIMENTS
[0012] The subject matter of this application is related to the technology described in the following U.S. Patents and Patent Applications: U.S. application Ser. No. 10/253,243 filed Sep. 24, 2002, U.S. Provisional Application No. 60/324,333 filed Sep. 24, 2001, U.S. Provisional Application No. 60/396,404 filed Jul. 15, 2002, U.S. Provisional Application No. 60/519,630 filed on Nov. 14, 2003, U.S. Provisional Application No. 60/519,629 filed on Nov. 14, 2003, U.S. application Ser. No. 10/712,182 filed Nov. 13, 2003, U.S. application Ser. No. 10/655,828 filed Sep. 5, 2003, U.S. patent application Ser. No. 10/698,084 filed Nov. 3, 2003, U.S. application Ser. No. 10/411,971 filed Apr. 11, 2003, U.S. application Ser. No. 09/641,363 filed Aug. 18, 2000 (now issued as U.S. Pat. No. 6,575,361), U.S. Provisional Application No. 60/149,740 filed Aug. 19, 1999, U.S. application Ser. No. 10/732,641 filed Dec. 10, 2003, the U.S. Application filed Dec. 19, 2003 under Attorney Docket No. 64243.000005, and the U.S. Patent Application filed Jan. 16, 2004 under Attorney Docket No. 64243.000006. All of these applications are incorporated herein by reference in their entirety. It should be appreciated that the authorization and activation of communication devices as described herein may be combined with the novel systems and methods of the applications referenced above.
[0013] FIG. 1 illustrates a system for authorizing the activation of a communication device according to an embodiment of the invention. The system comprises a manufacturer 14 , distributor 12 , one or more merchants 10 , one or more merchant terminals 4 , a central processor 2 , a central database 8 , a communication service provider 6 (also called “carrier” herein), and a carrier database 7 .
[0014] The communication device may comprise a wireless handset such as a wireless phone, PDA, pager, phone/PDA combination device, internet-enabled device, or any other communication device. The communication device may be in a package, for instance when it is sold. The communication device package may be any container, box, or packaging that may contain, hold, or otherwise couple to the device. In a preferred embodiment, the package contains the device 16 when the customer purchases the device at a merchant terminal 4 .
[0015] The manufacturer 14 manufactures communication devices and passes them to one or more distributors 12 . The distributors 12 ship the communication devices to one or more merchant stores 10 . The merchant stores 10 comprise one or more merchant terminals 4 . Customers purchase the communication devices at merchant terminals 4 .
[0016] The merchant terminals 4 comprise an input/output device for inputting communication device and/or package information (such as an identifier) during a purchase transaction and passing such information to the central processor 2 . For instance, the merchant terminals may comprise any point-of-sale terminal configured to process sale transactions between merchants and customers. The merchant terminal 4 may comprise a barcode scanner and credit card reader, and it may be in selective communication with a network as well-known in the art.
[0017] The central processor 2 may comprise any data processing system that stores, manages, and/or processes device-related information. In one embodiment, the central processor 2 may itself be a communication service provider 6 (also called a “telecommunications carrier” or “carrier” herein). The central processor 2 is configured to process device-related information (such as an identifier). The central processor 2 is further configured to store device-related information in a central database 8 . The information may comprise information received from a merchant terminal 4 during a device sale transaction. The central processor 2 is also configured to communicate information to and from a carrier 6 . For instance, the central processor 2 is configured to receive authorization requests and/or status inquiries from carriers 6 . The central processor 2 is configured to process information stored in the central database 8 based on such requests and inquiries. The central processor 2 is also configured to pass information to the carrier.
[0018] In one embodiment, the central processor 2 is configured to communicate with merchant terminals regarding device activation requests.
[0019] The carrier 6 may process information it receives from the central processor 2 . The carrier may also store information in a carrier database 7 . The carrier 6 is also configured to communicate with customers. For instance, the carrier 6 is configured to receive device activation requests from customers. The carrier 6 is also configured to process information based on the request and/or communicate with the central processor based on the request. The carrier 6 is also configured to pass information to the customer, such as an activation confirmation.
[0020] FIG. 2 illustrates an exemplary communication device 16 and package 18 , the activation of which may be authorized using methods according to the invention. The top left figure in FIG. 2 shows the front view of a typical communication device 16 such as a wireless phone. The top left figure shows the rear view of a typical communication device 16 .
[0021] The device 16 may have an identifier 20 associated with the device 16 . The identifier 20 may be applied to (e.g., labeled on) the device 16 , the package 18 , or both. The identifier 20 may comprise an electronic serial number (ESN), an IMEI, a subscriber information module (SIM), a UPC code, or other number or indicia that identifies the device 16 . For instance, the ESN, IMEI, and/or SIM code may comprise numbers or codes that are uniquely associated with the device 16 . The identifier may be applied in a SIM card 22 (or SIM card indicia 22 ), a magnetic strip 24 , and/or a barcode 26 . For instance, the barcode 26 may represent the ESN, IMEI, or SIM, and optionally the UPC. In one embodiment, the phone has a SIM card 22 or an equivalent of a SIM card.
[0022] The identifier 20 may be visible on the outside of the device 16 and/or package 18 , or it may be applied or otherwise encoded on the device 16 and/or package 18 . It also may be visible only after manipulating the device 16 , such as by taking out a battery. The identifier 20 may be used by the merchant, distributor, carrier, and customer to track the location and activation status of the device 16 , or for any other record-keeping purpose such as inventory management.
[0023] The device 16 is typically in a package 18 prior to and during sale to a customer. The package may have barcodes and other indicia on it. The package may have an ESN 20 in barcode form. This ESN 20 may also be printed (or magnetically encoded) on the phone itself. There may be more than one identifier 20 associated with the device 16 and/or package 18 . The package 18 and device 16 may also have other barcodes used during purchase or during inventory scanning or other product scanning purposes. The package 18 may have one or more identifiers that are identical to or different from the one or more identifiers 20 associated with the device. In a preferred embodiment, the device 16 and package 18 have at least one identifier 20 in common.
[0024] The bottom figure of FIG. 2 shows a package 18 configured to contain the handset 16 . The package 18 may have one or more identifiers printed or otherwise stored on the package 18 as described for the handset. The package identifiers may be the same or different from the handset identifiers. In a preferred embodiment, the package 18 and device 16 have at least one identifier that is identical on both the package 18 and device 16 , such as an ESN 20 .
[0025] FIG. 3 illustrates a flowchart showing a method of authorizing the activation of a communication device according to an embodiment of the invention. As used herein, the term “handset” refers generally to any type of communication device regardless of whether it actually comprises a handset.
[0026] In step 31 , handset identifier information is received. For instance, the central processor and/or carrier receives handset identifier information. The manufacturer (or distributor) of the handsets may pass an inventory list of handset ESNs (or other identifiers) to the central processor or carrier. Alternately, a merchant may provide a list of handset identifiers to the central processor or carrier after (or before) it receives the handsets from a distributor. The central processor will then have one or more handset identifiers that may eventually purchased from merchants.
[0027] In a preferred embodiment, each handset is pre-associated with a carrier. Thus, if the carrier receives handset identifier information, it would only receive handset identifier information for the handsets pre-associated with it. In another embodiment, a carrier is chosen after purchase by the customer. In this embodiment, the carrier would not receive identifier information at this stage.
[0028] In optional step 32 , the identifier information is stored and/or processed. For instance, the central processor and/or carrier stores identifier information. The central processor and/or carrier may store a list of ESNs corresponding to handsets that were received by a particular store, delivered by a particular distributor, or manufactured by a particular manufacturer. The information may be stored in a central database coupled to the central processor or a carrier database coupled to the carrier. The central processor (and/or carrier) may also store status information associated with each handset. Because the handsets have not yet been sold, the central processor (and/or carrier) may store information for each handset indicating that the handset is “not sold.” Other methods of storing and/or identifying stored information may be used.
[0029] In step 33 , a handset identifier is input at a merchant terminal during a handset purchase transaction. For instance, one or more handset identifiers may be input at a merchant terminal during a transaction in which a customer purchases the handset. In this step, the customer selects a handset to purchase and purchases the handset at a merchant terminal. During the sale, the handset package (or handset) is scanned at the merchant terminal. In a preferred embodiment, an ESN associated with the handset is input at the terminal by scanning the handset package. Whether the package or handset is scanned, the identifier input at the merchant terminal is uniquely associated with the handset itself.
[0030] Multiple identifiers may be input at the merchant terminal. For instance, a UPC code may be input as well as an ESN, IMEI, SIM, or other identifier. The UPC may input for merchant inventory purposes, while the ESN may be input for purposes of eventual handset activation.
[0031] It should be noted that the handset is inactive or disabled prior to delivery to the customer. For instance, the handset is hotlined or otherwise disabled in the switch. It may be actively or passively disabled. The merchant may disable the handset at (or prior to) purchase. In a preferred embodiment the handset is disabled before it is distributed to the merchant. In one embodiment, the carrier disables the handset, such as before the merchant receives the handset into merchant inventory. For instance, the SIM may be disabled. This may occur before it is offered to the customer (e.g., before the product is placed on the store shelves or otherwise offered to the customer), or it may occur during the purchase transaction. When the SIM is disabled, the handset is disabled and cannot enable wireless handset service. In order to activate the handset, the customer must later contact a central server (such as by calling an 800 number or accessing a website of the carrier) and activate the handset. The server may comprise a computer or handset system of a telecommunications provider (i.e., carrier), preferably the provider of the wireless service to be enabled on the customer's purchased handset.
[0032] In optional step 33 , the merchant terminal may also input information regarding the purchaser, such as the purchasers name, address, social security number, PIN, home or other telephone number, email address, website, or other information. Some of this information may be identified via a purchaser credit card or check, or the information may be provided by the customer at the request of the merchant. Customer information may also be passed to the central processor or carrier, which may store such information in a database. This information may be used to verify the identity of the purchaser when the purchaser later activates the phone.
[0033] In step 34 , the central processor receives a handset identifier. The identifier may be the identifier input in step 33 . For instance, the merchant terminal may input the identifier and then pass the identifier to the central processor during sale of the handset to a customer. In a preferred embodiment, this occurs simultaneously with the sale. For instance, the sale transaction may comprise inputting the identifier information and automatically passing the information to the central processor. For instance, a barcode may be scanned during purchase, as with typical transactions, and the barcode number may be passed to the central processor.
[0034] If a customer's funds are later determined to be invalid or insufficient, or if there is any other problem with the transaction (e.g., if the phone is returned), the merchant or merchant terminal may notify the central processor of the problem at that time. The phone may then become disabled again. Appropriate records of such return transactions may be stored and passed to the carrier and central processor.
[0035] Alternately, there may be a delay between inputting the information at the merchant terminal and passing identifier information to the central processor. For instance, the merchant terminal may wait until the customer's purchase funds clear to ensure that only validly purchased handset identifiers are passed to the central processor.
[0036] Also, if a handset is stolen or damaged, or is otherwise not eligible for distribution to a customer, the central processor may amend a database entry corresponding to the handset to reflect that the handset has been “cancelled.” Such a handset may not be activated, as reflected by its “cancelled” status.
[0037] In step 35 , the handset is registered as being validly purchased and/or ready for activation. For example, the phone may become enabled or activated in the switch. In a preferred embodiment, the central processor passes handset identifier information to a carrier system to indicate that the handset was validly purchased. It may pass such information via any communication device or means, such as via the internet, dedicated data line, telephone IVR, or other system.
[0038] In a preferred embodiment, the central processor transfers such information via an API so that the carrier system can easily recognize and process the information. After the carrier system processes the information, the handset is registered in the carrier's system as a validly purchased handset. For instance, the carrier may store the identifier in a carrier database file that includes identifiers for handsets that have been validly purchased. The fact that the handset is valid is apparent from the file it is stored in. Or, the carrier may amend an existing database entry corresponding to the handset to indicate that the handset has been validly sold.
[0039] Alternately, the central processor may store status information indicating that the handset is “sold and ready for activation.” It may store such information in the manner described for the carrier system, or in any manner known in the art.
[0040] In step 36 , the carrier receives from a customer a request to activate the handset. In this step, a customer contacts the carrier (via phone, internet, etc.) to activate the handset. For instance, the customer may call an 800 number that accesses a carrier IVR system, or the customer may access the carrier's website. The customer may also call a carrier customer service or activation department. The customer provides identifier information to the carrier system so that the carrier system can identify the specific handset for activation. For instance, the customer may provide the ESN or SIM, such as by entering the ESN at an internet or IVR prompt. Alternately, if the customer contacts the carrier using the handset itself, the handset may automatically provide identifier information to the carrier system.
[0041] The customer may also provide customer identification information. Such identification information may comprise a customer name, address, phone number, receipt number, product number, or other number or code that may be associated with the purchased phone, purchaser, vendor, or wireless service provider. The carrier may request to verify such information prior to activation.
[0042] In step 37 , the carrier determines whether the handset has been validly purchased. In a preferred embodiment, the carrier checks its database to determine whether the identifier is associated with a validly purchased handset. For instance, the carrier may determine whether an identifier associated with the handset (such as the ESN) is stored in a database corresponding to valid handsets.
[0043] In another embodiment, the carrier system contacts the central processor to determine whether the identified handset has been validly sold. For instance, the carrier system (such as a customer service center) may pass a handset identifier (such as the one provided in step 36 ) to the central processor. This may occur by accessing a central processor IVR system, or by any other method of communication as described herein. The central processor would receive the identifier, access its database to determine whether the identifier is associated with a validly purchased identifier, and then pass an authorization result back to the carrier. The authorization result may indicate that the phone was validly sold or that the phone was not validly sold (or that there was some other problem associated with the handset). For instance, the central processor may determine the authorization result based on stored authorization status information.
[0044] In step 38 , the carrier activates the handset or denies the customer's request. If the carrier determines that the handset was validly purchased, the carrier may activate the handset. If the carrier determines that the handset was not validly purchased, or if there is some other problem with the purchase of the handset, then the carrier may deny the customer's request and refuse to activate the phone.
[0045] When a carrier activates the handset, the handset becomes usable. For instance, if the handset is a wireless telephone, then activating the handset might allow the customer to use the handset to access the carrier's wireless telecommunications services.
[0046] FIG. 4 illustrates a flowchart showing a method of authorizing the activation of a communication device according to another embodiment of the invention. The method of FIG. 4 should be interpreted in light of the discussion of FIG. 3 .
[0047] In optional step 41 , the central processor stores identifier information, e.g., as described for step 32 .
[0048] In step 42 , a handset identifier is input at a merchant terminal during a handset purchase transaction, e.g., as described for step 33 .
[0049] In step 43 , the merchant terminal passes the identifier to the central processor, e.g., as described for 34 .
[0050] In step 44 , the central processor passes the identifier to the carrier.
[0051] In step 45 , the identifier is stored in a carrier database. A status of the identifier (and/or corresponding handset) may be stored and/or updated based on receiving the identifier from the central processor. The various status possibilities are described below with respect to FIG. 5 .
[0052] Steps 44 and 45 may occur when, e.g., the central processor inserts the identifier into a carrier database, e.g., using an API. This process is also described in step 35 .
[0053] In step 46 , the carrier receives a handset activation request, e.g., as described for step 36 .
[0054] In step 47 , the carrier determines whether to activate the handset. This may comprise accessing a carrier database to determine whether the identifier is in the database, or to determine whether the identifier is associated with a handset that has been approved for activation. This may also comprise determining the status of the identifier (and/or the corresponding handset).
[0055] In step 48 , the carrier responds to the customer request by either activating the handset or by denying the customer request. For instance, if the identifier is in the database (or if the identifier is associated with a handset approved for activation), the carrier will activate the handset. If not, then the carrier may deny the request.
[0056] FIG. 5 illustrates a flowchart showing a method of authorizing the activation of a communication device according to yet another embodiment of the invention. The method of FIG. 5 should be interpreted in light of the discussion of FIG. 3 .
[0057] In step 51 , the handset identifier is input at a merchant terminal during a handset purchase transaction, e.g., as described for step 33 .
[0058] In step 52 , the merchant terminal passes handset identifier information to the central processor, e.g., as described for step 43 .
[0059] In step 53 , the central processor processes and/or stores the identifier. For instance, the central processor may store the identifier in a database entry (or amend an existing database entry) to indicate that the identifier was received from a merchant terminal. The entry may be reflect that the corresponding handset has a particular status, e.g., that the handset is sold and ready for activation.
[0060] In step 54 , the carrier receives a handset activation request from the customer, e.g., as described for step 46 .
[0061] In step 55 , the carrier passes the activation authorization request to the central processor.
[0062] In step 56 , the central processor processes the identifier. The central processor may determine whether the identifier was validly sold. For instance, the central processor may determine whether the identifier was received in a transaction according to steps 51 and 52 . The central processor may also determine the status of the handset (and/or corresponding identifier). For instance, the central processor may determine that the handset has a particular status, such as “sold and ready for activation,” “not sold,” “sold and activated,” “sold and returned,” or “cancelled.” Depending on the status, the central processor may determine to pass a positive or negative (or other) activation response. For instance, the central processor may determine to send a positive response if the corresponding handset is “sold and ready for activation.” The central processor may pass a negative response if the status is “cancelled,” “not sold,” or “sold and returned.”
[0063] In step 57 , the central processor passes an activation authorization response to the carrier. The authorization response may be an indication to activate or to not activate. The authorization response may comprise status information about the identifier and/or corresponding handset.
[0064] In step 58 , the carrier either activates the handset or denies the customer's request, e.g., as described for step 48 . The carrier's action may be based on the central processor's response in step 57 .
[0065] It should be noted that different identifiers may be used in the different steps described herein, provided that the different identifiers are associated with a single handset. I.e., it is not necessary that the ESN be the single identifier that is used throughout the process. For instance, a barcoded number (e.g., a number that is mapped to or otherwise associated with a SIM or ESN in a database) may be scanned at the merchant terminal and passed to the central processor, but the processor may determine the SIM or ESN and pass it to the carrier. Here, the central processor may receive the UPC and determine the ESN or SIM that is associated with that barcode by processing information stored in a database (for instance, information received from the merchant associating UPC numbers with ESN numbers). Also, it should be appreciated that the term “identifier” may comprise information associated with the identifier. In other words, an identifier received by a carrier need not be the exact same as the identifier passed from a merchant terminal to a central processor in an earlier step, provided that the two identifiers are uniquely associated with the same device.
[0066] It should also be noted that the communication devices mentioned above may be activated in any manner as described for activating PINs in the above-referenced applications.
[0067] It will be understood that the specific embodiment of the invention shown and described herein is exemplary only. Numerous variations, changes, substitutions and equivalents will now occur to those skilled in the art without departing from the spirit and scope of the present invention. Accordingly, it is intended that all subject matter described herein and shown in the accompanying drawings be regarded as illustrative only and not in a limiting sense and that the scope of the invention be solely determined by the appended claims. | Systems and methods of authorizing the activation of a previously functioning by subsequently deactivated or disabled communication device are disclosed. The method comprises receiving at a central processor an authorization request from a merchant terminal at the merchant store to authorize activation of a communication device, the central processor being in selective communication with the merchant terminal and a communications service provider; determining at the central processor whether the communication device was validly sold from the merchant store in a purchase transaction; authorizing at the central processor activation of the communication device, responsive to a determination that the communication device was validly sold from the merchant store in a purchase transaction; and sending a notification from the central processor to the communications service provider that the communication device is authorized and ready for activation. | 7 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates to vehicles, in particular motor vehicles, which are equipped with systems making it possible to act remotely at the level of at least one of their openable-panels, for example at the level of a trunk openable-panel, so as to trigger the opening or closing thereof. It also relates to systems allowing the implementation of such control.
2. Description of the Related Art
There are, at present, a certain number of motor vehicles equipped with “hands free” access systems allowing a user to act on a vehicle, from outside this vehicle, if this user carries an appropriate identifier, of the transponder type, which is recognized by a transmitter/receiver recognition device with which the vehicle is equipped, when it lies in a specified geographical zone in the vicinity of the vehicle. Such an access system acts, for example, on the mechanism for locking/unlocking the locks of the openable-panels of a motor vehicle, in such a way as to allow these openable-panels to be opened by one or more users as soon as the recognition device, which the vehicle comprises, has detected the presence at a suitable distance of a specified identifier.
Automatic opening of all the openable-panels of a vehicle and in particular of a motor vehicle, by the access system, in addition to the unlocking of the locks, is not generally envisaged in so far as complete simultaneous opening such as this of all the openable-panels is not necessarily beneficial in the case of motor vehicles. Such opening could moreover be a source of risk for a vehicle with openable-panels, of the leaf type, and for whatever was then in its environment. On the other hand, it may be convenient for a user to be able to control the opening and/or the closing of one of the openable-panels, for example a side-opening door or a trunk openable-panel, without having to operate a control member. This is beneficial, for example, in respect of a user who wishes to put a load which he is carrying between his hands into a vehicle without having to set this load down in order to open the openable-panel manually, or alternatively to close an openable-panel, when his hands are full.
SUMMARY OF THE INVENTION
It is then necessary to envisage a means allowing the user to trigger the opening and/or the closing of an openable-panel, as he desires, as soon as he fulfills the conditions necessary to obtain such opening.
A known remote control system makes it possible to instruct automatic opening of a trunk openable-panel, it comprises sensors which are disposed in the vicinity of the trunk, for example on either side of the registration plate adjoining this trunk, and which are able to detect the presence of a hand in proximity. The instruction for opening the trunk is triggered by the successive detection of the hand of a user in front of each of the sensors. This detection of successive presences of a hand in front of each of the detectors during the to-and-fro control motion is envisaged so as to limit the risks of triggering by a user, or even by a third party, making movements at the level of the sensors, without intending to instruct opening. On the other hand, the triggering of an instruction by a motion of this kind is not necessarily practical, in particular when the user is carrying a load which is difficult to handle, for example because of its bulk or its weight.
The invention therefore proposes a vehicle, in particular a motor vehicle which comprises a control system allowing a user to act remotely on an actuator mechanism secured to an openable-panel, such as a trunk openable-panel or a door.
According to one characteristic of the invention, this control system comprises means, at the level of the vehicle, for controlling by way of a motion sensor, at least one action of the actuator mechanism, when a motion is detected by way of a motion sensor, along a favored axis of detection of motion of this sensor and characterized in that this motion corresponds to a predetermined motion.
According to a variant of the invention, the control system comprises means, at the level of the vehicle, for controlling at least one action of the actuator mechanism, on the basis of the signals produced by motion sensors, when one and the same motion detected by way of these sensors along their respective favored axes is manifested as a specified motion along a resultant axis whose orientation is dependent on the achieved combination of sensors.
According to a variant of the invention, the control system comprises means by way of which the speed of motion, along the favored axis of the sensor or along the resultant axis of the sensors of the control system, which speed is determined on the basis of the signals supplied by each sensor, is utilized for the control of the actuator mechanism, in the event of the detection of a motion.
According to a variant of the invention, the control system comprises means by way of which the distance traveled, along the favored axis of the sensor or along the resultant axis of the sensors of the control system, which is determined on the basis of the signals supplied by each sensor, is utilized for the control of the actuator mechanism, in the event of the detection of a motion, in particular, for travel or angular opening control purposes, at the level of the actuator mechanism.
According to the invention, the orientation of the sensor or sensors on the vehicle is fixed in such a way that the favored axis of each sensor of the control system which is associated with the actuator mechanism of an openable-panel is oriented so as to detect motions occurring in at least one of the directions corresponding respectively to the direction of opening or of closing of the openable-panel.
According to the invention, the vehicle comprises an openable-panel actuator mechanism which is an openable-panel opening and/or closing electromechanical or mechanical assembly.
According to a variant of the invention, the vehicle comprises an openable-panel control system which is associated with a “hands free” access device which controls a mechanism for locking/unlocking at least one lock of an openable-panel of the vehicle.
According to a variant of the invention, the openable-panel control system acts on an actuator mechanism ensuring the opening and/or the closing of an openable-panel, this control system comprising one or more motion sensors disposed on the openable-panel or in proximity to the openable-panel on the vehicle.
According to a variant of the invention, the control system comprises one or more motion sensors, of the ultrasound or microwave frequency signal transmitter/receiver type.
According to a variant of the invention, the control system comprises means for controlling an openable-panel actuator mechanism which are designed so as to determine the control action to be effected as a function of the direction of motion as defined on the basis of the signals supplied by the sensor or sensors, preferably on the basis of a predetermined minimum threshold value of motion.
According to a variant of the invention, the direction of the specified motion, required to control the opening or the closing of an openable-panel by an actuator mechanism under the control of the means making it possible to control this mechanism, is chosen so as to correspond to the direction of motion of opening or of closing of the openable-panel which is requested.
The invention also proposes a control system for vehicle openable-panel and in particular for trunk openable-panel of a vehicle, such as a motor vehicle, this system being devised so as to allow a user to act remotely on an actuator mechanism secured to the openable-panel in the vehicle. According to the invention this system comprises means, intended to be mounted on the vehicle, for controlling at least one action of the actuator mechanism, as a function of the displacement of an object, such as a hand, vertically in a delimited control zone adjoining the openable-panel, this displacement being determined on the basis of the signals supplied by at least one motion sensor, of the motion detection signals transmitter/receiver type, which the system comprises and which is intended to be placed in proximity to the openable-panel, the radiation pattern of the or of each of the sensors being fixed in such a way as to delimit the control zone in the vicinity of the openable-panel.
The invention, its characteristics and its advantages are detailed in the description which follows in conjunction with the figures mentioned below.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 depicts a diagram of a control system intended to allow a user to act remotely at the level of a mechanism secured to an openable-panel of a vehicle, this control system, according to the invention, here being assumed to be associated with an access control system, such as a “hands free” system.
FIG. 2 depicts a basic diagram relating to the positioning and to the operation of a sensor of a control system, according to the invention, this system being associated with a trunk openable-panel on a vehicle, in a nonlimiting exemplary embodiment.
FIG. 3 depicts a basic diagram relating to a variant implementation of the invention, as illustrated in FIG. 2 .
FIGS. 4 and 5 respectively depict a basic diagram relating to a second variant implementation of the invention, as illustrated in FIG. 2 .
FIG. 6 depicts a basic diagram relating to a third variant implementation of the invention, as illustrated in FIG. 2 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
A basic diagram depicting the essential constituent elements of a control system allowing a user to act remotely on an actuator mechanism, secured to an openable-panel of a vehicle, is depicted, by way of example, in FIG. 1 . Associated therewith is a “hands free” access system, as mentioned above, it being understood that this preferably envisaged association, is not, however, indispensable.
The control system, according to the invention, is designed to allow a user to act on an actuator mechanism 1 of an openable-panel of a vehicle, not represented in this figure.
The invention is intended, in particular, to be implemented on a motor vehicle and at the level of an openable-panel, for example a trunk openable-panel. It is, of course, applicable to the other openable-panels which the vehicle may comprise.
The actuator mechanism 1 , secured to the openable-panel which is considered here, is for example a mechanism making it possible to ensure the opening and/or the closing of the openable-panel. Here it is assumed to be able to act in response to at least one control action executed by a user, which action is sent to it through control logic 3 . As known, the response of the actuator mechanism to a control may be obtained mechanically, for example by involving one or more springs, or electromechanically, for example by involving an electric motor.
In a variant embodiment, the actuator mechanism 1 is associated with a mechanism for locking/unlocking 2 a lock of the openable-panel to which it is assigned, in such a way as to allow the opening of the openable-panel, when its lock is unlocked and, possibly, to allow its closure, before a locking of the openable-panel in the closed position is carried out. As is known, the operations of locking and unlocking at least one openable-panel of a vehicle may be controlled by way of an access control logic unit with which the vehicle is equipped. This unit reacts for example to an action carried out by the user by means of a control member or remote control member. It may possibly involve the presence of a specified user identifier at the level of the vehicle, in particular, if the latter is equipped with a “hands free” access system as mentioned above and as envisaged in FIG. 1 . In the example depicted and according to a known embodiment, the identifier allocated to a user is of the transponder type, and it is able to transmit an identification signal in response to a specified interrogation signal. This interrogation signal is transmitted under the supervision of control logic 4 , furnished with identifier recognition means, with which the vehicle is equipped. The transmission/reception device is here symbolized by the antenna 5 which is assumed to be linked to the logic 4 by a transmitter/receiver, not represented.
By way of example and as envisaged above, it is assumed here that the access control logic 4 makes it possible to act on the locking/unlocking mechanism 2 and that it cooperates with the control logic 3 acting on the actuator mechanism 1 . These two logic facilities are possibly combined into a logic assembly 6 , as known to the person skilled in the art, their cooperation is effective, during operations where the mechanisms 1 and 2 are involved.
According to the invention, there is provision for the control logic 3 , which makes it possible to act on the actuator mechanism 1 secured to an openable-panel, to be furnished with means allowing it to react as a function of the motion of an object, and in particular of a hand, in a delimited control zone adjoining the openable-panel.
The motion is determined on the basis of signals which are obtained from at least one motion sensor 7 which is, for example, placed on the vehicle in proximity to the openable-panel, as illustrated in FIGS. 2 and 6 , or else on the openable-panel itself, as depicted in FIG. 4 . The sensor or sensors may thus be placed above or below the level of the openable-panel on the vehicle and for example on a bumper near this openable-panel, when the latter is a trunk openable-panel. A positioning on one side of the vehicle, in proximity to a trunk openable-panel, may thus be envisaged so as to allow control of this openable-panel, when only side access is possible, because of the vehicle parking conditions.
The sensor 7 , envisaged above, comprises, for example, means allowing it to transmit signals, for evaluation purposes, and to recover them, when they are reflected by an element constituting a reflector which is then situated in the field of the sensor. This reflector element can in particular be a hand of a user. The sensor 7 is, for example, constructed around a standard circuit for transmitting/receiving ultrasonic signals or a circuit for transmitting/receiving microwave frequency signals. It is assumed to possess a favored axis of detection of motion F, such as schematized in FIG. 2. A processing of the motion evaluation signals, received by the sensor envisaged above, is performed at the level of a logic facility of this sensor or of the control logic 3 with a view to determining the direction and, for example, the speed or the distance traveled in respect of a detected motion. This is achieved by implementing logic means known to the person skilled in the art. These means are, for example, located at the level of a computation unit of the control logic 3 , duly programmed.
The control system, according to the invention, takes into account the motion of a reflector element over the path followed by the waves emitted by the sensor 7 , in a delimited control zone. As known, the delimitation of this zone is dependent on the radiation pattern envisaged when designing the sensor 7 , this pattern is here assumed to be chosen of conical shape and oriented along an axis F which is a favored axis of detection for the sensor. The cone of emission of the sensor 7 is designed to be narrow and of small extent lengthwise so as to ignore the motion of an object, forming a screen, in particular above the vehicle, a distance away which may not correspond to the position of a hand of a user acting for control purposes.
An example of positioning the sensor 7 for an openable-panel 8 , of the trunk openable-panel type of a vehicle 9 , is illustrated in FIG. 2 . The sensor 7 is disposed therein below the level of the openable-panel 8 on the vehicle and, for example, in the middle of the vehicle on the bumper 10 , near this openable-panel, the latter here being assumed to open through an upward tilting motion. The radiation pattern D of the sensor is vertically oriented and it is assumed to cover a narrow zone, of conical shape spreading upward and adjoining the trunk openable-panel. Of course, the orientation of the beam emitted by the sensor manifested by the radiation pattern may be modified, according to the forms and orientation of the part of the vehicle where the openable-panel to be remotely controlled is situated, as well as those of this openable-panel. In particular, it is conceivable to have a beam oriented in the reverse direction to that depicted, for example if the sensor 7 is fixed on the top of the vehicle, above a vertical or quasi-vertical openable-panel, and if it defines a control zone situated below it which extends over at least part of the height of this openable-panel. The sensor can also be disposed in such a way that the favored axis F of the sensor is only approximately vertical. Specifically, as shown diagrammatically in FIG. 1 , it is the vertical component “y” of the motion of the object forming a screen to the waves emitted by the sensor 7 which is taken into account by the logic 3 , for determining whether the component of the motion along the vertical axis corresponds to a predetermined motion characteristic of a control action executed by a user, as shown diagrammatically in FIG. 2 , for a motion of a screen object which is symbolized by an arrow M, in a vertical plane x, y.
In a given form of implementation, there is provision for the hand motion making it possible to control the upward opening of the trunk openable-panel 8 , shown diagrammatically in FIG. 2 , to correspond to a motion carried out upward in the control zone of vertical orientation delimited by the sensor 7 . This sensor is assumed here to be placed at the upper part of the bumper 10 . The carrying out of such a motion does not correspond to a customary action of a user at this level, in the absence of a control system according to the invention. It is manifested as a vertical component along the favored axis of the sensor 7 which is taken into account if it corresponds to a predetermined motion, along this axis.
A hand motion in the direction reverse to the previous may possibly be utilized to control the closing of the openable-panel by the mechanism 1 , when the latter is designed to carry out such opening/closing operations.
The working of the control system according to the invention may possibly be conditioned by the detecting of a user in the vicinity of the openable-panel. This may be obtained by use of a detection system with which the vehicle is moreover equipped and, for example, of a system for detecting obstacles by ultrasound which is used as an aid to vehicle parking.
There is also provision for the cooperation of a “hands free” access system with a control system, according to the invention, at the level of a vehicle to make it possible to carry out a remote openable-panel command, by detecting a defined motion in proximity to an openable-panel, only if the access system has determined the presence in proximity to the vehicle of an authorized user having an appropriate identifier. The actions of the various detection control and access control systems mentioned above may of course be coordinated in various ways, as a function of the requirements of users, in so far as the programming of the logic facilities which supervise them is envisaged for this purpose.
A variant embodiment is illustrated in FIG. 3 , in conjunction with a trunk openable-panel 8 ′ fitted with an actuator mechanism 1 ′ and equipping a vehicle 9 ′ similar to that shown diagrammatically in FIG. 2 .
The vehicle 9 ′ is equipped with a control system which corresponds functionally to that defined in conjunction with FIG. 1 and which comprises two motion sensors 7 A′ and 7 B′. These sensors make it possible to detect a motion of a reflector element and in particular of a hand of a user, in a delimited control zone in proximity to an openable-panel, so as to determine whether this motion corresponds to a control action executed by the user. The sensors 7 A′ and 7 B′ are aligned along the openable-panel, for example, on the bumper 10 ′ extending horizontally on the body of the vehicle below this openable-panel. They are disposed in such a way that their respective radiation patterns cut one another symmetrically along the openable-panel. In the embodiment depicted in FIG. 3 , the two sensors are disposed in such a way that their respective favored axes FA′ and FB′, symmetrically inclined the one towards the other, are in one and the same plane, for example vertical, perpendicular to the longitudinal mid-plane of the vehicle where they cut one another. The control logic, which supervises them, is for example programmed so as to trigger a control action only if it determines that there is equality of value and identity of direction for the vertical component of speed of displacement obtained on the basis of the measurements originating from a sensor and for the component obtained on the basis of the measurements performed by the other sensor.
In a preferred embodiment, the layout of the sensors of the control system, such as 7 A′ and 7 B′, on the equipped vehicle and, in particular, the orientation of their respective favored axes FA′, FB′ determine the orientation of a resultant axis R′ along which a motion, detected by the assembly formed by these sensors, is taken into account, so as to determine whether this motion corresponds to a predetermined control motion. This resultant axis R′ is assumed to have vertical orientation in the example depicted in FIG. 3 , another orientation may of course be chosen as a function of requirements, this orientation being for example oblique, or else horizontal as envisaged in respect of the embodiment illustrated in FIG. 6 .
In the exemplary implementation illustrated in FIG. 3 , each of the sensors associated with an openable-panel, in a control system according to the invention, performs measurements in the limited zone which is defined by its emission pattern. The control logic, which supervises these sensors, is, for example, programmed to trigger a control action, by taking as criterion one or more given conditions of speed, for the motion determined along the resultant axis R′, on the basis of the signals supplied by each sensor to the logic, in the event of the detection of one and the same motion by the sensors.
Similarly in the exemplary implementation illustrated in FIG. 2 , the control logic is programmed to trigger a control action by taking as criterion one or more given conditions of speed, for the motion determined along the favored axis F of the sensor 7 , on the basis of the signals supplied by this sensor, in the event of the detection of a motion of an element, and in particular of a hand, by this sensor.
The triggering of an action at the level of the actuator mechanism by a control system according to the invention can for example be obtained, as soon as the speed, determined by the logic, of the motion exceeds a predetermined minimum threshold value. Openable-panel opening or closing actions may thus be obtained, according to requirements, as a function of the direction of motion noted by way of the sensor or sensors.
In another implementation, the control logic which supervises the sensor or sensors is programmed so as to utilize the distance traveled, as determined along the favored axis, such as F, of a single sensor or along the resultant axis, such as R′, in the case of an assembly of sensors associated with one and the same openable-panel, as a criterion for the control of the actuator mechanism of this openable-panel. To avoid an inadvertant instruction by a user, there is provision, in one embodiment, not to trigger an instruction until the amplitude of the detected motion exceeds a specified minimum threshold value. There is also provision to utilize the criterion of distance traveled to control the angular opening of a pivoting openable-panel, such as the openable-panel 11 of the vehicle illustrated in FIG. 4 , or the magnitude of its travel in the case of a sliding openable-panel, such as the openable-panel 12 of the vehicle depicted in FIG. 6 , in such a way as to allow partial opening or closing. An openable-panel opening, proportional to the distance traveled by a hand in a predetermined direction of motion, may thus be obtained for a given instruction. As is known, the displacement of an element, in the control zone defined by one or more sensors, may be determined on the basis of speed measurements carried out on the basis of pulsed signals or else of Doppler type measurements carried out on the basis of continuously emitted waves. The determination of the trajectory followed during displacement may also possibly be carried out by correlation of the speed of the screen-forming object with its distance with respect to the sensor.
FIGS. 4 and 5 pertain to one implementation of the invention, at the level of a vehicle comprising a pivoting openable-panel 11 , where there is provided a motion sensor 13 assumed to be positioned at the level of an operating handle which this openable-panel comprises. The sensor 13 is mounted in such a way that its favored axis of detection F is oriented in such a way as to detect motions performed at least almost vertically by a user for example by means of a hand in the control zone which corresponds to the radiation pattern of this sensor. In the theoretical example given, this pattern of approximately ellipsoidal or ovoidal shape is oriented upward along the favored axis F of the sensor, as shown diagrammatically, in such a way as to take into account the motions of a reflector element and in particular of a hand in a control zone situated above the sensor 13 and deviating progressively outward from the openable-panel 11 , upward of this openable-panel 11 which it adjoins.
FIG. 6 pertains to an implementation of the invention, at the level of a vehicle comprising a sliding openable-panel 12 and at least one motion sensor 14 , here assumed to be fixed on a vehicle side wall along which the openable-panel slides. The sensor 14 is mounted in such a way that its favored axis of detection F is oriented in such a way as to detect motions performed at least almost horizontally by a user for example by means of a hand in the control zone which corresponds to the radiation pattern of this sensor. In a preferred embodiment, the orientation of the sensor or possibly of the sensors of the control system associated with this sliding openable-panel is chosen so as to ensure detection of the motions occurring in at least one of the directions corresponding respectively to the direction of opening or of closing of the openable-panel. This serves to allow the user to control the sliding of the openable-panel by a hand motion performed, along the vehicle and in proximity to the openable-panel, in the direction of motion desired for the openable-panel. | The invention concerns a vehicle comprising a system enabling a user to control remotely an actuating mechanism ( 1 ) connected to an opening panel, in particular a boot opening panel ( 8 ). The control system comprises means, equipping the vehicle, for controlling at least an action of the actuating mechanism, according to the movement of an object, such as a hand, vertically in a delimited control zone adjacent to the opening panel. Said movement is determined from signals obtained from at least a movement sensor ( 7 ) placed on or proximate to the opening panel and whereof the radiation pattern if fixed to delimit the control zone. | 4 |
BACKGROUND OF THE INVENTION
This invention relates generally to computed tomography (CT) imaging and more particularly, to a high-resolution kernel with low noise and low aliasing artifacts.
In some known clinical applications, it is desirable to be able to visualize small structures inside a human body. For example, in an Inner Auditory Canal (IAC) examination, radiologists examine small bony structures to discover abnormalities. Traditionally, such examinations are performed using high-resolution kernels, for example, a bone kernel or edge kernel, during the tomographic reconstruction process. The kernel provides that high frequency contents in the projection are enhanced such as by applying a polynomial weighting function to the original filter kernel, so that the high-frequency regions are scaled by a factor greater than one as set forth below:
G ( f )= w ( f )· R ( f ), where (1)
f is a frequency variable,
R is the original “Ramp” filter, and
w is the weighting function.
BRIEF DESCRIPTION OF THE INVENTION
In one embodiment, a system for visualizing relatively small structures within an object includes an image acquisition sub-system for acquiring a dataset for a volume of interest and processor for generating image data from the acquired data wherein the processor is programmed to execute a high resolution filter kernel algorithm that includes a weighting factor applied to a ramp filter that scales relatively high frequency regions of the image dataset by a factor greater than one. The high resolution filter kernel algorithm also includes a windowing function applied to the weighted ramp filter that facilitates reducing aliasing artifacts in reconstructed images generated from the image dataset.
In another embodiment, an imaging system includes an image acquisition portion for acquiring data, a controller configured to control the image acquisition portion, and a processor configured to receive a dataset for an object that includes relatively small structures, the processor is further programmed to process the dataset using a high resolution filter kernel algorithm including a weighting factor applied to a ramp filter that scales relatively high frequency regions of the image dataset by a factor greater than one. The filter kernel algorithm also includes a windowing function applied to the weighted ramp filter that facilitates reducing aliasing artifacts in reconstructed images generated from the image dataset.
In yet another embodiment, a method of visualizing relatively small structures within an object includes receiving a dataset for a volume of interest and applying a high resolution filter kernel algorithm to the dataset wherein the high resolution filter kernel algorithm includes a weighting factor and a windowing function. The weighting factor is applied to a ramp filter that scales relatively high frequency regions of the dataset by a factor greater than one and the windowing function is applied to the weighted ramp filter such that aliasing artifacts in reconstructed images generated from the image dataset are facilitated being reduced.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 illustrates an exemplary edge kernel function;
FIG. 2 illustrates an exemplary reconstructed head image acquired with full scan (2π gantry rotation) using the edge kernel shown in FIG. 1 ;
FIG. 3 illustrates an exemplary reconstructed head image acquired with a half-scan acquisition (π+fan angle) using the edge kernel shown in FIG. 1 ;
FIG. 4 is a pictorial view of a multi slice volumetric CT imaging system;
FIG. 5 is a block schematic diagram of the multi slice volumetric CT imaging system illustrated in FIG. 4 ; and
FIG. 6 is a graph 600 of an exemplary image reconstruction kernel that may be used with the system shown in FIG. 4 .
FIG. 7 is a graph of an exemplary image reconstruction kernel that may be used with the system shown in FIG. 4 ; and
FIG. 8 is a graph of another exemplary image reconstruction kernel that may be used with the system shown in FIG. 4 .
DETAILED DESCRIPTION OF THE INVENTION
As used herein, an element or step recited in the singular and proceeded with the word “a” or “an” should be understood as not excluding plural said elements or steps, unless such exclusion is explicitly recited. Furthermore, references to “one embodiment” of the present invention are not intended to be interpreted as excluding the existence of additional embodiments that also incorporate the recited features.
Also as used herein, the phrase “reconstructing an image” is not intended to exclude embodiments of the present invention in which data representing an image is generated but a viewable image is not. Therefore, as used herein the term, “image,” broadly refers to both viewable images and data representing a viewable image. However, many embodiments generate (or are configured to generate) at least one viewable image.
FIG. 1 illustrates an exemplary edge kernel function. In this example, the cutoff frequency of the kernel is 1.8 times the Nyquist value of a single projection. The exemplary edge kernel function design produces high resolution images. However, it also may produce reconstructed images with aliasing artifacts.
FIG. 2 illustrates an exemplary reconstructed head image acquired with full scan (2π gantry rotation) using the edge kernel shown in FIG. 1 . Aliasing artifacts are clearly visible.
FIG. 3 illustrates the exemplary reconstructed head image acquired with a half-scan acquisition (π+fan angle) using the edge kernel and aliasing artifacts become significantly magnified such that the image is un-useable from a clinical point of view.
FIG. 4 is a pictorial view of a multi slice volumetric CT imaging system 10 . FIG. 5 is a block schematic diagram of system 10 illustrated in FIG. 4 . In the exemplary embodiment, a computed tomography (CT) imaging system 10 is shown as including a gantry 12 representative of a “third generation” CT imaging system. Gantry 12 has a radiation source 14 that projects a cone beam 16 of x-rays toward a detector array 18 on the opposite side of gantry 12 .
Detector array 18 is formed by a plurality of detector rows (not shown) including a plurality of detector elements 20 , which together sense the projected x-ray beams that pass through an object, such as a medical patient 22 . Each detector element 20 produces an electrical signal that represents the intensity of an impinging radiation beam and hence the attenuation of the beam as it passes through patient 22 . An imaging system 10 having a multislice detector array 18 is capable of providing a plurality of images representative of patient 22 . Each image of the plurality of images corresponds to a separate “slice” of the volume. The “thickness” or aperture of the slice is dependent upon the thickness of the detector rows, system geometry, x-ray focal spot size, and the reconstruction algorithm.
During a scan to acquire radiation projection data, gantry 12 and the components mounted thereon rotate about an axis of rotation 24 . FIG. 5 shows only a single row of detector elements 20 (i.e., a detector row). However, multislice detector array 18 includes a plurality of parallel detector rows of detector elements 20 such that projection data corresponding to a plurality of quasi-parallel or parallel slices can be acquired simultaneously during a scan.
Rotation of gantry 12 and the operation of radiation source 14 are governed by a control mechanism 26 of CT system 10 . Control mechanism 26 includes a radiation controller 28 that provides power and timing signals to radiation source 14 and a gantry motor controller 30 that controls the rotational speed and position of gantry 12 . A data acquisition system (DAS) 32 (sometimes referred to herein as a sub-system) in control mechanism 26 samples analog data from detector elements 20 and converts the data to digital signals for subsequent processing. An image reconstructor 34 receives sampled and digitized radiation data from DAS 32 and performs high-speed image reconstruction. The reconstructed image is applied as an input to a computer 36 , which stores the image in a mass storage device 38 .
Computer 36 also receives commands and scanning parameters from an operator via console 40 that has a keyboard. An associated display 42 allows the operator to observe the reconstructed image and other data from computer 36 . The operator supplied commands and parameters are used by computer 36 to provide control signals and information to DAS 32 , radiation controller 28 , and gantry motor controller 30 . In addition, computer 36 operates a table motor controller 44 that controls a motorized table 46 to position patient 22 in gantry 12 . Particularly, table 46 moves portions of patient 22 through gantry opening 48 .
In one embodiment, computer 36 includes a device 50 , for example, a floppy disk drive or CD-ROM drive, for reading instructions and/or data from a computer-readable medium 52 , such as a floppy disk or CD-ROM. In another embodiment, computer 36 executes instructions stored in firmware (not shown). Generally, a processor in at least one of DAS 32 , reconstructor 34 , and computer 36 shown in FIG. 5 is programmed to execute the processes described below. Of course, the method is not limited to practice in CT system 10 and can be utilized in connection with many other types and variations of imaging systems. In one embodiment, Computer 36 is programmed to perform functions described herein, accordingly, as used herein, the term computer is not limited to just those integrated circuits referred to in the art as computers, but broadly refers to computers, processors, microcontrollers, microcomputers, programmable logic controllers, application specific integrated circuits, and other programmable circuits.
Set forth below is a description of an exemplary multislice CT system in accordance with one embodiment of the present invention. Although one embodiment of the system is described in detail below, it should be understood that many alternative embodiments of the inventions are possible. For example, although one particular detector and one particular pre-patient collimator are described, other detectors or collimators could be used in connection with the system, and the present invention is not limited to practice with any one particular type of detector. Specifically, the detector described below includes a plurality of modules and each module includes a plurality of detector cells. Rather than the specific detector described below, a detector which has non-segmented cells along the z-axis, and/or a detector which has multiple modules with multiple elements along the x-axis and/or z-axis joined together in either direction to acquire multislice scan data simultaneously, can be utilized. Generally, the system is operable in a multislice mode to collect one or more slices of data. Axial and helical scans can be performed with the system, and cross section images of a scanned object can be processed, reconstructed, displayed, and/or archived.
Although various embodiments are described above relative to a CT system, other medical imaging modalities, such as nuclear medicine, single positron emission tomography (SPECT), positron emission tomography (PET), nuclear magnetic resonance imaging (MRI), static X-ray imaging, dynamic (Fluoroscopy) X-ray imaging, and multimodality combinations thereof may also benefit form the methods described herein and the use of the present invention is contemplated with respect to these modalities
FIG. 6 is a graph 600 of an exemplary image reconstruction kernel that may be used with system 10 (shown in FIG. 4 ). Graph 600 includes an x-axis 602 graduated in units of frequency and a y-axis 604 graduated in units of magnitude. An upper frequency limit 606 defines an upper limit of a frequency region 608 and a lower frequency limit 610 defines a lower limit of frequency region 608 . A trace 612 illustrates the exemplary kernel shown in FIG. 1 . The aliasing artifacts illustrated in FIGS. 2 and 3 are caused by high-frequency in the projection aliased back into the low-frequency component of the projection. The aliasing artifacts can be reduced by zeroing out such aliased frequencies. A trace 614 illustrates an exemplary kernel capable of zeroing out the aliased high frequencies that result in aliasing artifacts. Trace 614 illustrates a kernel capable of zeroing out frequencies outside Nyquist region 608 , while maintaining the kernel shape inside Nyquist region 608 .
Mathematically, trace 614 is defined by:
K ( f )=Π( f )· G ( f ), where
Π(f) is a window function. The kernel illustrated by trace 614 preserves frequencies inside Nyquist region 608 and removes the high-frequency contents and facilitates suppressing the aliasing artifacts.
Compared to the “Edge” kernel illustrated in FIG. 1 , images reconstructed using the kernel illustrated in FIG. 6 preserve the sharpness of the bony structure of the head. Additional examination shows that the inner ear bony structures are well preserved when viewing with a wider display window.
Because of the zeroed out of frequencies in the windowed kernel, the amount of computation can be significantly reduced. For example, for the exemplary kernel shown in FIG. 6 , the forward FFT and multiplication with filter kernel can be obtained using approximately half of the computing power as it would using the “Edge” kernel illustrated in FIG. 1 .
FIG. 7 is a graph 700 of an exemplary image reconstruction kernel that may be used with system 10 (shown in FIG. 4 ). Graph 700 includes an x-axis 702 graduated in units of frequency and a y-axis 704 graduated in units of magnitude. A trace 712 illustrates the exemplary kernel shown in FIG. 1 . In the exemplary embodiment, a notch window 714 can be used such that only frequencies within a first predetermined window 716 of frequencies and a second predetermined window 718 of frequencies are removed, as illustrated in FIG. 7 . The notch filter is designed based on the characteristics of the system to remove the most pronounced aliasing while maintaining other high frequency content.
In yet another embodiment, the window functions (both π(f) and G(f) in the equation) are determined dynamically based on the anatomy that is scanned. For example, when scanning an inner ear region, the upper limit of the window function is substantially near the Nyquist frequency of the system, since significant aliasing artifact is likely to result. When scanning the mid-brain region, the upper limit is substantially higher since it is known a priori that the probability of aliasing artifact is low. Additionally, the shape of the reconstruction kernel, G(f), is different dependent on a reconstruction of the inner ear region or mid-brain region.
FIG. 8 is a graph 800 of an exemplary image reconstruction kernel that may be used with system 10 (shown in FIG. 4 ). Graph 800 includes an x-axis 802 graduated in units of frequency and a y-axis 804 graduated in units of magnitude. A trace 812 illustrates the exemplary kernel shown in FIG. 1 . In the exemplary embodiment, a “depth” 814 of the window function (or notch filter) is changed. As described above with reference to FIG. 7 , frequencies outside the frequency limit are set to zero. In the exemplary embodiment, frequencies outside the frequency limit are set to a relatively small value dependent on the desired outcome, as illustrated in FIG. 8 . This is mainly determined automatically or by the user based on the balance of aliasing artifact and the “sharpness” of the resulting image.
In yet another embodiment, the window functions (both π(f) and G(f) in equation) change with the reconstruction parameters. For example, the upper limit of the window function (or the notch filter location and width) changes with the reconstruction FOV, taking into account the reconstructed pixel size.
In yet another embodiment, the window functions (π(f) and G(f)) changes with the acquisition parameters. For example, the window functions can change with the helical pitch. It is known that at a low helical pitch (<1), more than 2π of projection data is available for the reconstruction of an image. Therefore, the reconstruction kernel Π(f) and the window function G(f) should include as much high frequency signal as possible to produce sharp images. When helical pitch increases (>1), the amount of high frequencies should be limited. For example, when helical pitch is between slightly larger than one, both window functions should reduce slightly in the high-frequency portion. However, when the helical pitch is significantly higher than 1, the upper limit of the frequency should be limited to near the Nyquist frequency to ensure aliasing free images.
In yet another embodiment, both functions should change with the “noise” level of the projection. When the noise level is high, the high frequency portion should be scaled back since the true high frequency signals are likely buried inside the noise and could not be observed in the reconstructed images. When the noise level is low, more high frequencies contents should be allowed in the window function.
Although the preceding embodiments are discussed with respect to medical imaging, it is understood that the image acquisition and processing methodology described herein is not limited to medical applications, but may be utilized in non-medical applications.
The description applying the above embodiments is merely illustrative. As described above, embodiments in the form of computer-implemented processes and apparatuses for practicing those processes may be included. Also included may be embodiments in the form of computer program code containing instructions embodied in tangible data storage device 38 , such as floppy diskettes, CD-ROMs, hard drives, or any other computer-readable storage medium, wherein, when the computer program code is loaded into and executed by a computer, the computer becomes an apparatus for practicing the invention. Also included may be embodiments in the form of computer program code, for example, whether stored in a storage medium, loaded into and/or executed by a computer, or as a propagated data signal transmitted, whether a modulated carrier wave or not, over some transmission medium, such as over electrical wiring or cabling, through fiber optics, or via electromagnetic radiation, wherein, when the computer program code is loaded into and executed by a computer, the computer becomes an apparatus for practicing the invention. When implemented on a general-purpose microprocessor, the computer program code segments configure the microprocessor to create specific logic circuits.
It will be appreciated that the use of first and second or other similar nomenclature for denoting similar items is not intended to specify or imply any particular order unless otherwise stated.
The above-described embodiments of an imaging system provide a cost-effective and reliable means for facilitating removing aliasing artifacts from reconstructed images and reducing the computing power needed for image reconstruction. More specifically, windowing a kernel to limit frequency above and below a predetermined Nyquist value facilitates reducing aliasing artifacts in images and zeroing the frequencies facilitates reducing the computations needed to reconstruct the images. As a result, the described methods facilitate image reconstruction in a cost-effective and reliable manner.
Exemplary embodiments of imaging system methods and apparatus are described above in detail. The imaging system components illustrated are not limited to the specific embodiments described herein, but rather, components of each imaging system may be utilized independently and separately from other components described herein. For example, the imaging system components described above may also be used in combination with different imaging systems. A technical effect of the various embodiments of the systems and methods described herein include facilitating reducing aliasing artifacts in images.
While the invention has been described in terms of various specific embodiments, those skilled in the art will recognize that the invention can be practiced with modification within the spirit and scope of the claims. | Methods and systems for a system for visualizing relatively small structures within an object are provided. The system includes an image acquisition sub-system for acquiring a dataset for a volume of interest and processor for generating image data from the acquired data wherein the processor is programmed to execute a high resolution filter kernel algorithm that includes a weighting factor applied to a ramp filter that scales relatively high frequency regions of the image dataset by a factor greater than one. The high resolution filter kernel algorithm also includes a windowing function applied to the weighted ramp filter that facilitates reducing aliasing artifacts in reconstructed images generated from the image dataset. | 6 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is based on and claims priority under 35 USC 119 from Japanese Patent Application No. 2014-120377 filed Jun. 11, 2014.
BACKGROUND
Technical Field
[0002] The present invention relates to a non-transitory computer readable medium, an information processing apparatus, and an attribute estimation method.
SUMMARY
[0003] According to an aspect of the invention, there is provided a non-transitory computer readable medium storing a program causing a computer to execute a process for attribute estimation. The process includes: extracting, for each user, feature quantities of plural pieces of image information that are associated with attributes of the user; integrating the extracted feature quantities for each user; and performing learning, input of the learning being an integrated feature quantity that has been obtained as a result of integration for each user, output of the learning being one attribute, and generating a learning model.
BRIEF DESCRIPTION OF THE DRAWINGS
[0004] Exemplary embodiments of the present invention will be described in detail based on the following figures, wherein:
[0005] FIG. 1 is a block diagram illustrating an example of a configuration of an information processing apparatus according to a first exemplary embodiment;
[0006] FIGS. 2A to 2C are schematic diagrams for describing learning operations performed by the information processing apparatus;
[0007] FIG. 3 is a schematic diagram for describing attribute estimation operations performed by the information processing apparatus;
[0008] FIG. 4 is a flowchart illustrating an example of learning operations performed by the information processing apparatus;
[0009] FIG. 5 is a flowchart illustrating an example of attribute estimation operations performed by the information processing apparatus;
[0010] FIG. 6 is a block diagram illustrating an example of a configuration of an information processing apparatus according to a second exemplary embodiment;
[0011] FIGS. 7A and 7B are schematic diagrams for describing a method of creating image label information in learning operations performed by the information processing apparatus;
[0012] FIG. 8 is a schematic diagram illustrating a configuration of image label information;
[0013] FIG. 9 is a schematic diagram for describing attribute estimation operations performed by the information processing apparatus;
[0014] FIG. 10 is a flowchart illustrating an example of learning operations performed by the information processing apparatus; and
[0015] FIG. 11 is a flowchart illustrating an example of attribute estimation operations performed by the information processing apparatus.
DETAILED DESCRIPTION
First Exemplary Embodiment
Configuration of Information Processing Apparatus
[0016] FIG. 1 is a block diagram illustrating an example of a configuration of an information processing apparatus according to a first exemplary embodiment.
[0017] An information processing apparatus 1 is constituted by a central processing unit (CPU) and the like, and includes a controller 10 that controls each unit and that executes various programs, a memory 11 that is constituted by a storage medium, such as a flash memory, and that stores information, and a communication unit 12 that performs external communication over a network.
[0018] The controller 10 executes an attribute estimation program 110 described below to thereby function as an image obtaining unit 100 , an image feature quantity extraction unit 101 , a feature quantity integration unit 102 , a learning model generation unit 103 , a user attribute estimation unit 104 , and the like.
[0019] The image obtaining unit 100 obtains learning image information 111 from the memory 11 in a learning stage. The learning image information 111 is image information that has been posted on a social networking service (SNS), and is image information for learning to which attributes of a user typically including sex, age, occupation, and the like have been assigned in advance as verified ones. In addition to information stored in the memory 11 , the learning image information 111 may be information that has been obtained from outside or that has been transmitted and received from outside via the communication unit 12 , or may be information prepared by manually assigning attributes to image information to which attributes have not been assigned in advance.
[0020] Furthermore, the image obtaining unit 100 obtains image information 116 from the memory 11 in an attribute estimation stage. It is assumed that the image information 116 is image information posted on an SNS, but attributes of a user who has posted the image information have not been assigned and are unknown. The image obtaining unit 100 not only obtains the image information 116 from the memory 11 , but may also receive image information obtained from outside or transmitted from outside via the communication unit 12 .
[0021] The image feature quantity extraction unit 101 extracts feature quantities from the learning image information 111 or the image information 116 obtained by the image obtaining unit 100 . The image feature quantity extraction unit 101 stores the feature quantities in the memory 11 as feature quantity information 112 . For example, the image feature quantity extraction unit 101 first extracts a local feature quantity using scale-invariant feature transform (SIFT) when extracting a feature quantity, performs clustering on the extracted local feature quantity using k-means, and takes K cluster centers that have been obtained as codewords. Next, the image feature quantity extraction unit 101 generates a bag-of-features (BoF) histogram for a neighbor codeword using a k-nearest neighbor algorithm and spatial pyramid matching (SPM), and assumes the histogram to be a feature quantity.
[0022] The feature quantity integration unit 102 integrates the feature quantities extracted by the image feature quantity extraction unit 101 for each user, and generates integrated feature quantity information 113 . The feature quantity integration unit 102 adds up, for each user, BoF histograms that are feature quantities, for example, and obtains the integrated feature quantity information 113 by performing normalization using the number of feature quantities.
[0023] The learning model generation unit 103 performs learning, the input of the learning being the integrated feature quantity information 113 that has been generated by the feature quantity integration unit 102 integrating, for each user, the feature quantities extracted from the learning image information 111 , the output of the learning being attributes of the user, and generates a learning model 114 . The learning model generation unit 103 uses an algorithm, such as a support vector machine (SVM), for example, when performing learning.
[0024] The user attribute estimation unit 104 estimates, by using the learning model 114 , attribute information from the integrated feature quantity information 113 that has been generated by the feature quantity integration unit 102 integrating, for each user, the feature quantities extracted from the image information 116 , and generates user attribute information 117 that is associated with the user.
[0025] The memory 11 stores the attribute estimation program 110 that causes the controller 10 to operate as the image obtaining unit 100 , the image feature quantity extraction unit 101 , the feature quantity integration unit 102 , the learning model generation unit 103 , and the user attribute estimation unit 104 , the learning image information 111 , the feature quantity information 112 , the integrated feature quantity information 113 , the learning model 114 , user information 115 , the image information 116 , the user attribute information 117 , and the like.
[0026] The user information 115 is information, such as a user identification (ID), for identifying a user who uses an SNS.
[0027] Note that the learning image information 111 , the user information 115 , the image information 116 , and the user attribute information 117 may be obtained from an external SNS server via the communication unit 12 .
Operations Performed by Information Processing Apparatus
[0028] Next, actions in the first exemplary embodiment will be described for (1) learning operations and (2) attribute estimation operations separately.
(1) Learning Operations
[0029] FIG. 4 is a flowchart illustrating an example of learning operations performed by the information processing apparatus 1 . FIGS. 2A to 2C are schematic diagrams for describing learning operations performed by the information processing apparatus 1 .
[0030] First, the image obtaining unit 100 obtains from the memory 11 the learning image information 111 regarding users who have a specific attribute (step S 1 ).
[0031] For example, in examples illustrated in FIGS. 2A to 2C , pieces of image information 111 a 1 , 111 a 2 , 111 a 3 , and so on are image information posted by a user 115 a , pieces of image information 111 b 1 , 111 b 2 , 111 b 3 , and so on are image information posted by a user 115 b , and pieces of image information 111 c 1 , 111 c 2 , 111 c 3 , and so on are image information posted by a user 115 c , and the users 115 a to 115 c have been assigned in advance respective attributes 111 a t to 111 c t .
[0032] A set of the attributes 111 a t and the pieces of image information 111 a 1 , 111 a 2 , 111 a 3 , and so on, a set of the attributes 111 b t and the pieces of image information 111 b 1 , 111 b 2 , 111 b 3 , and so on, and a set of the attributes 111 c t and the pieces of image information 111 c 1 , 111 c 2 , 111 c 3 , and so on described above are the learning image information 111 . If “male” has been selected as a specific attribute, for example, the image obtaining unit 100 obtains the pieces of image information 111 a 1 , 111 a 2 , 111 a 3 , and so on regarding the user 115 a and the pieces of image information 111 c 1 , 111 c 2 , 111 c 3 , and so on regarding the user 115 c . Note that a specific attribute may be selected by an administrator of the information processing apparatus 1 , or the information processing apparatus 1 may select “male”, “female”, and so on in order.
[0033] The image obtaining unit 100 may obtain image information regarding a user to which attributes have not been assigned in advance, the attributes being assigned by the user or an administrator of the information processing apparatus 1 thereafter, and may handle the image information and the attributes as the learning image information 111 .
[0034] Next, the image feature quantity extraction unit 101 extracts feature quantities respectively from the pieces of image information 111 a 1 , 111 a 2 , 111 a 3 , and so on and the pieces of image information 111 c 1 , 111 c 2 , 111 c 3 , and so on that have been obtained by the image obtaining unit 100 (step S 2 ). The image feature quantity extraction unit 101 stores the feature quantities in the memory 11 as the feature quantity information 112 .
[0035] Next, the feature quantity integration unit 102 integrates the feature quantities extracted by the image feature quantity extraction unit 101 for each user, and generates the integrated feature quantity information 113 (step S 3 ). That is, the feature quantities extracted from the pieces of image information 111 a 1 , 111 a 2 , 111 a 3 , and so on are integrated and assumed to be integrated feature quantity information 113 a regarding the user 115 a , and the feature quantities extracted from the pieces of image information 111 c 1 , 111 c 2 , 111 c 3 , and so on are integrated and assumed to be integrated feature quantity information 113 c regarding the user 115 c.
[0036] Next, the learning model generation unit 103 performs learning, the input of the learning being the integrated feature quantity information 113 a and 113 c , the output of the learning being an attribute of the users, that is, “male”, generates the learning model 114 (step S 4 ), and stores the learning model 114 in the memory 11 (step S 5 ).
[0037] Next, attribute estimation operations using the above-described learning model 114 will be described.
(2) Attribute Estimation Operations
[0038] FIG. 5 is a flowchart illustrating an example of attribute estimation operations performed by the information processing apparatus 1 . FIG. 3 is a schematic diagram for describing attribute estimation operations performed by the information processing apparatus 1 .
[0039] First, the image obtaining unit 100 refers to the user information 115 , as illustrated in FIG. 3 , determines a user 115 n to be a user who is to be a target of attribute estimation, and obtains pieces of image information 116 n 1 , 116 n 2 , 116 n 3 , and so on that have been posted by the user 115 n , from the memory 11 (step S 11 ). It is assumed that attributes 111 n t of the user 115 n are unknown. The image obtaining unit 100 may receive plural pieces of image information transmitted from a user for which attribute estimation is desired, and may assume the user to be a target of attribute estimation. That is, the image obtaining unit 100 need not refer to the user information 115 .
[0040] Next, the image feature quantity extraction unit 101 extracts feature quantities respectively from the pieces of image information 116 n 1 , 116 n 2 , 116 n 3 , and so on that have been obtained by the image obtaining unit 100 (step S 12 ).
[0041] Next, the feature quantity integration unit 102 integrates the feature quantities extracted by the image feature quantity extraction unit 101 , and generates the integrated feature quantity information 113 (step S 13 ). That is, the feature quantities extracted from the pieces of image information 116 n 1 , 116 n 2 , 116 n 3 , and so on are integrated and assumed to be integrated feature quantity information 113 n regarding the user 115 n.
[0042] Next, the user attribute estimation unit 104 estimates attribute information 117 n from the integrated feature quantity information 113 n , by using the learning model 114 generated as described in “(1) Learning Operations” (step S 14 ), and, if an attribute “male” is obtained, stores the attribute in the memory 11 as the user attribute information 117 while associating the attribute with the user 115 n (step S 15 ).
Second Exemplary Embodiment
[0043] A second exemplary embodiment is different from the first exemplary embodiment in that learning is performed by taking into consideration not only user attributes but also labels assigned to image information, and an attribute of a user who has posted image information is estimated on the basis of the result of the learning.
[0044] FIG. 6 is a block diagram illustrating an example of a configuration of an information processing apparatus according to the second exemplary embodiment.
[0045] An information processing apparatus 2 is constituted by a CPU and the like, and includes a controller 20 that controls each unit and that executes various programs, a memory 21 that is constituted by a storage medium, such as a flash memory, and that stores information, and a communication unit 22 that performs external communication over a network.
[0046] The controller 20 executes an attribute estimation program 210 described below to thereby function as an image obtaining unit 200 , an image feature quantity extraction unit 201 , an image label assigning unit 202 , a learning model generation unit 203 , an image label estimation unit 204 , a user attribute estimation unit 205 , and the like.
[0047] The image obtaining unit 200 has functions similar to the image obtaining unit 100 in the first exemplary embodiment. The image feature quantity extraction unit 201 has functions similar to the image feature quantity extraction unit 101 in the first exemplary embodiment. The image feature quantity extraction unit 201 stores feature quantities that have been extracted in the memory 21 as feature quantity information 212 .
[0048] The image label assigning unit 202 assigns image label information 213 that is generated by combining user attributes and image contents in accordance with the contents of learning image information 211 .
[0049] The learning model generation unit 203 performs learning, the input of the learning being feature quantities that have been extracted by the image feature quantity extraction unit 201 from the learning image information 211 , the output of the learning being image labels assigned to the learning image information 211 , and generates a learning model 214 .
[0050] The image label estimation unit 204 calculates, by using the learning model 214 , scores of the image labels from feature quantities that have been extracted by the image feature quantity extraction unit 201 from image information 216 , and estimates image labels to be associated with the image information 216 on the basis of the scores.
[0051] The user attribute estimation unit 205 integrates the image labels that have been estimated by the image label estimation unit 204 for each user, estimates an attribute of the user by comparing the scores of respective attributes, and generates user attribute information 217 that is associated with the user.
[0052] The memory 21 stores the attribute estimation program 210 that causes the controller 20 to operate as the image obtaining unit 200 , the image feature quantity extraction unit 201 , the image label assigning unit 202 , the learning model generation unit 203 , the image label estimation unit 204 , and the user attribute estimation unit 205 , the learning image information 211 , the feature quantity information 212 , the image label information 213 , the learning model 214 , user information 215 , the image information 216 , the user attribute information 217 , and the like.
Operations Performed by Information Processing Apparatus
[0053] Next, actions in the second exemplary embodiment will be described for (1) learning operations and (2) attribute estimation operations separately.
(1) Learning Operations
[0054] FIG. 10 is a flowchart illustrating an example of learning operations performed by the information processing apparatus 2 . FIGS. 7A and 7B are schematic diagrams for describing a method of creating the image label information 213 in learning operations performed by the information processing apparatus 2 . FIG. 8 is a schematic diagram illustrating a configuration of the image label information 213 .
[0055] First, the image label assigning unit 202 accepts selection of an attribute type for which learning (estimation) is desired (step S 31 ). Description will be given below while assuming that, as illustrated in FIG. 7A , there are attribute types including an attribute type 217 a that indicates “sex”, an attribute type 217 b that indicates “age”, and so on, and that the attribute type 217 a that indicates “sex” has been selected by an administrator or the like.
[0056] Next, the image label assigning unit 202 combines the attribute type 217 a that has been selected and image contents 213 a illustrated in FIG. 7B , and creates the image label information 213 illustrated in FIG. 8 (step S 32 ). The image label information 213 is obtained by combining attributes included in the attribute type 217 a and the image contents 213 a , and therefore, 30 image labels are created, the number “30” being obtained by multiplying the number of attributes “3” by the number of labels “10”.
[0057] Next, the image label assigning unit 202 assigns the created image labels of the image label information 213 to the learning image information 211 in accordance with operations performed by an administrator or the like (step S 33 ). Note that the learning image information 211 to which image labels have been assigned in advance may be prepared. Furthermore, a configuration may be employed in which feature quantities of the learning image information 211 are extracted, clustering is performed on the learning image information 211 on the basis of the feature quantities, the image label information 213 is created by using names, such as “class 1”, “class 2”, “class 3”, and so on, that are based on the clustering classification, instead of using the image contents 213 a , and the image labels are automatically assigned.
[0058] Next, the image feature quantity extraction unit 201 extracts feature quantities from the learning image information 211 (step S 34 ). The image feature quantity extraction unit 201 stores the feature quantities in the memory 21 as the feature quantity information 212 .
[0059] Next, the learning model generation unit 203 performs learning, the input of the learning being the feature quantities that have been extracted by the image feature quantity extraction unit 201 from the learning image information 211 , the output of the learning being image labels assigned to the learning image information 211 , generates the learning model 214 (step S 35 ), and stores the learning model 214 in the memory 21 (step S 36 ).
(2) Attribute Estimation Operations
[0060] FIG. 11 is a flowchart illustrating an example of attribute estimation operations performed by the information processing apparatus 2 . FIG. 9 is a schematic diagram for describing attribute estimation operations performed by the information processing apparatus 2 .
[0061] First, the image obtaining unit 200 refers to the user information 215 , determines a user who is to be a target of attribute estimation, and obtains pieces of image information posted by the user, from the memory 21 (step S 41 ). It is assumed that attributes of the user are unknown.
[0062] Next, the image feature quantity extraction unit 201 extracts feature quantities from the pieces of image information obtained by the image obtaining unit 200 (step S 42 ). The image feature quantity extraction unit 201 stores the feature quantities in the memory 21 as the feature quantity information 212 .
[0063] Next, the image label estimation unit 204 calculates, by using the learning model 214 generated as described in “(1) Learning Operations”, scores that are estimation values, each indicating the degree of matching with a corresponding image label, as illustrated in FIG. 9 , from the feature quantities that have been extracted by the image feature quantity extraction unit 201 from the image information 216 , and obtains score calculation results 204 a (step S 43 ). In an example illustrated in FIG. 9 , the score calculation results 204 a are results of calculation of the scores of all image labels, and items in the score calculation results 204 a are sorted in descending order of score.
[0064] Next, the user attribute estimation unit 205 integrates the scores of image labels for each attribute on the basis of the score calculation results 204 a (step S 44 ). For example, the scores of image labels that include “female” are added up, and the score of the attribute “female” is obtained. The scores of image labels that include “male” are added up, and the score of the attribute “male” is obtained. Similarly, the scores of image labels that include “unknown” are added up, and the score of the attribute “unknown” is obtained. Note that a method of integrating scores is not limited to a method using addition, and may be a method in which the highest score is selected for each attribute or may be based on other calculation methods.
[0065] Next, in a case where the score of the attribute “female”, which is 3.56, the score of the attribute “male”, which is 2.11, and the score of the attribute “unknown”, which is 0.22, are obtained, for example, the user attribute estimation unit 205 compares these values, estimates that the attribute “female” that has the highest score is an attribute of the user (step S 45 ), and stores the attribute in the memory 21 as the user attribute information 217 while associating the attribute with the user (step S 46 ).
[0066] In a case where an attribute is not alternatively determined but may have plural values, the user attribute estimation unit 205 estimates each attribute, an integrated value of which exceeds a predetermined threshold, to be an attribute of the user.
Other Exemplary Embodiments
[0067] Note that the present invention is not limited to the exemplary embodiments described above, and various modifications may be made without departing from the spirit of the present invention. In the first exemplary embodiment, while the functions of the image obtaining unit 100 , the image feature quantity extraction unit 101 , the feature quantity integration unit 102 , the learning model generation unit 103 , and the user attribute estimation unit 104 of the controller 10 are implemented only by the information processing apparatus 1 , some of the functions may be implemented by other server apparatuses or terminal apparatuses. Similarly, in the second exemplary embodiment, some of the functions of the image obtaining unit 200 , the image feature quantity extraction unit 201 , the image label assigning unit 202 , the learning model generation unit 203 , the image label estimation unit 204 , and the user attribute estimation unit 205 of the controller 20 may be implemented by other server apparatuses or terminal apparatuses.
[0068] The learning image information 111 , the feature quantity information 112 , the integrated feature quantity information 113 , the learning model 114 , the user information 115 , the image information 116 , and the user attribute information 117 need not be stored in the memory 11 of the information processing apparatus 1 , and the learning image information 211 , the feature quantity information 212 , the image label information 213 , the learning model 214 , the user information 215 , the image information 216 , and the user attribute information 217 need not be stored in the memory 21 of the information processing apparatus 2 . These pieces of information may be obtained from an external database or an external apparatus, or may be transmitted and received from an external apparatus without being stored in the memory 11 or the memory 21 , and may be used by each unit.
[0069] In the exemplary embodiments described above, while the functions of the image obtaining unit 100 , the image feature quantity extraction unit 101 , the feature quantity integration unit 102 , the learning model generation unit 103 , and the user attribute estimation unit 104 of the controller 10 , and the functions of the image obtaining unit 200 , the image feature quantity extraction unit 201 , the image label assigning unit 202 , the learning model generation unit 203 , the image label estimation unit 204 , and the user attribute estimation unit 205 of the controller 20 are implemented by the programs, all or some of the units may be implemented by hardware, such as an application-specific integrated circuit (ASIC). The programs used in the above-described exemplary embodiments may be stored in a recording medium, such as a compact disc read-only memory (CD-ROM), and provided. Furthermore, the steps described in the above exemplary embodiments may be interchanged, deleted, or added, for example, without changing the spirit of the present invention.
[0070] The foregoing description of the exemplary embodiments of the present invention has been provided for the purposes of illustration and description. It is not intended to be exhaustive or to limit the invention to the precise forms disclosed. Obviously, many modifications and variations will be apparent to practitioners skilled in the art. The embodiments were chosen and described in order to best explain the principles of the invention and its practical applications, thereby enabling others skilled in the art to understand the invention for various embodiments and with the various modifications as are suited to the particular use contemplated. It is intended that the scope of the invention be defined by the following claims and their equivalents. | There is provided a non-transitory computer readable medium storing a program causing a computer to execute a process for attribute estimation. The process includes: extracting, for each user, feature quantities of plural pieces of image information that are associated with attributes of the user; integrating the extracted feature quantities for each user; and performing learning, input of the learning being an integrated feature quantity that has been obtained as a result of integration for each user, output of the learning being one attribute, and generating a learning model. | 6 |
FIELD OF THE INVENTION
The present invention relates to the field of textile production, and more particularly, to a knitted bi-ply fabric construction with particular application to multi-purpose apparel.
BACKGROUND OF THE INVENTION
Double knit, or bi-ply, fabrics have been knitted together for over a century. One of the earliest of these fabric constructions (U.S. Pat. No. 709,734) comprises two knitted fabric webs that are united by stitches causing the yarn in one of the webs to engage the other web at specified intervals. The bi-ply fabric produced thereby was found to exhibit several desirable characteristics, including the ability to have one web, or face, formed from one type of yarn, and the other web formed of yarns of a distinctly different type. The earliest of these bi-ply constructions included a wool outer face and a cotton inner face, providing the combination of warmth and comfort.
Over the past one hundred years, various constructions of bi-ply fabrics have evolved, with particular emphasis on creating specific characteristics in each ply of the fabric that could not be achieved in either ply alone. In more recent years, bi-ply fabric constructions have been developed to take advantage of other features that can be accomplished with the known bi-ply constructions. For example, U.S. Pat. No. 5,373,713 to Miller discloses a bi-ply structure where one web is formed with thin and thick yarns grouped in adjacent courses, where the grouped courses are alternated to produce a ridged effect in the fabric. The thick yarns produce ridges and the intermediate thin yarns produce air entrapment channels in one web. These air entrapment channels provide a double layer of insulating air, one layer at the inside surface of the fabric and the second layer within the interior of the fabric.
There is also known a method of alternating interlock stitches in a bi-ply construction to produce a series of individual air pockets arranged in a checkerboard pattern on the inner layer of the fabric. This construction, however, does not permit air movement or channeling between the overlying webs.
What is needed is a bi-ply construction wherein both webs of the fabric may be formed of similarly sized yarns and similar yarn materials, while providing air channels for movement between the two plies of the fabric construction.
There are also known in the art specialty garments having functional aspects intended to address particular known problems. For example, there is known a garment having an electronic heating control system incorporate therein. There are also known specialty garments that incorporate physiological monitoring or medicinal stimulation to a wearer. Each of these very specific garment constructions addresses one particular known problem; however, they provide little or no other known utility. What is also needed, therefore, is a multi-purpose, multi-functional fabric and apparel.
SUMMARY OF THE INVENTION
The present invention is directed to a knitted bi-ply fabric, a method of forming a knitted bi-ply fabric, and multi-functional apparel formed therefrom the knitted fabric.
The knitted fabric is formed on a conventional circular knitting machine as two overlying, confronting webs. Knitted on this type of machine, each web is formed as a series of continuous lengths of yarn extending generally parallel to one another and having loops arranged in both the walewise and coursewise directions. The overlying webs are united at spaced intervals by a tuck stitch of yarn of one web engaging the other web. The tuck stitches are spaced apart walewise by a plurality of courses and coursewise by a plurality of wales to create channels running walewise between the stitches.
At least one channel-opening yarn is inserted between the two overlying webs during the knitting operation. This yarn, or yarns, may be cotton, polyester, nylon, or rayon between 36/1 and 14/1. The channel-opening yarn is held substantially in parallel relation to the parallel lengths of yarn forming each of the two overlying webs. Specifically, the channel-opening yarn is inserted under tension during the knitting operation. At the completion of the knitting operation, when the fabric and channel-opening yarn is permitted to relax, the channel-opening yarn causes the confronting webs to be spaced apart within each of the channels between the tuck stitches.
The number of channel-opening yarns that are inserted is dependent upon the spacing, in courses, between the tuck stitches; however, the use of the tuck stitches in combination with the channel-opening yarns permits both of the overlying webs not only to be formed of the same yarn materials and sizes, but also eliminates the need for introducing large and small yarns in the fabric construction to enable opening of the channels. For example, in one embodiment, each of the two confronting webs may be formed of cotton yarns between 28/1 and 12/1. Alternatively, the two webs can be formed of different materials having different properties. For example, for winter-weight apparel, the outer web may be formed substantially of hydrophobic yarns for water resistance and the inner web may be formed of hydrophilic yarns to move moisture away from the wearer.
Another aspect of the present invention is directed to apparel formed from the knitted fabric described above. While not limited thereto, the bi-ply fabric may be formed into upper and lower garments such as tops and bottoms.
Yet another aspect of the present invention is directed to apparel in which the channel-opening yarns are also wire; i.e., the yarns are metallic and are desirably conductive. Apparel formed from such a fabric construction may enable the introduction of supplemental heating, electronic signal transmission and reception, and/or micro-computerization.
These and other aspects of the present invention will become apparent to those skilled in the art after a reading of the following description of the preferred embodiments when considered in conjunction with the drawings. It should be understood that both the foregoing general description and the following detailed description are exemplary and explanatory only and are not restrictive of the invention as claimed.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a view of a garment incorporating the bi-ply fabric of the present invention;
FIG. 2 is a sectional view of the bi-ply fabric of the present invention taken along Line 2 — 2 of FIG. 1 when the fabric is in a relaxed condition in the course direction;
FIG. 3 is an enlarged diagrammatic view of the bi-ply fabric, illustrating in greater detail how the air pockets or channels are formed by the fabric construction of the present invention; and
FIGS. 4A and 4B are views of a garment incorporating the bi-ply fabric of the present invention having conductive yarns incorporated therein and an electronic device connected thereto.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring first to FIG. 1 , a garment is shown comprising a top 12 and a bottom 14 , both made from a bi-ply fabric constituted by inner and outer knitted webs tucked together at intervals to form a composite fabric.
The fabric is produced on a rotating dial and cylinder (bi-ply/jersey type) circular knitting machine, modified so that each feed is knitted either by the dial or cylinder. For example, for the #1 feed, the high butt cylinder needles are welting, the low butt cylinder needles are tucking, and the dial needles are knitting. A suitable machine is a 14-gauge machine having twenty feeds, although the fabric may also suitably be formed on machines of other gauges. In the present instance, the 14-gauge machine comprises a dial having 612 needles and a cylinder having 612 needles. The cylinder needles produce the outer ply 22 of the fabric and the dial needles form the inner ply 26 of the composite fabric tube (see FIGS. 2 and 3 ).
As shown in FIGS. 2 and 3 , the inner ply 26 and the outer ply 22 are interconnected at intervals by a tuck stitch 28 . On the knitting machine, the outer ply 22 is formed simultaneously with the inner ply 26 to form a continuous tube of two plies of fabric which, during fabrication are positioned so that the cylinder-knitted web is on the outside and the dial-knitted web is on the inside. During the knitting of the fabric, as the cylinder rotates past the feeders, the stitch cams elevate the tuck needle every ten courses to engage behind a dial needle and form a tuck stitch to tie the two plies of the fabric together.
In accordance with the present invention, the knitting machine is set up to feed yarns of similar size to the different yarn feeders of the circular knitting machine. Table I (below) is a chart of the knitting pattern for the fabric illustrated in FIGS. 2 and 3 . The columns represent the positions of the regular-butt cylinder needles R, the low-butt cylinder needles L, and the dial needles D, respectively, as the cylinder is rotated past each feed. The knit pattern repeats on 20 feeds, as shown. Each row in the chart represents a feed. The character of the yarn at each feed is represented for convenience by the reference A or B, although in the embodiment shown in FIGS. 2 and 3 , A and B are similar yarns. As will be discussed below, the A and B yarns may be of different sizes and types, depending upon the features desired in the final composite fabric.
The dial needles knit yarn from the odd numbered feeds, alternately. The cylinder needles, on the other hand, knit with the yarns at the even numbered feeds throughout the 20-course repeat. The stitches produced by this pattern are diagrammatically illustrated in FIG. 3 . Each yarn (A, B) extends generally parallel to the other yarns, producing a single coursewise row of loops within the repeat. The regular butt needles form wales R in the fabric, the low butt cylinder needles form wales L, and the dial needles form wales D. In setting up the machine, in each set of 12 cylinder needles, there may be a single low butt needle, and the remainder will be regular butt needles so that the tuck stitches are knitted in every twelfth cylinder wale.
TABLE I
Regular Butt
Low Butt
Cylinder
Cylinder
Feed Number
Needles
Needles
Dial Needles
Yarn Type
1
Welt
Tuck
Knit
A
2
Knit
Knit
Welt
B
3
Welt
Welt
Knit
A
4
Knit
Knit
Welt
B
5
Welt
Welt
Knit
A
6
Knit
Knit
Welt
B
7
Welt
Welt
Knit
A
8
Knit
Knit
Welt
B
9
Welt
Welt
Knit
A
10
Knit
Knit
Welt
B
11
Welt
Welt
Knit
A
12
Knit
Knit
Welt
B
13
Welt
Welt
Knit
A
14
Knit
Knit
Welt
B
15
Welt
Welt
Knit
A
16
Knit
Knit
Welt
B
17
Welt
Welt
Knit
A
18
Knit
Knit
Welt
B
19
Welt
Welt
Knit
A
20
Knit
Knit
Welt
B
21
Welt
Tuck
Knit
A
22
Knit
Knit
Welt
B
23
Welt
Welt
Knit
A
24
Knit
Knit
Welt
B
25
Welt
Welt
Knit
A
26
Knit
Knit
Welt
B
27
Welt
Welt
Knit
A
28
Knit
Knit
Welt
B
29
Welt
Welt
Knit
A
30
Knit
Knit
Welt
B
31
Welt
Welt
Knit
A
32
Knit
Knit
Welt
B
33
Welt
Welt
Knit
A
34
Knit
Knit
Welt
B
35
Welt
Welt
Knit
A
36
Knit
Knit
Welt
B
37
Welt
Welt
Knit
A
38
Knit
Knit
Welt
B
39
Welt
Welt
Knit
A
40
Knit
Knit
Welt
B
In one embodiment, the outer ply 22 is desirably formed of cotton yarns between 26/1 and 12/1, although the invention is not limited thereto. The outer ply 22 may alternatively have an even feed of a different type of yarn or yarn size, although when similarly sized yarns are used, the outer ply 22 provides a smooth and neat appearance. Other natural or synthetic-fiber yarns may be substituted to produce any special features that may be desired in the outer ply 22 . The inner ply 26 also comprises cotton yarns between 26/1 and 12/1. The interconnected plies 22 , 26 ultimately provide an air entrapment barrier to the inside channel formed between the inner and outer plies.
In a second embodiment, the inner ply 26 is formed of hydrophilic yarns, such as cotton, to promote the movement of moisture away from a wearer of a garment formed from the composite fabric. The outer ply 22 is then formed of hydrophobic yarns, such as polyester or nylon, to provide a water-repellent exterior. As those skilled in the art will appreciate, there are numerous possible combinations of yarn types and sizes.
At least one channel-opening yarn C is inserted between the two overlying webs during the knitting operation. In one embodiment, the yarn, or yarns, may be cotton, polyester, nylon, or rayon between 36/1 and 14/1. The channel-opening yarn C is held substantially in parallel relation to the parallel lengths of yarn forming each of the two overlying webs. Specifically, the channel-opening yarn C is inserted under tension during the knitting operation. At the completion of the knitting operation, when the fabric and channel-opening yarn is permitted to relax, the channel-opening yarn C causes the confronting webs to be spaced apart within each of the channels between the tuck stitches. As shown in FIGS. 2 and 3 , when the fabric is permitted to relax, the channel-opening yarns C retract into a sinusoidally-shaped orientation in the coursewise direction. Each yarn C is fed through the stop motion of the storage feeder (not around the feedwheel). The yarn is then pulled in between the two layers of fabric in front of a dial knit feed. The tension of each feed is between about 4 grams and 6 grams. This permits a yarn draw of between 94 inches per revolution and 106 inches per revolution of the cylinder; however, as those skilled in the art will appreciate, draw is directly related to the weight per square yard of the fabric.
The number of channel-opening yarns that are inserted is dependent upon the spacing, in courses, between the tuck stitches; however, the number and spacing of the channel-opening yarns is not critical to the present invention. The use of the tuck stitches in combination with the channel-opening yarns permits both of the overlying webs to be formed of the same yarn materials and sizes, and also eliminates the need for introducing large and small yarns in the fabric construction so as to create channel openings otherwise.
With the machine setup for forming the bi-ply fabric construction, certain settings are made for laying-in/inserting the one to three strands of channel-opening yarns between the tucks in the bi-ply fabric. The cap of the knitting machine is raised to a setting of 0.110 inches to make space for the laid-in yarns. The storage feeders for the channel-opening yarns are mounted between the cylinder tucks for stop motion only.
Another aspect of the present invention is directed to the bi-ply fabric as described above wherein the channel-opening yarns C are formed of a wire material that is desirably conductive. In one embodiment, the wire yarns are selected from the group of metallic yarns consisting of stainless steel, copper, nichromium and silver; however, the yarns are not limited thereto so long as they provide suitable electrical conductivity, resistance, radio frequency transmission, etc. as required for the intended applications described hereinbelow. Further, the metallic yarns may have outer covers such as silicon encapsulated wire for ultimate connection to a silicon microcomputer chip. Depending upon the particular application, the wire yarns are between about 27 American Wire Gauge (AWG) and 33 AWG. The wire yarns may further be braided or tinned and may be coated or uncoated. Suitable coatings/covers include cotton fabric outer sheathing, polyvinyl chloride (PVC) coating, or silicone encapsulation.
In one embodiment, the channel-opening yarns C of wire yarns provide two functions. First, they provide the channel-opening described above, and secondly, they provide a resistance heating structure between the outer 22 and inner 26 plies of the fabric construction of the present invention. The channel-opening/conductive yarns C are inserted into the fabric structure in the same manner described above. It has been found that a battery-powered or solar-powered resistance temperature device 42 , 46 (shown in FIGS. 4A and 4B ) may be interconnected to the terminal ends of the channel-opening/conductive yarns to complete the resistance heating circuit. Such a device is typical of suitable compact resistance temperature devices that may easily be inserted into a pocket or pouch 43 , 47 and interconnected via a connector 41 , 45 to the conductive yarns. If desired, a thermostatic controller, or rheostat (not shown) may be installed in the circuit to provide a wearer with the ability to regulate the amount of heat generated by the device 42 , 46 . Where multiple channel-opening/conductive yarns are incorporated into the fabric, and/or where a garment comprises multiple tubular pieces of fabric that are seamed together, the free ends of the channel-opening/conductive yarns may be joined by conductive flat seam stitches, tacks, conductive patches, or the like, at the seams 49 a , 49 b , 49 c.
In a second embodiment, one or more of the channel-opening/conductive yarns C serve as an antenna for the receipt and transmission of radio frequency (RF) signals. An antenna of this type and structure is capable of receiving and transmitting radio frequency signals for portable devices 42 , 46 such as cell telephones, wireless digital devices, etc. that are capable of transmitting voice and data signals.
In yet another embodiment, the conductive yarns C are connectable to a micro-computer device such as a global positioning system (GPS), personal digital assistant (PDA), etc.
Although the present invention has been described with preferred embodiments, it is to be understood that modifications and variations may be utilized without departing from the spirit and scope of the invention, as those skilled in the art will readily understand. Such modifications and variations are considered to be within the purview and scope of the appended claims and their equivalents. | A knitted fabric comprising two confronting webs, each web being formed by a series of continuous lengths of yarn extending generally parallel to one another and having loops arranged in walewise and coursewise rows. One web overlies the other and, the two webs being united at intervals by a tuck stitch of yarn of one web engaging the other web. The tuck stitches are spaced apart walewise by a plurality of courses to create channels between the stitches. The channels extend walewise of the webs. At least one yarn is inserted under tension between the two fronting webs and held in parallel relation to the parallel lengths of yarn. When relaxed, the yarn inserted under tension causes the confronting webs to be spaced apart within each of the channels. | 3 |
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
The Federal Government has certain rights pertaining to the present invention pursuant to Contract No.: NNX-08-CD-36 awarded by the National Aeronautics and Space Administration.
CROSS-REFERENCE TO RELATED APPLICATIONS
Not Applicable
BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates to a nanoscale surface plasmonics sensor comprising a fluid control system for delivering fluids to the sensor, and a quantitative protein assay method.
2. Description of Related Art
Conventional quantitative protein assays of bodily fluids typically involve multiple steps to obtain desired measurements. Such methods are not well suited for fast and accurate assay measurements in austere environments such as spaceflight and in the aftermath of disasters. Consequently, there is a need for a protein assay technology capable of routinely monitoring proteins in austere environments. For example, there is an immediate need for a urine protein assay to assess astronaut renal health during spaceflight. The disclosed nanoscale surface plasmonics sensor provides a core detection method that can be integrated to a lab-on-chip device that satisfies the unmet need for such a protein assay technology.
Assays based upon combinations of nanoholes, nanorings, and nanoslits with transmission surface plasmon resonance (SPR) are used for assays requiring extreme sensitivity and are capable of detecting specific analytes at concentrations as low as 10 −14 M in well controlled environments. Existing SPR-based sensors, however, do not lend themselves to repetitive assays of biological fluids because they are not compatible with fluidic control systems, sample handling, and washing between samples.
The present SPR sensor with nanofluidic control overcomes the aforementioned limitations associated with existing protein assays. The SPR-based sensor provides for a protein sensor and assay method that may also be used for the detection and quantitation of a wide variety of analytes from a wide variety of sources.
BRIEF SUMMARY OF THE INVENTION
The present invention incorporates transmission mode nanoplasmonics and nanofluidics into a single, microfluidically-controlled device. The device comprises one or more arrays of aligned nanochannels that are in fluid communication with inflowing and outflowing fluid handling manifolds that control the flow of fluid through the array(s). The array acts as an aperture in a plasmonic sensor. Fluid, in the form of a liquid or a gas and comprising a sample for analysis is moved from an inlet manifold, through the nanochannel array, and out through an exit manifold. The fluid may also contain a reagent used to modify the interior surfaces of the nanochannels, and/or a reagent required for the detection of an analyte.
The device operates in a transmission mode configuration in which light is directed at one planar surface of the array, which functions as an optical aperture. The incident light induces surface plasmon light transmission from the opposite surface of the array. The presence of a target analyte is detected by changes in the spectrum of light transmitted by the array when a target analyte induces a change in the refractive index of the fluid within the nanochannels.
This occurs, for example, when a target analyte binds to a receptor fixed to the walls of the nanochannels in the array. Independent fluid handling capability for individual nanoarrays on a nanofluidic chip containing a plurality of nanochannel arrays allows each array to be used to sense a different target analyte and/or for paired arrays to simultaneously analyze control and test samples in parallel.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an end-on cross section drawing showing the construction of a nanochannel array according to the present invention.
FIG. 2 is an end-on cross-section of a nanochannel coated on its metal surface with an analyte-binding material.
FIG. 3 is an illustration of a nanochannel array with microfluidic fluid control.
FIG. 4 is a side cross-section view along a nanochannel of a nanofluidic wafer.
FIG. 5 illustrates a urine protein analysis device comprising three nanochannel plasmonic sensor arrays.
DETAILED DESCRIPTION OF THE INVENTION
Nanofluidics, as used herein, refers to the behavior, manipulation, and control of fluids that are confined inside flow channel structures in which the cross-sectional dimensions are between 10 and 800 nanometers.
A “nanochannel,” as used herein, is a tubular structure having a rectangular cross-sectional shape. The dimensions of a channel are described by length, depth, and width, wherein the depth is measured perpendicular to the plane of a nanofluidic chip containing the nanochannel and length and width are measured in directions lying in the plane of a wafer containing a nanochannel array. Maximum depth and width, when used to describe a nanochannel having a rectangular cross-section, refer to a channel having a constant width and depth.
The sensor comprises a flat, transparent dielectric substrate 1 upon which a 30 nm to 500 nm thickness metal film 2 is formed ( FIG. 1 ). The metal film 2 may be formed directly on the substrate 1 or the substrate 1 may be coated with a 1-10 nm layer of another metal such as chromium or titanium to promote adhesion of the metal layer 2 to the substrate 1 . The metal film 2 , in turn, is covered with a 1-50 nm thickness of a transparent dielectric layer 3 . Aligned, uniform nanoslits having a width of between 10 nm and 800 nm, preferably 30 nm to 300 nm, are milled all the way through the transparent dielectric layer 3 and the metal film 2 with a regular periodicity ranging from 100 nm to 800 nm to form a nanoslit array. The nanoslits may be milled, for example, by means of a dual beam scanning electron microscope/focused ion beam. A transparent top layer 4 covers the transparent dielectric layer and seals the tops of the nanoslits to form nanochannels 5 which, in turn, form a nanochannel array 6 . The number of nanochannels per array may range from 5 to 5000 and preferably from 20 to 100. The metal film 2 may be made of any suitable metal and preferably a metal selected from Au, Ag, Cu, Pt, or combinations thereof. The transparent dielectric substrate 1 , dielectric layer 3 , and transparent layer 4 may be made, for example of PDMS, PMMA, quartz, SiOx, or a glass. In preferred embodiments, the substrate is made of quartz or a glass, the metal layer is made of gold or silver, the dielectric layer is made from SiOx or a glass, and the transparent top layer is made of PDMS or PMMA.
EXAMPLE
Array Fabrication
A quartz microscope slide is cleaned with a piranha solution (3:1H 2 SO 4 /H 2 O 2 ) at 80° C. for at least 10 minutes, rinsed with deionized water, and dried under nitrogen. A 1-3 nm Ti layer is deposited on the quartz surface using an e-beam evaporator. A 100 nm-200 nm Au film is deposited on the Ti layer. Nanoslits are milled with a focused ion beam system. For a typical nanoslit array, sets of 40 individual nanoslits are fabricated with a spacing defined by the array's periodicity. For transmission measurements, a reference window is milled into the same Au film that contains the nanoslit arrays. Normal beam conditions for the reference window are 30 kV and 30 pA.
All or a portion of the luminal surfaces of the nanochannels in an array may be modified to control their binding and or light transmission characteristics such as nonspecific binding and refractive index. To facilitate selective detection of particular target analytes, all or a portion of the lumenal surfaces of the nanochannels may be coated with substances that selectively bind to one or more analytes. For example, a self-assembling monolayer 2 a of molecules capable of cross-linking or associating with target analyte specific binding agents may be formed on the lumenal surfaces of the metal layers 2 of the nanochannels 5 ( FIG. 2 ). To selectively detect serum albumin, for example, in urine or other sample fluids, gold surfaces in nanochannels may be coated with a monolayer of N-succinimidyl-3-(2-pyridyldithio)propionate (SPDP) with a cross-linking group for anti-albumin antibody immobilized to the nanoslit surface, followed by coupling of the SPDP with anti-albumin antibody. To selectively detect IgG, protein A may be immobilized to gold nanoslit surfaces via SPDP.
To move fluids, including samples and reagents through the nanochannels in an array, the nanochannels are in fluid communication with inlet and outlet manifolds and means for moving fluid. The nanochannels may be formed in such a way as to have open ends that communicate directly with manifolds that overlap the nanochannels in the wafer containing the array. Such an arrangement can be formed, for example, by etching inlet and outlet manifolds into the substrate, metal, and dielectric layers before applying the transparent top layer of the wafer. Alternatively, the nanochannels may be formed as sealed tubes and communicate with manifolds located in a plane above or below the plane of the nanochannel array. FIG. 3 is a scanning electron microscope (SEM) image of a wafer 13 comprising 3 μm deep inlet 10 and outlet 11 manifolds formed in a transparent top layer overlapping the sealed ends 14 of 125 nm deep nanochannels in a nanochannel array 6 . FIG. 4 is a side cross-section view (not to scale) showing the relative positions of the wafer components including nanochannel inlet 10 a and outlet 11 a as well as the relative positions of a light source and detector in a sensor device comprising the wafer. Arrows within the wafer indicate the path of fluid flow, while arrows outside the wafer indicate the direction of light directed toward and light transmitted from the wafer.
A protein SPR sensor device comprising three nanochannel arrays 6 is illustrated in FIG. 5 . The apparatus consists of a light source 46 , an optical detection system 41 , a data acquisition unit 42 , and a microfluidic-based urine protein assay cartridge 43 comprising three nanochannel plasmonic sensor arrays 6 . The surfaces of the nanochannels in the plasmonic sensor arrays 6 are functionalized with an ultrathin film of receptors that may be nonspecific for binding to protein generally or may specific for binding target proteins to be detected in the urine. The sensor integrates to a microfluidic network 45 and pumping means 12 configured for reagent and fluid flow handling. Nanoslit array transmission spectra of light from a white light source 46 incident upon the top of the arrays 6 are captured by an optical detection system 41 comprising a fiber optical array, mini-spectrometer or CCD, for example, and processed and stored in a data acquisition unit 42 .
Fluid communication between a nanochannel array 6 and fluid handling manifolds allows fluid to be moved through the nanochannel array 6 using a pumping means 12 configured to move fluid through the nanochannel array 6 . The pumping means 12 includes, for example, electrokinetic, electrothermal, and peristaltic pumps and may be incorporated into the cartridge 43 or may be a separate unit as shown in FIG. 5 . The fluid handling capability of an individual nanoarray may be incorporated into nanofluidic chips containing a plurality of nanochannel arrays with each array being used to sense a different target analyte, for example, or to assay test and control samples simultaneously.
Devices of this type may also be used to detect a wide variety of analytes including proteins in biological samples such as urine, blood, saliva, as well as samples of non-biological origin.
Reference to particular embodiments of the present invention have been made for the purpose of describing a nanoscale surface plasmonics sensor with nanofluidic control. It is not intended that such references be construed as limitations upon the scope of this invention except as set forth in the following claims. | A microfluidically-controlled transmission mode nanoscal surface plasmonics sensor device comprises one or more arrays of aligned nanochannels in fluid communication with inflowing and outflowing fluid handling manifolds that control the flow of fluid through the array(s). Fluid comprising a sample for analysis is moved from an inlet manifold, through the nanochannel array, and out through an exit manifold. The fluid may also contain a reagent used to modify the interior surfaces of the nanochannels, and/or a reagent required for the detection of an analyte. | 8 |
This is a divisional of application Ser. No. 08/136,265 filed Oct. 15, 1993 now U.S. Pat. No. 5,411,639 granted May 2, 1995.
BACKGROUND OF THE INVENTION
Increasing the filler content of paper can provide the papermaker with numerous benefits, including savings in the cost of raw materials, improved optical properties, and better print quality. There are, however, limits to the amount of filler that can be substituted for papermaking fiber. At high filler contents, paper can suffer losses in strength, stiffness and sizing. All commonly used untreated fillers (e.g. clay, titanium dioxide, calcium carbonate) are known to have a detrimental effect on strength and sizing. Increasing the concentration of filler in conventional paper-making furnishes results in increased size demand to maintain the desired degree of water repellency in the finished paper. This is because a disproportionate fraction of the size is adsorbed on the high surface area filler in the furnish. This adsorbed size may be lost from the furnish due to poor retention, or more likely, the increased sizing demand is due to the manner in which the size becomes attached on the conventional high surface area filler components. This link is not permanent and does not contribute significantly to the paper's hydrophobicity. Thus the effectiveness of the size is reduced which results in an increase in sizing demand (see article entitled "Diagnostic Sizing Loss Problem Solving in Alkaline Systems", B. M. Moyers, 1991 TAPPI Papermakers Conference Proceedings, pages 425-432).
In particular, poor sizing efficiency and loss of water repellency over time (size reversion) are problems associated with the use of alkyl ketene dimer (AKD) and alkenyl succinic anhydride (ASA) sizing agents and calcium carbonate pigments, particularly in highly filled alkaline papers. These problems are generally accentuated when filler levels approach and exceed about 20%. In addition, strength properties decrease as filler levels increase, impacting negatively on converting operations and end use functionality. Thus, in circumstances where increasing filler content would be advantageous, associated sizing problems have occurred affecting paper quality, machine performance and runnability.
The mechanism by which permanent AKD sizing is imparted to alkaline papers is generally agreed to include the retention, distribution and anchoring of the size with proper molecular orientation onto the cellulose fibers. There has been some controversy as to the anchoring mechanism itself and whether or not a covalent bond is formed between cellulose hydroxyl groups and the lactone ring of the AKD molecule. Sizing losses over time have been attributed to interference on the molecular level by wet end additives and contaminants, as well as AKD/pigment interactions and the effects of AKD hydrolysis products. These results are reported for instance in the article entitled "The Interactions of Alkyl Ketene Dimer with other Wet-End Additives", by A. R. Colasurdo and I. Thorn, TAPPI Journal, September 1992, pages 143-149.
AKD sizing agents are basically waxes with relatively low melting points (approximately 115° F.). Their fluidity increases as sheet drying temperatures increase. According to accepted theory, once the size is retained in the sheet matrix, the sub-micron particles melt and spread over fiber and filler surfaces during the drying process before reacting with the cellulose fibers.
Efforts by others to reduce the sizing demand of filled papers include the invention disclosed in U.S. Pat. No. 5,147,507. This patent teaches a method for improving papermaking with the use of a calcium carbonate pigment modified by surface treatment with a cationic polymer. A polymer of the type used is sold under the tradename HERCON. In fact, HERCON is a tradename for a reactive size material. Thus, the '507 patent teaches a process whereby a reactive size is associated directly with the calcium carbonate pigment. The result is alleged to improve the papermaking process by reducing the usage of wet end sizing agent, improving opacity, improving filler retention and causing better drainage on the papermachine. However when used according to the patent, the surface treated pigment is combined with synthetic sizing agents such as AKD or ASA which results in the use of more sizing agent than would be required according to the present invention. In addition, the treatment specified in the '507 patent is more expensive than the process of the present invention.
SUMMARY OF INVENTION
In accordance with the present invention, a process has been developed for producing a modified pigment for improved sizing efficiency. The invention relates in general to a treatment for inorganic calcium carbonate pigments and the use of the treated pigments in a papermaking process. More specifically, the invention relates to both precipitated (PCC) and ground (GCC) calcium carbonate pigments which have been surface treated with a starch-soap complex. The specific morphologies of PCC that have been found to be useful in the practice of the present invention include the scalenohedral, rhombohedral and acicular forms. The pigment modification is achieved by complexing a fully cooked corn or potato starch with a soluble soap. The starch-soap complex is then mixed with a calcium carbonate pigment slurry where the starch-soap complex is precipitated on the pigment surfaces. This reaction takes place by displacement of sodium by calcium ions in the pigment slurry. The benefits of the surface treatment are manifested in improved sizing efficiency, reduced size reversion and increased dry strength properties when the surface treated pigment is incorporated in a conventional alkaline papermaking furnish. Unlike an untreated pigment, the treated pigment of the present invention provides sites for bonding sizing agents with proper molecular orientation so that they remain available to contribute to the hydrophobicity of paper made from the paper making furnish. Scalenohedral forms of PCC surface treated with the starch-soap complex surprisingly produce an increase in water repellency as filler loadings increase at the same size addition. With rhombohedral forms of PCC, the sizing values remain constant as filler loadings increase. These findings are based on the use of an industry standard Hercules size test (HST). All other forms of ground and precipitated calcium carbonate pigments show improvement in HST values as compared with papers containing untreated control pigments.
The starch-soap complex of the present invention is precipitated onto the pigment surfaces in the presence of ions which make the soap insoluble. A related product is disclosed in a paper entitled "A Precipitated Starch Product", by C. C. Kessler and W. C. Black, presented at the Annual Meeting of the Technical Association of the Pulp and Paper Industry, February 16-19, 1942. In the paper, Kessler and Black disclose paper machine trials where a starch-soap complex was added to a papermaking furnish and completely precipitated by aluminum ions in intimate association with the fibers of a papermaking furnish. The use of the product in papermaking is described as providing high starch retention.
In the present invention, the starch-soap complex is precipitated on the surfaces of an inorganic pigment, preferably a calcium carbonate pigment. The process can be carried out by precipitating the starch-soap complex directly onto the pigment before the treated pigment is introduced into a papermaking furnish, or the starch-soap complex may be prepared first, precipitated, and then introduced into a papermaking furnish containing the pigment. In the preferred method, the pigment is surface treated prior to incorporation into a papermaking furnish to achieve optimum sizing efficiency. Since starch is chemically similar to cellulose, it is postulated that once the starch-soap complex precipitates and becomes anchored on pigment surfaces, permanent covalent bonds between the sizing material and the starch hydroxyl groups associated with the treated pigment are formed. This ability to form permanent covalent bonds with starch hydroxyl groups as well as the hydroxyl groups associated with cellulose fibers, increases the proportion of size which has reacted either with cellulose or starch in the paper web, thereby increasing the ultimate water repellency of the papers. Thus, the size becomes permanently anchored on both the cellulose fibers and the treated filler component of the paper web.
This modification of the pigment component of the papermaking furnish permits the use of higher than normal filler loadings in coated and uncoated fine papers, bleached board products, and other paper grades that contain filler. The potential benefits from the use of the modified pigment include improved smoothness and print quality, reduced fiber and size usage, as well as the possible elimination of cationic starch addition to the wet end.
BRIEF DESCRIPTION OF THE DRAWING
The drawing diagrams the process for making the treated pigment of the invention.
DETAILED DESCRIPTION
The process for making the treated pigment of the present invention is illustrated schematically in the drawing. The initial step involves conventional cooking of a corn or potato starch either in a batch cook or continuously in a starch jet cooker. Unmodified corn or potato starches are preferred although modified starches such as oxidized starches can also be used.
The second step in the process involves physically mixing the starch solution with the soap component comprising, sodium or potassium salts of fatty acids, in concentrations ranging from about 1% to about 10%. The complexed starch products produced will totally precipitate when sufficient calcium, magnesium or aluminum ions are introduced into unmodified starch solutions, and will be partially precipitated with the use of a modified starch. The addition of divalent or trivalent calcium or aluminum ions will form an insoluble soap and a precipitate of the complex.
The third step in the process involves metering between about 1.5 and 30.0 parts of the starch-soap complex per 100 parts pigment into a pigment slurry under moderate rates of shear, or into a pigment-containing papermaking furnish under shear. When mixed with a precipitated calcium carbonate slurry, or a papermaking furnish containing precipitated calcium carbonate, sufficient calcium ions are present to completely precipitate the complexed starch products onto the pigment surfaces. Precipitation of the complexed starch is virtually instantaneous.
In order to test the theory of the present invention, a treated pigment was prepared as follows. A standard pearl corn starch supplied by A. E. Staley was batched cooked at 2.0% solids for 20 minutes at 95°-98° C. After completion of the cook, 3.0% soap flakes were added to the starch paste at 90° C. while mixing with a magnetic stir bar. The fatty acid composition of the soap is summarized in Table 1.
TABLE 1______________________________________Acid Percent______________________________________Myristic (C.sub.14) 0.11Palmitic (C.sub.16) 25.98Palmitoleic (C.sub.16) 7.42Stearic (C.sub.18) 16.72Oleic (C.sub.18) 38.48Shorter than (C.sub.14) 5.73______________________________________
The soap flakes were mostly a mixture of C 16 to C 18 fatty acids. The predominant fatty acid component was oleic acid followed by palmitic and stearic acids.
After the temperature had dropped to about 80° C., variable concentrations of the complexed starch product were metered into separate batches of a 20% solids ALBACAR HO calcium carbonate pigment slurry supplied by Specialty Minerals, Inc., to produce a surface treated pigment according to the preferred method of the invention. This particular PCC pigment displayed a scalenohedral morphology with an average particle diameter of about 1.6 microns.
The following examples illustrate the sizing benefits obtainable with the use of the surface treated pigment described hereinbefore.
EXAMPLE I
Surface treated pigments having complexed starch concentrations ranging from zero (a control), up to about 7.50 parts per 100 parts pigment were incorporated into an 80% hardwood/20% softwood bleached kraft fiber furnish. The complexed starch contained 3.0% soluble soap as described hereinbefore. Furnish additives included 12.0 lb/ton Cato 232 cationic starch, 3.0 lb/ton Keydime E alkyl ketene dimer size, 5.0 lb/ton aluminum sulfate and 0.5 lb/ton Reten 1523H anionic polyacrylamide retention aid. Handsheets were prepared at a target 50 lb/ream basis weight (ream size 3,300 sq. ft.). The handsheets were dried at 240° F. and conditioned for 1.5 hours prior to initial water repellency testing. HST sizing tests were also completed 4 weeks after manufacture to determine the extent of size reversion. Table 2 summarizes the sizing results.
TABLE 2______________________________________Starch/100 parts HST Sizing (sec).Pigment PCC % Initial 4 wks.______________________________________Control 26.6 41 151.50 27.3 225 1063.75 26.9 428 3797.50 26.5 439 473______________________________________
The benefits associated with pigment treatment on sizing are apparent. As the concentration of complexed starch on pigment was increased to about 7.50 parts per 100 parts pigment, the initial sizing values increased from 41 to 439 seconds at a constant 3.0 lb/ton addition of AKD size. Size reversion also decreased with increasing concentrations of complexed starch. Meanwhile, the dry strength properties of handsheets made from the furnish with surface treated pigment also increased without adversely affecting the optical properties of the paper.
EXAMPLE II
In a second experiment, the concentration of the complexed starch used in Example I was increased to about 30.0 parts/100 parts pigment. This pigment was incorporated into handsheets as outlined above in Example I, except that the Reten 1523H concentration was increased to 0.75 lb/ton. Table 3 summarizes the sizing results.
TABLE 3______________________________________Starch/100 parts HST Sizing (sec).Pigment PCC % Initial 4 wks.______________________________________Control 16.4 96 4030.0 17.2 244 244Control 22.8 6 130.0 23.6 288 253______________________________________
Two concentrations were evaluated, a control with untreated pigment, and a sample containing pigment treated with 30.0 parts starch/100 parts pigment. Enhanced sizing and essentially no size reversion were achieved with the use of the surface treated pigment. The high concentration of complexed starch on pigment resulted in large increases in the internal bond of the handsheets.
EXAMPLE III
In a third experiment, target filler loadings of from about 15-50% were evaluated to determine the effect of the surface treated pigment on sizing efficiency. Furnish conditions were the same as the previous study described above except for the use of a treated pigment reacted with a starch-soap complex prepared with 5.0% soluble soap. Each condition contained 7.50 parts complexed starch/100 parts pigment. The results of the HST sizing test are shown in Table 4.
TABLE 4______________________________________ HST Sizing (Sec.)Condition PCC % Initial 4 wks.______________________________________Control 15.3 281 217Treated 16.3 387 354Control 19.9 131 22Treated 21.5 439 453Control 26.3 3 1Treated 25.8 614 677Control 35.2 1 0Treated 34.4 640 579Control 50.6 0 0Treated 48.0 243 336______________________________________
With the untreated control pigment, initial sizing values decreased from 281 to 3 seconds as filler loadings increased from about 15% to 26%. This was not unexpected, since reductions in sizing with increased filler loadings and the significant loss of sizing over time, is typical for PCC pigments in commercial applications. However, with the surface treated pigment, initial sizing values increased from 387 to 640 seconds as filler loadings increased from 16-34%. Even at the 48% filler level, substantial water repellency was achieved without increasing the concentration of the sizing agent. With the treated pigment, sizing was also stable over time as shown by the 4 week measurements. This is a result of the present invention that was unexpected, since generally higher levels of sizing agent are required to maintain equivalent HST size values as filler loadings are increased.
EXAMPLE IV
Table 5 summarizes the impact of the soluble soap component of the starch-soap complex on HST sizing values. For this example, the furnish components were identical to those outlined in Example III and the treated pigment contained 7.50 parts starch/100 parts complexed pigment.
TABLE 5______________________________________ HST Sizing (Sec.)Soap on Starch % PCC % Initial 4 wks.______________________________________Control (0.0) 27.0 370 381 5.0 25.8 614 67710.0 26.8 604 615______________________________________
An initial sizing value of 370 seconds was achieved with the control when 7.5 parts of non-complexed pearl corn starch was added to the PCC pigment. This occurred because pearl corn starch will partially precipitate in the presence of soluble calcium ions while a portion of the starch remains in solution. Nevertheless, the addition of 5.0% and 10.0% of the soluble soap to the cooked starch showed a substantial increase in sizing benefits. At the 5.0% level of soap addition, essentially all of the starch precipitated on the pigment surfaces.
EXAMPLE V
Data comparing unmodified pearl corn starch and potato starches are shown in Table 6.
TABLE 6______________________________________Starch Starch/100 Parts HST Sizing (Sec.)Type Pigment PCC % Initial 4 wks.______________________________________Control 0.0 15.3 264 201Corn 15.0 17.2 428 405Potato 15.0 16.1 407 362Control 0.0 26.7 13 6Corn 15.0 24.9 564 520Potato 15.0 24.1 390 140______________________________________
In this experiment, each starch product was cooked at 1.0% solids. Exactly 3.0% soluble soap was added to each starch paste following the same procedure previously outlined. Fifteen parts complexed starch was added to each 100 parts pigment. Furnish and wet end additive concentrations were identical to those in the experiment summarized in Table 2. In this comparison, both starches outperformed the untreated control although the corn starch produced superior initial sizing values and better sizing stability over time.
At target filler loadings of about 25%, using 3.0 lb/ton AKD size, initial sizing values with an untreated PCC pigment ranged between about 3 and 41 seconds. With the surface treated pigment according to the present invention, at the same AKD concentration, sizing values were an order of magnitude higher. Furthermore, at filler levels as high as 48%, good sizing values and no reversion was measured with no increase in the concentration of sizing agent.
EXAMPLE VI
The study summarized in Table 7 shows the results of an investigation of the impact of reducing the AKD concentration on HST sizing while using a surface treated pigment in accordance with the present invention. This is significant since lower concentrations of sizing agents could reduce machine deposits in commercial applications. Furnish and wet end additive concentrations are identical to those outlined in connection with Example I, and the PCC pigment was surface treated with 7.50 parts starch/100 parts complexed pigment. The complexed starch contained 3.0% soluble soap.
TABLE 7______________________________________AKD Conc. HST Sizing (secs.)lb/ton PCC % Initial 4 wks.______________________________________1.0 27.4 1 --1.5 25.4 11 82.0 26.3 427 3693.0 26.0 644 583______________________________________
The data in Table 7 indicate that a 33% reduction in AKD size produced an initial HST sizing value of 427 seconds. Moreover, the sizing value remained substantially stable after four weeks (369 seconds). This experiment demonstrated that good water repellency with reduced use of internal size can be achieved with the surface treated pigments of the present invention.
EXAMPLE VII
In another experiment, a rhombohedral pigment, ALBAGLOS S, supplied by Specialty Minerals Inc., was evaluated. This pigment displayed a mean particle diameter of 0.5 microns. Untreated and surface treated pigments were compared in a handsheet study with target filler loadings of 5-25%. Pearl corn starch from A. E. Staley was complexed with 3.0% soluble soap. Furnish and wet end additives were identical to those outlined in previous experiments. The data are summarized in Table 8.
TABLE 8______________________________________Pigment HST Sizing (secs.)Treatment PCC % Initial 4 wks.______________________________________No 5.4 326 296Yes 5.5 334 300No 11.0 222 194Yes 10.9 280 270No 16.4 85 53Yes 15.5 326 301No 22.0 9 7Yes 19.4 347 327No 27.7 1 0Yes 26.1 307 290______________________________________
With the surface treated pigment, constant initial sizing values were substantially maintained over the entire range of filler loadings. As expected, the handsheets containing the control pigment showed systematic decreases in HST sizing as filler levels increased. Dry strength properties were also significantly higher for handsheets containing the surface treated pigment.
EXAMPLE VIII
In this study, an ultra fine ground calcium carbonate pigment (OMYAFIL), supplied by the Omya Corporation, was evaluated. This pigment had a mean particle diameter of 0.7 microns. The unmodified pearl corn starch was complexed with 3.0% soap flakes. Exactly 7.50 parts complexed starch were added to 100 parts pigment following the procedure outlined in previous examples. Significant sizing benefits versus the untreated controls were achieved and are summarized in Table 9.
TABLE 9______________________________________ HST Sizing (secs.)Condition PCC % Initial 4 wks.______________________________________Control 16.2 170 137Treated 16.2 239 250Control 21.9 51 20Treated 21.3 211 191Control 27.4 1 1Treated 26.4 188 185______________________________________
In summary, the novel features of the surface treated pigments of the present invention include enhanced sizing efficiency and reduced size reversion as filler loadings increase without the necessity of adding higher concentrations of size. This result is contrary to any known effect in conventional papermaking furnishes. The invention also substantially eliminates the size reversion problems associated with precipitated calcium carbonate pigments. Finally, the invention provides the ability to effectively size papers containing PCC pigments when filler loadings are higher than about 20%, while still retaining dry strength properties.
The invention has been described in detail in connection with the use of precipitated calcium carbonate pigments. However, those skilled in the art will appreciate that the surface treatment described herein is readily adaptable to ground calcium carbonate or other inorganic pigments capable of being reacted with the starch-soap complex of the invention. The use of the invention with PCC is significant because of the current shift to alkaline papermaking processes which use satellite PCC pigment manufacturing processes. The present invention is readily adaptable to such satellite manufacturing processes.
Accordingly, while the invention has been fully described, many changes and variations in the use of the treated pigments may be made by those skilled in the art within the context of the claims annexed hereto. | A papermaking process with improved sizing efficiency and reduced size reversion is characterized by the use of a calcium carbonate pigment which is surface treated with an anionic starch-soap complex. The starch-soap complex is precipitated onto the pigment surfaces to provide bonding sites for sizing agents which impart water repellency to the paper. The sizing agents become bound to the starch component of the starch-soap complex to yield more reacted size in paper webs formed from the furnish than would be present without the use of the treated pigment. The use of the surface treated pigment also allows the papermaker to increase the filler content of the paper without sacrificing dry strength properties. | 3 |
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