description stringlengths 2.98k 3.35M | abstract stringlengths 94 10.6k | cpc int64 0 8 |
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TECHNICAL FIELD
The invention relates generally to a baseball pitching apparatus, and more particularly with a professional and portable training target to focus and gauge the accuracy of a thrown or struck baseball while dramatically reducing the forward force of the baseball as it is striking the target so it falls harmlessly to a front pocket for later retrieval.
BACKGROUND ART
The baseball pitching apparatus of the present invention provides a good target for a professional level baseball player to focus and gauge the accuracy of his pitches and yet it effectively dissipates the energy and redirects the baseball without any complex mechanism. Prior art reveals several different targets for baseballs and the like but most such devices as U.S. Pat. No. 5,083,774 employs a complex mechanism to help dissipate the energy from a thrown baseball. The frame assembly of the '774 patented device is connected to an underlying base by pivotal bolts and utilizes two extension springs attached diagonally between the frame assembly ends and the base. The other type of angled rearwardly frames with netting as shown in U.S. Pat. Nos. 4,863,166 and 4,932,657 also lack the target area and stability of the present invention which provides a large and ample target for pitching but yet captures the thrown baseball without having the baseball bound away if the center target area is missed.
While the '744 patent attempts to alleviate the impact force of pitched baseballs, the spring mechanism and pivoting bolts are going to provided maintenance problems over a number of pitches and the netting overall presents a less desirable target for throwing baseballs because the netting poorly simulates a solid target like a catchers glove and the reference point of where the balls are hitting the netting is hard to decipher for a pitcher.
These baseball target systems, as shown in the prior art, are incapable of addressing the energy dissipating problem yet provide a good pitching target zone for a professional baseball player like the present invention.
SUMMARY OF THE INVENTION
Accordingly, an important object of the present invention is to provide a baseball pitching apparatus having a portable frame and fabric drape combination that holds the pitching target area erect and very effectively dissipates the energy of the thrown baseball as it hits the target without a complex mechanism.
A further object of the invention is to provide a portable baseball pitching apparatus having a light weight tubular frame that flexes rearwardly as the baseball moves into a fabric drape having the pitching target thereon to dissipate the energy of the baseball and to redirect the baseball into a front pocket of the draped fabric for holding the expended pitches.
Another object of the invention is to provide a portable baseball pitching apparatus that can be quickly disassembled, reassembled and transported from one location within a short period of time and either no tools or a minimum of tools required for assembly.
In the preferred embodiment of the invention, the invention is comprised of a tubular frame generally configured into a number of interconnected rectangular shapes in different planes, a fabric drape positioned to attach to at least one end of a predetermined number of planar rectangular shapes to suspend the fabric in a generally vertical target area for a pitching target that permits the rectangular tubular shapes to flex in relationship to one another for dissipating the energy of the baseball hitting the target area of the fabric drape.
In one embodiment, the tubular frame of the portable baseball pitching apparatus is comprised of three quarter inch outside diameter 18 gauge steel tubing. The easily assembled frame consists generally often component parts of steel tubing that join together to form the unique portable baseball pitching apparatus. Two component parts are horizontal base members which are parallel and spaced apart from one another in the assembled frame that are generally mirror images of each other. Each tubular base member includes a generally vertical extension of the tubing that is perpendicular to its length and located toward the rear end thereof, and a nearly adjacent extension of tubing that is generally angled away from the vertical extension in an angle greater than 90° toward the front end of the tubular base member when assembled. The front and rear ends of each tubular base member are open. The front ends of each tubular base member slope upwardly at an angle less than 90° from the horizontal plane of each members length. Four component parts of the frame are U-shaped cross bar members of generally the same dimensions having a predetermined length in the middle with generally rounded corners of approximately 90° degrees and each having legs on the U-shape extending upwardly from the middle length to tapered male ends. Next, four component parts of the frame are generally straight upright members of generally the same dimensions that have an open female end and a male tapered end.
The assembly of the ten component pans of the frame requires no tools. First, the front and rear ends of each tubular base member are joined in a predetermined fixed parallel and spaced apart relationship to one another by inserting the tapered male ends of two cross bar members into the front and rear corresponding female ends of the base member, respectively. The four tubular upright members of a predetermined length are then inserted with their male tapered ends into the corresponding female mating ends at the top of the generally vertical and angled extensions on the tubular base members. The four tubular upright members that are mated securely to the vertical and angled extensions on the tubular base lengths are then joined to their opposing upright member on the other tubular base member at their respective top female ends by inserting the male tapered ends of the two remaining U-shaped tubular cross bar members into the top female ends of the upright members in the vertical and angled extensions, respectively.
When the ten tubular components of the frame are assembled in the mated manner as previously described above, there are generally four rectangular planes. Two planes are formed by the base assembly. One plane is horizontally oriented which forms a stable base for the frame and a second rectangular shaped plane slopes upwardly from the base plane at the front of the apparatus toward the pitcher. A third rectangular plane is formed by the two upright members inserted in the vertical extensions on the tubular base members with a cross bar member joined between the top ends of each upright member. A fourth rectangular plane is formed by the two uprights extending up from the angled extensions on the tubular base members that are joined together at their tops by the cross bar member therebetween.
A pitching tarp consisting of a 19 ounce laminated coated vinyl fabric forms the target drape on this apparatus. The generally rectangular shaped tarp includes a sewn front end enclosed space extending laterally across the tarp for the insertion of the front cross bar member therethrough to secure the front end of the tarp to the cross bar member. Next, the tarp drapes across the base member and extends upwardly to a laterally sewn pocket in the tarp that the cross bar member across the upright members in the angled extensions is inserted. The tarp then drapes down behind its connection at the top of the angled uprights cross member and forms a loop before extending upwardly again to the top the vertical cross bar member where another sewn lateral pocket receives the vertical cross bar member therein to secure the rear of the tarp to the frame for providing a pitching target that is securely joined to the frame. This means of affixing the tarp to the frame provides a pitching apparatus that can receive baseballs thrown at any velocity by little league to major league pitchers without adverse effects to the apparatus.
Yet another embodiment includes a heavier frame of 1" O.D. 14 gauge tubular steel that is formed of basically the same dimensioned tubular frame members but further includes semicircular side plates with nuts and bolts that secure the cross bar members to the base members, the vertical and angled extensions and upright members. As a heavier duty construction, it can withstand even more high velocity pitches than the previous embodiment without adverse effects.
Other features and advantages of the invention, which are believed to be novel and nonobvious, will be apparent from the following specification taken in conjunction with the accompanying drawings in which there is shown a preferred embodiment of the invention. Reference is made to the claims for interpreting the full scope of the invention which is not necessarily represented by any one embodiment.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 illustrates the construction of a baseball pitching apparatus according to the present invention.
FIG. 2 is a cross section of FIG. 1 taken along lines 2--2.
FIG. 3 is a cross section of FIG. 1 taken along lines 3--3.
FIG. 4 is a top plan view of the apparatus of FIG. 1.
FIG. 5 is a front elevation of the apparatus of FIG. 1.
FIG. 6 is a left side elevation of the apparatus of FIG. 1.
FIG. 7 is a rear elevation of the apparatus of FIG. 1.
FIG. 8 is a cross section of FIG. 7 taken along lines 8--8.
FIG. 9 is an exploded right front perspective view of the frame of the baseball pitching apparatus as shown in FIG. 1.
FIG. 10 is a perspective view of the mating of the tapered ends and openings in the frame tubing as shown in FIG. 9.
FIG. 11 is a second embodiment of the exploded right front perspective view of the frame of the baseball pitching apparatus as shown in FIG. 1.
FIG. 12 is an exploded view of the couplings and bolts or pins that connected the frame members as shown in FIG. 11.
DETAILED DESCRIPTION
Although this invention is susceptible to embodiments of many different forms, a preferred embodiment will be described and illustrated in detail herein. The present disclosure exemplifies the principles of the invention and is not to be considered a limit to the broader aspects of the invention to the particular embodiment as described.
FIG. 1 shows a baseball pitching apparatus 10 according to the present invention. The apparatus 10 comprises a tubular frame 12 fabricated from various lengths of semi-rigid material such as steel. The frame 12 may also be constructed from aluminum, reinforced fiberglass or polyvinylcholoride or the like so long as the framing material is somewhat flexible. Although the steel frame 12 of the present invention is fabricated from round tubular steel, it may have an angle, square, or rectangular cross section too. The frame 12 is made from a tubular 3/4" O.D. 18 gauge steel. A tarp 14 fabricated from 19 ounce laminated coated vinyl is draped over the frame 12 to form a pitching target 16 for a baseball 20 that is thrown by a pitcher or hit by a batter. The frame 12 is comprised of ten component members. The component members are two base members 20 and 22, respectively, which are mirror images of each other. The right base member 20 includes a right vertical extension 24 at approximately a 90° to the length of the base member 20 and an right angled extension 26 that is angled toward a front end 28 and forms an angle of less than 90° with respect to the front end of the base member 20. Both the vertical and angled extensions 24 and 26, respectively, are located near the rear of the base member 20 and have male tapered ends 25. The front end 28 of base member 20 is slightly sloped upwardly at an angle greater than 90° with respect to the base member 20. The base member 22 includes the same left vertical and angled extensions 30 and 32, respectively, with the male tapered ends 31 and a slightly sloped upwardly front end 34 which are mirror images of the shapes and dimensions of base member 20.
As shown in FIGS. 1 and 9, the frame 12 further includes four U-shaped cross bar members 36 of generally similar dimensions having a pair of legs 38 with male tapered ends 40. In addition, the frame 12 includes four straight uprights 42 having female mating openings 44 for receiving the male tapered ends 38 of the cross bar members 36 and the tapered males ends 25 and 31 of the right and left vertical and angled extensions of base members 20 and 22, respectively. The frame 12 is simply assembled without tools by inserting the cross bar members 36 in the openings of the right and left front ends 28 and 34, respectively, and a right and a left rear ends 44 and 46, respectively of base members 20 and 22. The four upright members 42 are inserted over the tapered male ends 25 and 31 on the right and left base members 20 and 22, respectively. Then the two remaining cross bar members 36 have their tapered ends 40 inserted into the openings 44 on the top end of the upright member 42. The tapered male ends and the female openings may include a ball and detent or other means to more securely mate the tubular parts together.
FIG. 2 is a cross section taken along lines 2--2 of FIG. 1. FIG. 2 shows a cross section of cross bar member 36 in a pocket 50 having a pair of sewn ends 52 so that the pocket 50 is fit over the cross bar member 36 to vertically drape the tarp 14 downwardly to form a front channel 54 out of the tarp 14 as it slopes upwardly to attached to the front cross bar member 36. FIG. 3 is a cross section taken along lines 3--3 and its shows the cross bar member 36 extending through an opening 54 formed by the tarp rapped around the cross bar member 36 and sewn at a lateral stitch 56 back onto itself.
Referring back to FIG. 1 and FIGS. 6, 7 and 8, a pair of nylon straps 58 or the like are sewn at one end 60 spaced apart on either side of the tarp 14 at a predetermined point above the base member 20 and 22 and rear cross bar member 36 forming a generally rectangular plane 62. The straps extended downwardly to the rear cross bar member 36 and wraps around the bar and includes a button snap 64, as shown in FIG. 8, for securing the tarp 14 to the lower base rectangular plane 62. The tarp 14 which is draped over a rectangular plane 66 formed by the angled extensions 26 and 32, uprights 42 and the cross bar member 36 provides the target area for the pitcher while a rectangular plane 68 formed by the vertical extensions 24 and 30, uprights 42 and cross bar member 36 adds stability to the frame and fabric drape of the tarp combination so that the target area 16 is held erect while effectively dissipating the energy of the baseball 18 as shown in FIGS. 1 and 6. The stability is furthered by the tarp 14 having a second pocket 70 that fits over the rear cross bar member 36 as shown in FIGS. 1, 2, 4, 5, 6, and 7 while the straps 58 put tension between the rectangular planes 66 and 68 with the tarp 14 drape over their cross bar members 36.
FIG. 4 show a top view of the baseball pitching apparatus with its tarp 14 cut away for viewing the rear pocket 70, middle pocket 50 and front opening 54 for mounting the cross bar members 36 therein to hold the pitching target 16 and the tarp 14 in a fixed relationship with respect to the assembled frame 12 and to form a retention channel 55 in front of the angled upright rectangular plane 66.
FIG. 5 shows a front elevation of the baseball pitching apparatus in which the cross bar members 36 are dotted line in their pockets and openings on the frame 12. It gives a good look at what the pitcher sees as he gets ready to throw his practice pitches into the target area 16.
FIG. 7 is rear elevation of the baseball pitching apparatus in which the pair of straps 58 are shown sewn or affixed to the tarp at point 60 at either side of the tarp 14. One of the straps 58 is detached from the rear cross bar member 36 and the other strap 58 is attached around the rear cross member bar 36.
FIG. 8 is a cross section of FIG. 7 taken along lines 8--8, in which the construction of the strap 58 and its button snap 64 are shown in more detail as it wraps around the rear cross bar member 36 to hold the tarp in tension between the plane 66 and 68.
FIG. 9 shows an exploded right front view of the frame 12 for a baseball pitching apparatus 10 made in according with the present invention. The unique light weight steel frame 14 of the invention shows how easily the frame 14 can be transported in ten separate component members erected, used and disassembled by anyone without the need for a single tool for assembly.
FIG. 10 demonstrates the mating of an opening 44 in an upright 42 and a tapered end 25, 31 or 40 on the right and left angled or vertical extensions and cross bar members, respectively. Although one type of construction is shown, other types of fastening means like ball and detent may be used to secure the various tubular members to one another.
FIG. 11 shows the construction of a heavier duty frame 14 for the present invention. Instead of the male and female mating arrangement of the earlier embodiment for assembling the Frame component members together, semicircular steel plates 72 with a pair of openings 80 and 82 therethrough and a threaded bolt 74 having a washer 76 and a capture nut 78 to tighten the plates against the tubular members of the frame 14 in a very secure fashion which replaces the mating arrangement or may be used in addition to the mating arrangement to securely fasten the tubular frame members together.
In short, the baseball pitching apparatus according to the present invention provides a portable training device that not only creates a target area for the pitcher to focus on and gauge the accuracy of his pitch in the strike zone, but the front plane 66 defined by the upright members 42 and cross bar member 36 with the tarp thereover flexes slightly backward as a baseball 18 strikes the tarp 14 at a high velocity of speed and the combination of the tarp and flexing tubular members of the frame cleanly dissipates the force of the baseball as shown in FIGS. 1 and 6. The baseball 18 is then directed to the front channel 55.
The front upright members 42 anchored in the angled extensions 26 and 32 is angled forward in a predetermined fashion. The tarp 14 which drapes down from the front cross bar member 36 and its pocket 50 therein hangs unencumbered and moves with the baseball without striking the structural frame or upright members 42. The flexing of the upright members 42 in the rectangular plane 66 further dissipates the energy by flexing as the baseball moves into the drape of the tarp 14.
The front portion of the tarp 14 acts to frame the target area 16 and collect misguided baseballs that miss the strike zone. The rear portion of the tarp 14 draped over the rectangular plane 68 can be marked with the appropriate target to help focus the pitchers on different areas of the strike zone. In this case, the target area 16 frames an opening through the front drape of the tarp 14 on rectangular plane 66, an the baseball goes therethrough when a strike is thrown to hit the rear drape on plane 68. The rear drape of the tarp 14 acts to dissipate the energy of the baseball and redirects it down to a unique baffle 84. A ball bag or container (not shown) can be affixed to one end of the baffle to collect the baseballs.
The unique baseball pitching apparatus according to the present invention allows for the practical and cost effective manufacturing by using tubular components with similar dimensions, wedged ends or split couplings with bolts or quick pull pins that make it easy to assemble or disassemble and to transport to another location with a minimum of tools necessary to do the job.
While the specific embodiments have been illustrated and described, numerous modifications are possible without departing from the scope or spirit of the invention. One such modification is to have the baseball strike the front drape in plane 66 for all throws and eliminate the strike zone 16 that leads the baseball to the rear drape to dissipate the energy. The framing material may be changed to a something different than steel and still give the same flexing ability necessary for the draped tarp 14 and supports members on the frame to dissipate the energy from the baseball. | A baseball pitching apparatus having an unique light weight tubular steel frame separable into components parts and a fabric drape the makes it easy to transport, erect, use and disassemble. The frame and fabric drape combination hold the target area erect while effectively dissipating the energy and redirecting the baseball without any complicate mechanical or electrical mechanisms. | 0 |
FIELD OF THE INVENTION
The present invention relates to tunable oscillators and, more particularly, to the self-calibration of tunable oscillators to produce constant gain over a wide tuning range.
BACKGROUND OF THE INVENTION
Many electrical and computer applications and components have critical timing requirements that compel generation of periodic clock waveforms that are precisely synchronized with a reference clock waveform. A phase-locked loop (“PLL”) is one type of circuit that is widely used to provide an output signal having a precisely controlled frequency that is synchronous with the frequency of a reference or input signal. Wireless communication devices, frequency synthesizers, multipliers and dividers, single and multiple clock generators, and clock recovery circuits are but a few examples of the manifold implementations of PLLs.
Frequency synthesis is a particularly common technique used to generate a high frequency clock from a lower frequency reference clock. In microprocessors, for example, an on-chip PLL can multiply the frequency of a low frequency input (off-chip) clock, typically in the range of 1 to 4 MHz, to generate a high frequency output clock, typically in the range of 10 to over 200 MHz, that is precisely synchronized with the lower frequency external clock. Another common use of PLLs is recovery of digital data from serial data streams by locking a local clock signal onto the phase and frequency of the data transitions. The local clock signal is then used to clock a flip-flop or latch receiving input from the serial data stream.
FIG. 1 is a block diagram of a typical PLL 10 . The PLL 10 comprises a phase/frequency detector 12 , a charge pump 14 , a loop filter 16 , a voltage-controlled oscillator (“VCO”) 18 and frequency divider 20 . The VCO can be a current-controlled oscillator (“CCO”) having input provided by a voltage-to-current converter as will be appreciated by those skilled in the art. The PLL 10 receives a reference clock signal CLK REF and generates an output clock signal CLK OUT aligned to the reference clock signal in phase. The output clock frequency is typically an integer (N) multiple of the reference clock frequency; with the parameter N set by the frequency divider 20 . Hence, for each reference signal period, there are N output signal periods.
The phase/frequency signal detector 12 receives on its input terminals two clock signals CLK REF and CLK* OUT (CLK OUT , with its frequency divided down by the frequency divider 20 ). In a conventional arrangement, detector 12 is a rising edge detector that compares the rising edges of the two clock signals. Based on this comparison, the detector 12 generates one of three states. If the phases of the two signals are aligned, the loop is “locked”. Neither the UP nor the DOWN signal is asserted and VCO 18 continues to oscillate at the same frequency. If CLK REF leads CLK* OUT , than the VCO 18 is oscillating too slowly and the detector 12 outputs an UP signal proportional to the phase difference between CLK REF and CLK* OUT . Conversely, if CLK REF lags CLK* OUT , than the VCO 18 is oscillating too quickly and the detector 12 outputs a DOWN signal proportional to the phase difference between CLK REF and CLK* OUT . The UP and DOWN signals typically take the form of pulses having a width or duration corresponding to the timing difference between the rising edges of the reference and output clock signals.
The charge pump 14 generates a current I CP that controls the oscillation frequency of the VCO 18 . I CP is dependent on the signal output by the phase/frequency detector 12 . If the charge pump 14 receives an UP signal from detector 12 , indicating that CLK REF leads CLK* OUT , I Cp is increased. If the charge pump 14 receives a DOWN signal from the detector 12 , indicating that CLK REF lags CLK* OUT , I CP is decreased. If neither an UP nor a DOWN signal is received, indicating that the clock signals are aligned, the charge pump 14 does not adjust I CP .
The loop filter 16 is positioned between the charge pump 14 and the VCO 18 . Application of the charge pump output current I CP to the loop filter 16 develops a voltage V LF across the filter 16 . V LF is applied to the VCO 18 (or to a voltage-to-current converter which then supplies a current to a CCO) to control the frequency of the output clock signal. The filter 16 also removes out-of-band, interfering signals before application Of V LF to the VCO 18 . A common configuration for a loop filter in a PLL is a simple single-pole, low-pass filter that can be realized with a single resistor and capacitor.
The output clock signal is also looped back through (in some applications) the frequency divider 20 . The resultant CLK* OUT is provided to the phase/frequency detector 12 to facilitate the phase-locked loop operation. The frequency divider 20 facilitates comparison of the generally higher frequency output clock signal with the lower frequency reference clock signal by dividing the frequency of CLK* OUT by the multiplication factor N. The divider 20 may be implemented using trigger flip-flops, or through other methods familiar to those of ordinary skill in the art. Thus, the PLL 10 compares the reference clock phase to the output clock phase and eliminates any detected phase difference between the two by adjusting the frequency of the output clock.
In the prior art there have been many different designs for tunable oscillators for use in such PLL circuits as well as other applications. It is often desirable for the tunable oscillator to have linear gain over a large frequency bandwidth extending to high frequencies, but prior-art designs have not been fully successful in this regard.
FIG. 2 shows a prior-art relaxation type current-controlled oscillator (CCO) 201 with a single timing capacitor 203 suitable for use in tunable oscillator applications, for example in the VCO 18 of FIG. 1 . The frequency of the CCO 201 is adjusted using the current control source IC 202 . A p-channel CMOS transistor 205 and an n-channel CMOS transistor 207 have their drains coupled to the capacitor 203 . These transistors 205 , 207 serve as switches for allowing current to enter and leave the capacitor 203 . A p-channel CMOS transistor 206 has its source coupled to the drain of the transistor 205 and an n-channel CMOS transistor 208 has its source coupled to the drain of the transistor 207 . These transistors 206 , 208 act as current sources for supplying current to and withdrawing current from the capacitor 203 . Control circuitry 209 is coupled to both the gates and drains of the transistors 205 , 207 as well as to the capacitor 203 . The control circuitry 209 alternatively switches the transistors 205 and 207 on and off, allowing the transistors 206 and 208 to charge and discharge the capacitor 203 . The voltage on the capacitor 203 oscillates between an upper threshold voltage VTH 211 and a lower threshold voltage VTL 213 provided by the control circuitry 209 . If VTH 211 and VTL 213 are closer together then the frequency of the CCO 201 is higher and vice-versa.
FIG. 3 shows a prior-art relaxation type CCO 300 with double timing capacitors 301 and 303 . The frequency of the CCO 300 is adjusted using the current control source IC 302 .
A p-channel CMOS transistor 305 and an n-channel CMOS transistor 307 have their sources coupled to the capacitor 301 . These transistors 305 , 307 serve as switches for allowing current to enter and leave the capacitor 301 . A p-channel CMOS transistor 309 has its source coupled to the drain of the transistor 305 . This transistor acts as a current source for supplying current to the capacitor 301 .
A p-channel CMOS transistor 311 and an n-channel CMOS transistor 313 have their sources coupled to the capacitor 303 . These transistors 311 , 313 serve as switches for allowing current to enter and leave the capacitor 303 . A p-channel CMOS transistor 315 has its source coupled to the drain of the transistor 311 . This transistor acts as a current source for supplying current to the capacitor 303 .
Control circuitry 321 is implemented using two comparators 317 and a digital flip-flop 319 . The control circuitry 321 is coupled to both the gates and sources of the transistors 305 , 307 as well as to the capacitor 301 . The control circuitry 321 alternatively switches the transistors 305 , 307 on and off, allowing the transistor 309 to charge the capacitor 301 and allowing the capacitor 301 to discharge to ground.
The control circuitry 321 is also coupled to the gates and sources of the transistors 311 , 313 as well as to the capacitor 303 . The control circuitry 321 alternatively switches the transistors 311 , 313 on and off, allowing the transistor 315 to charge the capacitor 303 and allowing the capacitor 303 to discharge to ground.
The voltage of the capacitors 301 , 303 reaches a level determined by a reference or threshold voltage Vref 323 input into the control circuitry 321 .
To begin with, if the transistor 305 is on and the transistor 307 is off, then the capacitor 301 is charged by a current provided by the transistor 309 .
Eventually the voltage on the capacitor 301 reaches the reference or threshold voltage Vref 323 causing the output of the comparator 317 to switch and causing the flip-flop 319 to switch the output to the gates. Thus, the transistor 305 is turned off and the transistor 307 is turned on: With the transistor 305 turned off, the transistor 309 no longer supplies current to the capacitor 301 . With the transistor 307 turned on, the capacitor 301 is discharged to ground through the transistor 307 . The capacitor 301 begins to recharge once the voltage on the other capacitor 303 reaches the reference or threshold voltage Vref 323 , causing the flip-flop to switch the on/off states of the transistors 305 , 307 .
As for the capacitor 303 , if the transistor 311 is on and the transistor 313 is off, then the capacitor 303 is charged by a current provided by the transistor 315 . Eventually the voltage on the capacitor 303 reaches the reference or threshold voltage Vref 323 causing the output of the comparator 317 to switch and causing the flip-flop 319 to switch the output to the gates. Thus, the transistor 311 is turned off and the transistor 313 is turned on. With the transistor 311 turned off, the transistor 315 no longer supplies current to the capacitor 303 . With the transistor 313 turned on, the capacitor 303 is discharged to ground through the transistor 313 . The capacitor 303 begins to recharge once the voltage on the other capacitor 301 reaches the reference voltage Vref 323 , causing the flip-flop to switch the on/off states of the transistors 311 , 313 .
Because the capacitor 301 is begins to charge again when the voltage on the capacitor 303 reaches the reference voltage Vref 323 , and the capacitor 303 begins to charge again when the voltage on the capacitor 301 reaches the reference voltage Vref 323 , the capacitors 301 and 303 charge and discharge 180 degrees out of phase with each other. The frequency of the CCO 300 is determined by the charging and discharging of the capacitors.
Compared to the single-capacitor CCO 201 of FIG. 2 , the double-capacitor CCO 300 has improved performance for use in applications such as in the tunable oscillator 18 of FIG. 1 .
1. The double-capacitor CCO 300 requires only one threshold voltage while the single-capacitor CCO 201 requires an upper and lower threshold voltage.
2. The double-capacitor CCO 300 can provide a capacitor voltage having a greater amplitude than can the single-capacitor CCO 201 because the CCO 300 capacitor can have a voltage range from approximately 0V to the threshold voltage while the CCO 201 capacitor can only have a voltage range from the low threshold voltage to the high threshold voltage. The low threshold voltage has to be greater than zero in order for the circuit components to function, resulting in the smaller amplitude of the capacitor voltage.
3. It is much easier to obtain a 50% duty cycle with the CCO 300 than with the CCO 201 .
It can be seen from FIG. 3 that there will be some delay T d between the time the capacitor voltages reach the reference voltage Vref 323 and the time the transistors are switched between on and off. This delay T d , also called propagation delay, is caused by delays in the electronic components such as the time it takes for the comparators 317 to compare the input signals, the time for the flip-flop 319 to change states and the time it takes the transistors 305 , 307 , 311 , 313 to switch between on and off.
In the double-capacitor CCO 300 , if delay T d caused by the comparators 317 , flip-flop 319 and transistors is ignored, the output frequency is directly proportional to the control current as:
f ideal = I C 2 CV ref . ( 1 )
It can be seen that the frequency is linearly dependent on the control current as expected. Also, as the reference voltage decreases the frequency increases. This is because the capacitor performs a charging/discharging cycle more quickly if it is not charged to as high a voltage. Also, as the capacitance decreases the frequency increases. This is because a capacitor having lower capacitance also performs a charging/discharging cycle more quickly.
Actually, the delay T d caused by the comparators 317 , flip-flop 319 and transistors cannot be ignored, and this delay introduces nonlinearity into the control characteristic of the CCO 300 . The actual frequency can be related to the ideal frequency by:
f
actual
=
f
ideal
1
+
T
d
f
ideal
.
(
2
)
As shown in FIG. 4 , while the oscillator gain characteristic 401 for the ideal case is linear, the oscillator gain characteristic 403 for the actual case is no longer linear and in fact falls off substantially at higher frequencies.
The nonlinear gain characteristic is partly a result of the delay T d causing a voltage overshoot of the capacitor voltage. This voltage overshoot is illustrated by FIG. 5 , which is a graph 501 of capacitor voltage, for example the capacitor 301 , as a function of time. A voltage signal 503 can represent the rising and falling voltage on the capacitor 301 . In the ideal situation the voltage 503 increases to the reference or threshold voltage level 323 (illustrated as the voltage level 505 ). Upon reaching the voltage level 505 , the transistors 305 , 307 receive voltages from the control circuitry 321 changing their state from on to off and off to on. In the ideal case this will cause the capacitor to discharge upon reaching the voltage level 505 and will result in the ideal CCO 300 oscillation frequency. However, due to the propagation delay, the voltage signal 503 continues to increase for a propagation delay time 509 and reaches a voltage level 507 greater than the voltage level 505 before the capacitor 301 discharges. The overshoot voltage 508 is the difference between the voltage levels 505 and 507 .
The voltage-overshoot problem becomes more severe as the current from the current control source IC 302 increases, leading to the nonlinear oscillator gain characteristic 403 of FIG. 4 . The voltage signal 511 represents the rising voltage on the capacitor for a higher current from the current control source IC 302 . The propagation delay time is the same as for the voltage signal 503 , but because of the greater current from the current control source IC 302 , the voltage rises all the way to a voltage level 513 during the propagation delay time. This results in an overshoot voltage 515 given by the difference between the voltage levels 513 and 505 . Thus, as the current from the current control source IC 302 increases, the oscillator gain decreases, approaching a limiting oscillation frequency.
The same analysis holds true for the capacitor 303 and the transistors 311 , 313 .
This nonlinear characteristic makes it difficult to control the output frequency by varying l, and also makes it difficult to control the gain or sensitivity.
In view of the above, there is a need for a tunable oscillator having an improved voltage-to-frequency characteristic and a more precisely controllable output frequency.
SUMMARY OF THE INVENTION
The present invention uses a variable reference voltage to compensate for propagation delay in a current controlled oscillator caused by delays in the electronic components. The result is an improved voltage-to-frequency characteristic (gain) over a broad range of control currents and output frequencies, and a more precisely controllable output frequency. The reference voltage is decreased as the control current increases and is varied in frequency to match the phase of the oscillator.
In more general terms, the present invention comprises a tunable oscillator having linear gain over a broad frequency range. A control supply, for example a control current source, outputs a control output, for example a control current, for tuning the tunable oscillator. An oscillator circuit outputs a frequency which increases with increasing control output. A control circuit controls the frequency of the oscillator circuit in response to a comparison, using a comparator, for example, of an oscillator circuit signal with a reference signal. A propagation delay compensation circuit varies the amplitude of the reference signal at substantially the same frequency as the oscillator to compensate for propagation delay of signals from the control circuit to the oscillator circuit.
BRIEF DESCRIPTION OF THE FIGURES
Further preferred features of the invention will now be described for the sake of example only with reference to the following figures, in which:
FIG. 1 is a block diagram illustrating the architecture of a typical phase-locked loop.
FIG. 2 is a diagram of a single-capacitor relaxation-type current-controlled oscillator (CCO) of the prior art.
FIG. 3 is a diagram of a double capacitor relaxation-type CCO of the prior art.
FIG. 4 is a graph showing the effects of propagation delay (e.g. caused by comparators and switches) on the oscillator gain characteristic.
FIG. 5 is a graph of capacitor voltage as a function of time to illustrate the voltage overshoot caused by the propagation delay.
FIG. 6 is a graph of capacitor voltage as a function of time for two different control current levels illustrating the variable threshold voltage for compensating the propagation delay.
FIG. 7 is a graph showing the improved linearity of the oscillator gain characteristic resulting from the propagation delay compensation of the present invention compared to a graph showing the oscillator gain of the prior art.
FIG. 8 includes two graphs illustrating the variable threshold voltage and the capacitor voltage for two different control current levels.
FIG. 9 is a circuit diagram illustrating the placement of the propagation delay compensation circuit in a double capacitor relaxation-type CCO similar to the CCO of FIG. 2 .
FIG. 10 is a more detailed view of the propagation delay compensation circuit of FIG. 9 .
FIG. 11 is a more detailed view of the oscillator circuit of FIG. 9 .
FIG. 12 is a more detailed view of the comparator circuit of FIG. 9 .
DETAILED DESCRIPTION OF THE EMBODIMENTS
The present invention solves the propagation delay time problem in tunable oscillators such as the relaxation type CCO 300 with double timing capacitors 301 and 303 of FIG. 3 by providing a variable reference voltage to replace the constant reference or threshold voltage 505 of FIG. 5 used in the circuit. The reference voltage is varied to decrease more for larger CCO control currents than for smaller CCO control currents. FIG. 6 is a graph of capacitor voltage as a function of time for two different control current levels illustrating the present invention's variable threshold voltage for compensating the propagation delay. A capacitor voltage signal 601 produced by a lower level first control current is shown next to a more quickly rising capacitor voltage signal 603 produced by a higher level second control current. A reference voltage 607 is lowered relative to a reference voltage 605 . By using a lower reference voltage 607 with the larger control current, and a higher reference voltage 607 with the smaller control current, the capacitor voltage signals 601 and 603 are made to peak at the same level. Thus, the oscillation frequency produced by the higher current is raised. Additionally, the reference voltage values 605 , 607 are made to vary in phase with the capacitor voltages 601 , 603 , respectively.
FIG. 7 is a graph showing the improved linearity of the oscillator gain characteristic resulting from the propagation delay compensation of the present invention compared to a graph of the prior-art gain. The oscillator gain characteristic 701 shows the nonlinear gain of a tunable oscillator without the variable reference voltage. The oscillator gain characteristic 703 shows the improved linear gain of a tunable oscillator using the variable reference voltage. As can be seen, the linear gain of the curve 703 extends into the higher frequency ranges.
FIG. 8 includes two graphs illustrating the variable threshold voltage and the capacitor voltage for two different control current levels. The curve 803 shows the capacitor voltage for a relatively higher oscillator control current while the curve 807 shows the capacitor voltage for a relatively lower control current. The capacitor is charged more quickly in the case of the curve 803 than in the case of the curve 807 .
The curve 801 shows the variable threshold voltage for the higher control current case while the curve 805 shows the variable threshold voltage for the lower control current case. The threshold voltages 801 , 805 are shown as performing two oscillation cycles for each single oscillation cycle of the capacitor voltages 803 , 807 . This is because for clarity the capacitor voltages are only shown for one of the capacitors. Actually there. is an additional oscillation peak belonging to the second capacitor, between each of the capacitor oscillation peaks. Thus there is a voltage threshold oscillation peak for each of the two capacitors oscillation peaks.
As can be seen from the figure, the variable voltage thresholds make the capacitor voltages 803 , 807 peak at the same voltage level even though the control currents are varied. Thus the method compensates for the propagation delay in the tunable oscillator to provide linear gain.
FIG. 9 is a circuit diagram of a tunable oscillator 901 for implementing the variable voltage threshold propagation delay compensation of the present invention by placing a propagation delay compensation circuit 903 in a double capacitor relaxation-type CCO essentially the same as the CCO 300 of FIG. 3 . For simplicity of illustration, the details of the propagation delay compensation circuit 903 are separately shown in FIG. 10 , the details of the oscillator circuit 911 are separately shown in FIG. 11 and the details of the comparators 925 are separately shown in FIG. 12 . Although there are two comparators 925 , they are illustrated using the same reference numbers, rather than different reference numbers, since in most applications the same type of comparator will be used for both.
The oscillator circuit 911 of FIGS. 9 and 11 can be the same as that used in the prior art of FIG. 3 . Control circuitry 905 (same as the control circuitry 321 in FIG. 3 ) provides outputs through leads 1101 , 1102 to the oscillator circuit 911 . A control current 913 is supplied to the oscillator circuit 911 for charging the capacitors 301 , 303 of FIG. 11 as in FIG. 3 . The oscillator circuit 911 has leads 1103 , 1104 for providing voltage signals to the leads 1202 of comparators 925 of the control circuitry 905 . The comparators 925 provide outputs to a flip-flop 929 through leads 1204 .
FIG. 12 shows one of the comparators 925 in more detail. The comparator includes nine transistors. The current source 907 of FIG. 9 supplies current to the comparators 925 through leads 1201 . The comparator 925 compares (1) the input to the lead 1202 from the oscillator circuit 911 with (2) a variable reference voltage input to the lead 1203 from a lead 923 of the propagation delay compensation circuit 903 . The output of the comparator 1204 is switched depending on the result of the comparison.
The propagation delay compensation circuit 903 of FIG. 10 serves to output a variable reference voltage through the lead 923 to control circuitry 905 . The circuit 903 includes capacitors 1003 and 1005 which alternately charge and discharge through resistors 1001 and 1007 in response to switches triggered by inputs 919 , 921 to produce voltage reference signals 801 , 805 such as in FIG. 8 . Two capacitors are used so that the circuit can vary the reference voltage in phase with voltage levels on the double capacitors 301 , 303 of the oscillator circuit 911 . The inputs 919 , 921 are provided by the control circuit 905 . These inputs are the same signals that trigger the gates of the transistors 305 , 307 , 311 , 313 of the oscillator circuit 911 of FIG. 11 through the leads 1101 , 1102 (same as the signals output by the flip-flop 319 of the control circuitry 321 of FIG. 3 ). The circuit 903 receives as input a lower reference voltage from the voltage source 909 through the lead 915 . The circuit also receives as input an upper reference voltage through a lead 917 from the voltage source 910 .
The control circuitry inputs 919 and 921 cause the propagation delay compensation circuit 903 to switch between the lower and upper reference voltage inputs 915 , 917 in phase with the oscillations of the double capacitors 301 , 303 of the oscillator circuit 911 . The circuit 903 thus provides a signal, such as the variable reference voltages 801 , 805 of FIG. 8 , from the output 923 .
The values of the voltage sources 909 , 910 , capacitors 1003 , 1005 and resistors 1001 , 1007 are chosen so that the amplitude and phase of the variable reference voltage output 923 will cause the voltage on the oscillator circuit 911 capacitors 301 , 303 to peak at approximately the same value over a broad. range of input control currents 907 (or 302 in FIG. 3 ). This results in a linear oscillator gain over a broad frequency range.
In the illustrated embodiments, other combinations and modifications are possible. The invention is by no means limited to double-capacitor type tunable oscillators. For example, using a few modifications, the same invention can be applied to single-capacitor relaxation-type current-controlled oscillators (CCO). The present invention can be helpful for increasing the linearity of the gain when used with many different types of tunable oscillators having propagation delay problems. Also, different particular arrangements of the electronic components can be used while still producing a variable voltage reference for providing more linear oscillator gain. Thus, although the invention has been described above using particular embodiments, many variations are possible within the scope of the claims, as will be clear to a skilled reader. | A tunable oscillator comprises a control supply configured to output a control output operable to tune the tunable oscillator. The tunable oscillator further comprises an oscillator circuit configured to output a signal such that a frequency of the signal increases with increasing control output. A control circuit is configured to control the frequency of the oscillator circuit signal in response to a comparison of the oscillator circuit signal with a reference signal. A propagation delay compensation circuit is configured to vary an amplitude of the reference signal at substantially the same frequency as the oscillator circuit signal to compensate for propagation delay of signals from the control circuit to the oscillator circuit. | 7 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to construction tools, and more particularly relates to a jig for installing properly dimensioned doorframes and for maintaining the integrity of a doorframe during construction of fixtures proximate to the doorframe.
2. Description of the Related Art
Doorframes and door jambs are well-known in the art. Typically, in most residential and commercial settings, doorframes, for mounting hinged doors, comprise wooden frames or hollow metal frames including the following principal components: a head jamb (constituting a horizontal member above the recess and below the lintel); jambs (constituting vertical members laterally defining the recess meant to house the door), and a sill (constituting a horizontal member below the recess designed to house the door). The head jamb, jambs, and sill may rest on or above concrete, metal, and/or wood structural components of a wall, building, bulkhead, etc.
Typically, in residential and commercial construction projects, doorframes are created with stamped light gauge metal components of various widths (or other wooden components well known to those of skill in the art) during the framing phase in construction, which precedes the finishing phase. The wooden components are affixed together using nails, screws, gusset plates 111 , and the like, while the metal components may be welded, screwed or bolted.
While construction workers are careful during framing to define door recesses of exact dimensions called for by plans, blue prints, and the like, the framing is never completely rigid or stable until construction is finished. As the framing phase progresses, some framing components are strained through tensile and/or compressive forces, which often alter the dimensions of, squareness, and/or parallelism of, the jambs or other components in the walls including the doorframe.
The doorframe installation process can be tedious. Components must be precisely measured and assembled, and there exists no efficient guides in the art for use in installing doorframes.
Even when the finishing phase is in progress, drywall (i.e. gypsum board) being affixed to the framing components can strain framing and alter the dimensions of the doorframe, ultimately warping the doorframe such that doors created to standard or specified dimensions do not fit in the doorframe after finishing, or align properly with the frame. Doors installed in misformed frames may have non-uniform spacing between the door and the jambs. A properly installed door should touch the frame uniformly across the side of the door comprises the latch.
Current methods and apparatii do not readily facilitate a quick method for properly securing, stabilizing and readying a doorframe for installation. It is therefore desirable that a portable, stable tool be provided which can be used by construction crews to install a doorframe, and which can secure and stabilize a doorframe after its components are affixed together such that the doorframe remains properly in position during subsequently construction.
SUMMARY OF THE INVENTION
From the foregoing discussion, it should be apparent that a need exists for a doorframe installation tool. Beneficially, such an apparatus would overcome many of the difficulties with prior art by providing a means for properly installing and verifying newly installed doorframes.
The present invention has been developed in response to the present state of the art, and in particular, in response to the problems and needs in the art that have not yet been fully solved by currently available apparatii and methods. Accordingly, the present invention has been developed to provide a doorframe jig comprising a generally rectangular frame comprising: an elongated upper member between 0.2 meters and 5 meters in length, for abutting a head jamb, the upper member formed from a rigid substance, the upper member permanently affixed to one or more of a right lateral member and a left lateral member; an elongated lower member, for abutting a sill, between 0.2 meters and 5 meters in length, the lower member formed from a rigid substance, the lower member permanently affixed to one or more of the right lateral member and the left lateral member.
The jig comprises the right lateral member is for abutting a door jamb, wherein the right lateral member is permanently disposed within the frame in generally parallel orientation to the left lateral member, the right lateral member permanently affixed to the upper member at an angle of between 60 and 110 degrees, the right lateral member permanently affixed to the lower member at an angle of between 60 and 110 degrees.
The jig comprises the left lateral member, for abutting a door jamb, wherein the left lateral member is generally parallel orientation to the right lateral member, the left lateral member permanently affixed to the upper member at an angle of between 60 and 110 degrees, the left lateral member permanently affixed to the rear member at an angle of between 60 and 110 degrees.
The doorframe jig may further comprise a plurality of handles detachably affixed to one or more of the right lateral member and the left lateral member using one of bolts, screws, brackets, and welded joint(s).
The doorframe jig may further comprise a second generally rectangular frame hingedly affixed to the rectangular frame, the length of the second rectangular frame added to the length of the rectangular frame equally the length of standard door.
The jig may further comprise one or more elongated crossbeam(s), formed from a rigid substance, each crossbeam affixed at one end to a point of intersection between two or more of the upper member, the lower member, the left lateral member and the right lateral member, and affixed at an opposing end to one or more of the upper member, the lower member, the left lateral member and the right lateral member.
The jig further may also further comprise a girder, formed from a rigid substance, affixed at one end to the right lateral member and affixed at an opposing end to the left lateral member.
The members may comprise elongated, hollow metal tubes. In some embodiments, the members comprise one of bar stock, angle iron beams, pipe, I-shaped beams, H-shaped beams, tubes, and U-shaped beams.
Alternatively, the members may comprise a number of holes drilled through the members for securing the doorframe jig to one of clamps and braces detachably affixable to a doorframe.
In some embodiments, each of the right lateral member, left lateral member, lower member, and upper member are affixed with one or more gusset plate(s) to the jig.
The doorframe jig may further comprise a plurality of handles affixed to one or more of the right lateral member and the left lateral member.
A second embodiment of a doorframe jig is disclosed which comprises a generally triangular truss comprising: an elongated first crossbeam between 0.2 meters and 5 meters in length, the first crossbeam formed from a rigid substance, the first crossbeam permanently affixed at opposing ends to a lateral member and a second crossbeam; and an elongated second crossbeam, between 0.2 meters and 5 meters in length, the second crossbeam formed from a rigid substance, the second crossbeam permanently affixed to one or more of the lateral member and the first crossbeam.
The truss further comprises the lateral member, for abutting a door jamb, wherein the lateral member is permanently affixed to both the first crossbeam and to the second crossbeam at respective angles of between 30 and 120 degrees.
The second doorframe jig also comprises an elongated upper member between 0.2 meters and 5 meters in length, for abutting a head jamb, the upper member formed from a rigid substance, the upper member permanently affixed the lateral member and a second lateral member; and an elongated lower member, for abutting a sill, between 0.2 meters and 5 meters in length, the lower member formed from a rigid substance, the lower member permanently affixed to the lateral member and a second lateral member.
The second doorframe jig also comprises the second lateral member, for abutting a door jamb, wherein the right lateral member is oriented parallel to the lateral member, the second lateral member permanently affixed to the upper member at an angle of between 60 and 110 degrees, and the right lateral member permanently affixed to the lower member at an angle of between 60 and 110 degrees.
A method of installing a doorframe during construction is also disclosed, the method comprising: temporarily inserting a generally rectangular doorframe jig into the doorframe to maintain the integrity of the doorframe dimensions during installation to ensure the doorframe stays in the proper position; wherein the rectangular doorframe jig is approximately identical in dimensions of width and height to a recess defined by the doorframe, the recess for receiving a door, wherein the doorframe jig abuts all of the head jamb, sill, and door jambs; inserting the jig into the doorframe to confirm alignment of the sill, head jamb, and door jambs; removing the jig; drywalling the building; positioning the rectangular jig in the doorframe during drywalling of the building to confirm the doorframe is in the proper position and of the proper dimensions after drywalling.
The temporarily inserted rectangular frame may further abut a doorstop of the doorframe. The method may further comprise temporarily inserting a second generally rectangular frame into the doorframe for additional support, the rectangular frame forming part of the doorframe jig.
These features and advantages of the present invention will become more fully apparent from the following description and appended claims, or may be learned by the practice of the invention as set forth hereinafter.
BRIEF DESCRIPTION OF THE DRAWINGS
In order that the advantages of the invention will be readily understood, a more particular description of the invention briefly described above will be rendered by reference to specific embodiments that are illustrated in the appended drawings. Understanding that these drawings depict only typical embodiments of the invention and are not therefore to be considered to be limiting of its scope, the invention will be described and explained with additional specificity and detail through the use of the accompanying drawings, in which:
FIG. 1A is a side elevational perspective view a doorframe jig in accordance with the present invention;
FIG. 1B is a lower elevational perspective view of another embodiment of a doorframe jig in accordance with the present invention;
FIG. 1C is an upper elevational perspective view of another embodiment of a doorframe jig in accordance with the present invention; and
FIG. 2 is a process flow chart of a method of stabilizing a doorframe in accordance with the present invention.
DETAILED DESCRIPTION OF THE INVENTION
Reference throughout this specification to “one embodiment,” “an embodiment,” or similar language means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment of the present invention. Thus, appearances of the phrases “in one embodiment,” “in an embodiment,” and similar language throughout this specification may, but do not necessarily, all refer to the same embodiment.
Furthermore, the described features, structures, or characteristics of the invention may be combined in any suitable manner in one or more embodiments. In the following description, numerous specific details are provided to provide a thorough understanding of embodiments of the invention. One skilled in the relevant art will recognize, however, that the invention may be practiced without one or more of the specific details, or with other methods, components, materials, and so forth. In other instances, well-known structures, materials, or operations are not shown or described in detail to avoid obscuring aspects of the invention.
FIG. 1A is a side elevational perspective view a doorframe jig 100 in accordance with the present invention. The doorframe jig 100 unit comprises a left lateral member 102 , a right lateral member 104 , an upper member 106 , a lower member 108 , a crossbeam 110 a , a crossbeam 110 b , a gusset plate 111 , a girder 112 , a truss 114 , a node 116 a , a node 116 b , a node 116 c , and a node 116 d.
In the shown embodiment, the left lateral member 102 , the right lateral member 104 , the upper lateral member 106 , and the lower member 108 are affixed, or welded to one another, at generally right angles between 80 and 100 degrees (each of the left lateral member 102 , the right lateral member 104 , the upper lateral member 106 , the lower member 108 , the crossbeams 110 a - b , and the girder 114 are collectively referred to herein after as the “members 102 - 112 ”). The members 102 - 112 may be affixed together using nails, screws, welded joints, gusset plates 111 , bolts, and the like.
Each of the members 102 - 112 , in the shown embodiment, comprise elongated, hollow metal tubes. Each of the members 102 - 112 may alternatively comprise rods, beams, plates, bar stock, angle, or pipe(s). Each of the members 102 - 112 may alternatively comprise cubic-shaped polymer housings. Each of the members 102 - 112 may alternatively comprise I-shaped, H-shaped, or U-shaped beams. The members 102 - 112 may comprise square- or rectangular-shaped tubing through the members' 102 - 112 cross-section. The members 102 - 1126 may comprise a number of holes, bores, or apertures drilled through the members 102 - 112 for securing the doorframe jig 100 to the clamps or braces.
The members 102 - 112 may be manufactured from polymers, wood, metals, alloys, aluminum, magnesium, titanium, carbon-fiber, and the like.
The left lateral member 102 , the girder 112 , the crossbeam 110 a and the crossbeam 110 b collectively form the truss 114 of the doorframe jig 100 . The truss 114 is designed to withstand tensile and compressive forces imposed upon the doorframe jig 100 by the building structure as it is improved through subsequent construction. In the shown embodiment, the truss 114 is triangular rectangular from a top perspective view. In alternative embodiments, the truss 114 , from this perspective, may be circular, elliptical, triangular, polygonal, or otherwise.
In some embodiments, the upper member 106 , the lower member 108 , and/or the girder 112 comprise a level integrated into, above, or beneath said member, for use in leveling the doorframe jig 100 and corresponding doorframe. In some embodiments, the level is detachably affixed to one of the members 102 - 112 . In some embodiments, one or more of the members 102 - 112 comprises one or more magnets or plates for securing the level. In many embodiments, the members 102 , 104 , 106 , 108 are affixed at right angles (i.e. 90 degree angles) to one another.
In some embodiments of the present invention, the doorframe jig 100 comprises two trusses 114 . The trusses may have opposed left lateral members 102 . The trusses may overlay one another, or may meet at a node 116 in the middle of the doorframe jig 100 .
FIG. 1A shows a plurality of nodes 116 , each node 116 representing an intersection point of two or more members 102 - 112 . For instance, node 116 a represents the intersection point of the upper member 106 , the left lateral member 102 and the crossbeam 110 a . In the shown embodiments, these said members 102 , 106 , 110 a are welded together at node 116 a . Likewise, nodes 116 b , 116 c , and 116 d each respectively represent the intersection of various other members 102 - 112 .
Gusset plates 111 may overlay the nodes 116 a - d to add additional stability to the doorframe jig 100 . The gusset plates 111 and/or members 102 , 104 , 106 , 108 may be labeled with information about the doorframe jig size and dimensions. The left lateral member 102 , the right later member 104 , the upper member 106 , and the lower member 108 may each comprise one or more handles, know to those of skill in the art, for transporting and positioning the doorframe jig 100 . The handles may be permanently affixed to the doorframe jig, or detachable.
As construction progresses after the doorframe is constructed, the subsequent construction tends to warp, contort, or strain the doorframe, and pressure is exerted principally at the nodes 116 a - d . For this reason, the nodes 116 are reinforced with various member 102 - 112 traveling in a plurality of directions across the x- and z-axes of the doorframe jig 100 .
In some embodiments of the present invention, additional crossbeam(s) 110 run from the intersection of the upper member 106 and the right lateral member 104 to node 116 d or to the midsection of the crossbeam 110 a.
Likewise, in some embodiments of the present invention, additional crossbeam(s) 110 run from the intersection of the lower member 108 and the right lateral member 104 to node 116 d or to the midsection of the crossbeam 110 b.
The width and length of the doorframe jig 100 may be conformed to specific dimensions of standard doors, such as 36×84 inches, and the like, or to specially sized doors of non-standard dimensions.
In some embodiments of the present invention, the doorframe jig 100 is inserted into framing before the doorframe is constructed around it. In this manner, the doorframe jig 100 serves not only to stabilize the doorframe during finishing and after construction, but also to serve as guide during installation of the doorframe itself.
FIG. 1B is a lower elevational perspective view of another embodiment of a doorframe jig 150 in accordance with the present invention. The doorframe jig 150 comprises a left lateral member 102 , a right lateral member 104 , an upper member 106 , a crossbeam 110 a , a crossbeam 110 b , a girder 112 , a turnscrew 152 a , and a turnscrew 152 b.
In the shown embodiment, the girder 112 , the upper member 106 and the lower member 108 are telescopic. Each can be adjusted laterally using means known to those of skill in the art to change the width of the doorframe jig 150 . In some embodiments, the doorframe jig 150 can additionally or alternatively be adjusted vertically (i.e. longitudinally) to change the length or height of the doorframe jig 150 .
The girder 112 , upper member 106 and lower member 108 may each comprise an inner sleeve affixed to the left lateral member 102 such that the left lateral member 102 slides out laterally away (with the inner sleeves) from the remaining body of doorframe jig 150 .
In some embodiments, the upper member 106 , girder 112 and lower member 108 are drilled with holes at predetermined distances for interlocking the doorframe jig 150 at different size increments using a cotter pin, r-clip, or clevis pin, and/or a hitch pin inserted through the drilled holes (for securing the inner sleeves and width of the doorframe jig 150 ).
The turnscrews 152 a - b , in the shown embodiment, are affixed to the base of the lower member 108 . These turnscrews 152 a - b can be manually adjusted to raise or lower the doorframe jig 150 within the doorframe, or adjusted prior to installing or constructing the doorframe to change the height and assist in holding the doorframe level.
In some embodiments, the doorframe jig is designed to fold in one or more places. In those embodiments, one or more of the members 102 - 112 is divided into two “halves” which are hingedly connected together such that the entire doorframe jig 150 folds over and is more easily transportable.
In other embodiments, the doorframe jig 150 additionally or alternatively comprises clamps for gripping the sides of the doorframe during or after installation and/or construction. These clamps may be affixed to any of the members 102 - 112 .
FIG. 1C is an upper elevational perspective view of another embodiment of a doorframe jig 180 in accordance with the present invention. The jig 180 comprises two independently manufactured sections, an upper section and a lower section, each section comprising an upper member 106 , a right lateral member 104 , a left lateral member 102 , a crossbeam, and a lower member 108 . The upper section additionally comprises two handles 182 a - b and a hinge 184 . The corners of each section comprises nodes 116 .
In various embodiments, the upper section and lower section are welded or affixed together using bolts, brackets, screws, or via other means known to those of skill in the art. In some embodiments, spacers may be affixed between the upper and lower sections, permanently or detachably, to change the length of the jig 180 in assembled form. In other embodiments, the upper and lower sections are hingedly connected with one or more hinges 184 to allow the sections to fold over one another to facilitate ease of transport.
FIG. 2 is a process flow chart of a method 200 of stabilizing a doorframe in accordance with the present invention.
The method 200 begins 202 with the installation (e.g. construction) 204 of a doorframe in a residential or commercial building using means well-known to those of skill in the art, including standard wood or metal framing techniques. During the framing phase, the doorframes are installed with a head jamb, sill, and two door jambs. The framing structure of the building being constructed is then drywalled, or fitted with gypsum board, paneling, plywood, or the like. During the drywall phase, drywall is attached to the framing, usually with nails, or screws and using techniques well-known to those of skill in the art. In some embodiments, gypsum board, paneling or plywood is affixed to the framing.
Finally, after the drywall is installed, the metal frame or jig is inserted 210 into the doorframe to again confirm that the frame had not moved during the installation of the drywall. This will allow a door of predetermined dimensions to be inserted 212 into the doorframe with proper clearances and fit. The rectangular metal frame inserted into the doorframe may comprise the doorframe jig 100 further described above in relation to FIG. 1 . The rectangular metal frame may comprise a plurality of beams, girders 112 , and crossbeams 110 as necessary to withstand the compressive and/or tensile forces exerted upon the doorframe during drywalling and during subsequent framing construction.
In many embodiments, the doorframe is constructed around a metallic, rectangular doorframe jig which is mounted in place before doorframe construction. The doorframe jig may be mounted on a wooden or concrete constructed surface using nails, clamps, lashing, or compressive forces from structural components adjoining the mounted doorframe jig. Alternatively, the doorframe jig may be mounted to framing components in the structure, such as 2×4s.
In some embodiments of the present invention, the doorframe jig 100 is left in the doorframe from the time installation of the doorframe begins until construction on the wall is finished. The jig 100 may be repeatedly reinserted 214 into the doorframe to test the alignment of the components 102 , 104 , 106 , 108 . Finally, after construction is complete, a door is inserted 216 into the doorframe.
The present invention may be embodied in other specific forms without departing from its spirit or essential characteristics. The described embodiments are to be considered in all respects only as illustrative and not restrictive. The scope of the invention is, therefore, indicated by the appended claims rather than by the foregoing description. All changes which come within the meaning and range of equivalency of the claims are to be embraced within their scope. | A portable doorframe installation jig is disclosed, adapted to allow a construction worker to readily install a new doorframe plum, level, and in plane. It also may be used as a brace to retain doorframe position during installation of framing and/or drywall. It may also be used as a reinspection tool after installation of drywall. The door jig further serves the purpose of stabilizing the doorframe, in some embodiments, during construction. | 4 |
[0001] This application is a Continuation of U.S. patent application Ser. No. 11/821,659 filed Jun. 25, 2007 and copending herewith.
FIELD OF THE INVENTION
[0002] 1) This invention relates to an ultra high molecular weight polyethylene material and more particularly to a non-fibrous high modulus ultra high molecular weight polyethylene tape.
BACKGROUND OF THE INVENTION
[0003] 2) Ultra high molecular weight polyethylene (UHMWPE) fibers are frequently used in the manufacture of ballistic panels. The ballistic panels are typically formed from a plurality of woven or nonwoven sheets of UHMWPE fibers and several sheets are typically stacked together to form a panel with the required projectile stopping power. Typically, the UHMWPE fibers employed in ballistics panels must be fitted very tightly together to form an effective ballistics panel.
[0004] 3) Unfortunately, the production of UHMWPE fibers, which are typically formed by a gel-spun process, is a very expensive process. Gel-spun polyethylene fibers are prepared by spinning a solution of ultra-high molecular weight polyethylene, cooling the solution filaments to a gel state, and then removing the spinning solvent. One or more of the solution filaments, the gel filaments and the solvent-free filaments are drawn to a highly oriented state. Gel-spun polyethylene fibers are typically formed by extruding a first solution of polyethylene in a non-volatile solvent and then cooled to form a first gel. The first gels are then extracted with a volatile solvent to form a second gel. The low throughput of the gel-spun process, the high cost of separating and recovering all of the various solvents, and the extra expense of forming the fibers into sheets via weaving or other processes makes polyethylene fibers an expensive option for the production of ballistics panels.
[0005] 4) UHMWPE fibers have also been produced by the slitting and fibrillating of sheet material, such as shown in U.S. Pat. No. 5,200,129. This patent discloses polyethylene materials of enhanced orientation characteristics obtained by compression molding ultrahigh molecular weight polyethylene powder at a temperature below its melting point, drawing and stretching the resultant compression molded polyolefin into an oriented film, and slitting and fibrillating the oriented film to produce highly oriented UHMWPE fibers. Although the method shown in U.S. Pat. No. 5,200,129 eliminates the solvent and solvent recovery expense involved with gel-spun products, the resultant fibers must still be formed into a sheet by weaving or a similar process to form layers for ballistics applications.
[0006] 5) Additionally, it is well known that UHMWPE fibers, whether gel-spun or slit and fibrillated from sheet material, have inherent defects that negatively affect properties such as the tensile modulus. These defects are a function of stress concentrators or microscopic stress points that result from the narrow fiber thickness and the relatively large surface area of the individual fibers. Although the polyethylene fibers individually may have a substantially high modulus value, when formed into sheets for ballistics panels the stress concentrators along the edges and boundaries of the individual fibers could lead to failure or inadequate performance of a ballistics panel constructed from the fibers.
[0007] 6) What is needed therefore is a non-fibrous, high modulus, ultra high molecular weight polyethylene product that eliminates the stress concentrator problems inherent in fibrous ultra high molecular weight polyethylene.
SUMMARY OF THE INVENTION
[0008] 7) The invention is a non-fibrous, monolithic, ultra high molecular weight polyethylene tape having a width of 1-inch or greater and a modulus of 1,400 grams per denier or greater. The non-fibrous UHMWPE tape is obtained by compression molding ultrahigh molecular weight polyethylene powder at a temperature below its melting point and then calendering and drawing and the resultant compression molded polyolefin at a total draw ratio of at least 100:1. The UHMWPE tape can be produced in weights of 6,000 denier to 90,000 denier. The UHMWPE tape of the present invention minimizes the effect of stress concentrators and thereby allows the tape to be drawn at much higher draw ratios than is possible with fibrous UHMWPE. When used in ballistics panels, the high modulus high molecular weight polyethylene tape of the present invention provides superior ballistic performance by increasing the dissipation of the impact energy of a projectile.
OBJECTS AND ADVANTAGES
[0009] 8) The non-fibrous, high modulus UHMWPE tape of the present invention includes several advantages over the prior art, including:
[0010] (1) The UHMWPE tape of the present invention enables the production of a UHMWPE product with higher properties, such as tensile strength and modulus, than can be obtained from the processing of fibers of UHMWPE. The is a result of the small incidence of stress points along the edges of the tape of the present invention as compared to the large incidence of stress points along the edges of multiple filament fibers or fibers fibrillated from narrow sheets. The small incidence of stress points along the edges of the current tape product has negligible effect on the breaking strength of the tape. As a result, the tape product of the present invention can be drawn to significantly higher draw ratios and processed under much higher tensions without breaking.
[0011] (2) The UHMWPE tape is a monolithic product, formed as a single piece without joints or seams. This monolithic non-fibrous structure leads to significant savings in the production of ballistic laminates as the monolithic structure eliminates stress concentrators that are a significant disadvantage of fibrous UHMWPE.
[0012] (3) Stress concentrators or imperfections are greatly reduced with the monolithic tape product of the present invention as a result of the vastly reduced surface area per given length versus UHMWPE fibers. Fibers, consisting of a plurality of individual elements, whether filaments or narrow fibrillated portions, have a large surface area. As a result of their high surface area, fibers include a higher incidence of microscopic stress points or local defects at side chains, terminals, and the like in the molecules and these lead to undesirable variances in break strength and modulus. As a result of the compact, monolithic, sheet structure of the tape material, only the two sides and edges of the tape are exposed, and this leads to a greatly reduced amount of defects per given length versus fibrous UHMWPE.
[0013] (4) The tensile modulus is increased significantly over prior art fibers produced from compaction of UHMWPE powder because, with the processing of tape versus fibers, more stringent drawing conditions can be applied to the UHMWPE.
[0014] (5) The weight range is increased significantly over prior art fibers produced from compaction of UHMWPE powder, including deniers of 6,000 to 90,000 and even higher. Prior art UHMWPE processes were limited to the production of fibers, with typical weights of 700 or 1,000 denier. The weight range of high modulus UHMWPE is extended substantially by the UHMWPE product of the present invention. The higher weights available in the present invention enable significant savings in the production of ballistic laminates as a single tape of, for example, 19,000 denier can replace approximately 19 fibers of nominally 1,000 denier each. In producing a ballistic laminate, the current product therefore eliminates the necessity of loading a large number of packages of fibers in a creel, spreading the fibers out evenly, applying adhesive to the fibers, and processing the fibers into a laminate.
[0015] (6) The smooth surface area of the high modulus tape product of the present invention enables a greater polyethylene to adhesive ratio in ballistics panels than is available with ballistics panels formed from fibrous UHMWPE. The vastly greater surface area per layer of UHMWPE material within ballistics panels formed from fibers, as a result of the fibers and the voids between the fibers created by the woven or nonwoven construction, requires a higher amount of adhesive to bind the separate fibrous layers together. Higher adhesive ratios reduce the effectiveness of ballistics panels, as the adhesive portion does not contribute to the modulus of the product.
[0016] (7) The UHMWPE tape of the present invention does not include oils or similar surface treatments to be produced and processed into ballistics products. Polyethylene fibers must be coated with oils or similar treatments in order to be conveyed, wound onto bobbins, and processed into sheets for use as ballistic products. The absence of oils and similar surface treatments on the polyethylene tape of the present invention enables better bonding to adhesives in the production of ballistics panels. Adhesive bonding in fibrous polyethylene is potentially compromised by the surface treatments applied thereto.
[0017] (8) The polyethylene tape of the present invention, having been drawn to a ratio of at least 100:1, has a non-permeable surface. The non-permeable surface holds any adhesives on the surface of the tape thereby enabling bonding of sheets with a minimal amount of adhesive.
[0018] (9) Fibers must be processed into sheets or fabrics to provide the layer structure required to build a ballistics panel. This adds to the overall cost of the product. The polyethylene tape of the present invention may be simply butted together to form a sheet, bonded together by simply applying pressure to the sides of the sheet, and several sheets bonded together by pressure, pressure and heat, or adhesive and pressure to form a ballistics panels. The polyethylene tape of the present invention eliminates the weaving or other processing step of fibrous UHMWPE and thereby enables the production of ballistics panels at lower cost.
[0019] (10) Layers of the tape product of the present invention form a more intimate fit between layers. The polyethylene tape of the present invention has a width of at least 1 inch, which presents two wide flat sides for bonding purposes. Therefore, application of pressure and, if required, some heat, or a light application of adhesive plus pressure is all that is necessary to form a plurality of tapes into a sheet. In contrast, sheets formed by fibers are typically woven and include a large number of interstices as a result of the narrow width of the fibers and the weaving process. A heavy layer of adhesive is typically required to bond fiber sheets together as a result of the adhesive flowing into the interstices. The tape product of the present invention requires pressure and/or heat or a minimal amount of adhesive for bonding sheets than do sheets formed of polyethylene fibers.
[0020] (11) The UHMWPE tapes of the present invention can be produced at a much lower unit cost than fibers. Gel-spun fibers require a great deal of processing, including one or more solvents in the gel-spinning process and separation and recovery of those solvents thereby adding greatly to the cost of production. The UHMWPE tape of the present invention is formed directly from UHMWPE powder without the use of solvents. The high modulus UHMWPE tapes of the present invention can be produced at roughly a third of the price of conventional UHMWPE fibers.
[0021] 9) These and other objects and advantages of the present invention will be better understood by reading the following description along with reference to the drawings.
DESCRIPTION OF THE DRAWINGS
[0022] 10) FIG. 1 is a schematic representation of a first portion of a production process for the production of UHMWPE tape according to the present invention.
[0023] 11) FIG. 2 is a schematic representation of a second portion of a production process for the production of UHMWPE tape according to the present invention.
Table of Nomenclature
[0024] 12) The following is a listing of part numbers used in the drawings along with a brief description:
[0000]
Part Number
Description
20
first portion of UHMWPE tape process
22
raw material hopper
24
conveying belt
26
compaction station
28
friable UHMWPE sheet
30
preheater rolls
32
rolling station or calendering station
34
calendered sheet
36
trimming unit
38
trimmed sheet
40
first stage drawing unit
42
pull roll set
44
super drawing unit
46
first godet stand
48
first hot shoe drawing unit
50
first in-line tension sensor
52
second godet stand
54
second hot shoe drawing unit
56
second in-line tension sensor
58
third godet stand
60
nip roll stand
62
fourth godet stand
DETAILED DESCRIPTION OF THE INVENTION
[0025] 13) With reference to FIG. 1 there is shown a first portion 20 of a process for producing high modulus ultra high molecular weight polyethylene tape with low incidence of stress concentrators according to the present invention. The process for forming the ultra high modulus polyethylene tape includes compression molding of particulate UHMWPE at a temperature below the melting point and subsequent calendering and drawing to produce the high modulus tape. The process includes compacting a very specific class of UHMWPE particles under very carefully controlled temperature conditions to yield compacted sheets, calendering the compacted sheet, and then drawing the calendered sheet at a high draw ratio under careful tension control at a temperature near the onset of the unconstrained melt of the UHMWPE material to produce a high modulus UHMWPE tape. Although the UHMWPE product of the present invention is termed a “tape” herein, the product could also be defined as a film or sheet as it is substantially rectangular shaped and includes a width that is significantly larger than the thickness. The term “tape” as used herein refers to UHMWPE products having widths on the order of at least ½ inch or greater and preferably greater than 1 inch, of a generally rectangular cross-section and having smooth edges and is specifically used to distinguish from the “fiber” UHMWPE products of the prior art that are on the order of ⅛ of an inch wide or narrower and contain a large amount of stress concentrators or microscopic stress points about their edges or periphery. The UHMWPE tape of the present invention includes a width of at least 1.0 inch, a thickness of between 0.0015 and 0.004 inch, and a modulus of 1,400 grams per denier (gpd) or greater. The present invention is a high modulus UHMWPE tape that includes a very high width to thickness ratio, unlike fibrous UHMWPE, which has a width that is substantially similar to the thickness. A high modulus UHMWPE tape according to the present invention, for example, may include a width of 1.0 inch and a thickness of 0.0025 inch, which indicates a width to thickness ratio of 400:1. The UHMWPE tape of the present invention can be produced in weights from 6,000 denier to 90,000 denier and higher. There is no theoretical limit to the width of the high modulus UHMWPE tape according to the present invention, as tape widths of up to 8.1 inches are currently possible and increases in machine sizes could produce even larger width tapes. Similarly, the denier is not limited to 90,000 but could be increased beyond that by larger processing equipment.
[0026] 14) As shown in FIG. 1 , a raw material hopper 22 introduces a high average molecular weight polyethylene powder exhibiting a high crystallinity and a high specific heat of fusion to a conveying belt 24 that is conveying from left to right in the figure. Preferably, the ultra high molecular weight polyethylene has a viscosity-average molecular weight of 2,000,000 or greater. Compression force is applied at compaction station 26 at a temperature lower than the melting point of the polyethylene. The compression force compacts the polyethylene powder into a friable UHMWPE polyethylene sheet 28 that is conveyed through preheater rolls 30 and then through rolling station 32 . The rolling station 32 compresses, shears, and elongates the UHMWPE sheet, thereby orienting and stretching the large UHMWPE molecules. According to the present invention, the UHMWPE particles or powder introduced at the compaction station 26 must exhibit high crystallinity, preferably above 76% as determined by X-ray diffraction, and a heat of fusion equal to or greater than 220 joules/gram as determined by differential scanning calorimetry, to ensure low levels of entanglement downstream of the rolling station 32 . Outside of these crystallinity and heat of fusion parameters, the extremely large UHMWPE molecules undesirably entangle or form knots at the discharge of the rolling station 32 . Outside of the stated crystallinity and heat of fusion parameters, the UHMWPE cannot be drawn into a smooth sheet but rather is entangled with knots. It is critically important to the successful practice of the present invention that the input starting material particulate UHMWPE possesses the degree of crystallinity and heat of fusion stated herein to meet the low entanglement requirements.
[0027] 15) As a result of the compression, shearing, and drawing of the UHMWPE molecules in the rolling station 32 , the calendered sheet 34 exits the rolling station 32 in a partially oriented state. As shown in FIG. 1 , after the rolling station 32 , the calendered UHMWPE sheet 34 enters a trimming unit 36 in which the edges may be trimmed off. The sheet 38 then passes through a first stage drawing unit 40 in which the sheet is drawn at a ratio of between 2:1 to 4:1. At the exit of the first stage drawing unit 40 of the compacting/calendering/drawing process 20 shown in FIG. 1 , the UHMWPE sheet has undergone a total draw ratio of between 14:1 and 24:1 and is at a thickness of between 0.0065 and 0.0105 inch. Several pull roll sets 42 are included in the compacting/calendering/drawing process 20 of FIG. 1 for advancing the UHMWPE sheet through the process.
[0028] 16) An important difference between the process of the present invention and that described in the referenced prior art relates to the compaction step that is performed on the input UHMWPE material at the compaction station 26 to obtain the product that forms the starting material for the subsequent calendering and drawing steps. According to the preferred fabrication process of the present invention, the compaction step described in the prior art cited hereinabove is performed at a very carefully controlled temperature range. The UHMWPE materials do not exhibit a discrete “melt temperature” in the conventional sense but rather “melt” over a relatively wide temperature range of generally between about 100 to about 143° C. (actual melting in the conventional sense). Hence while the preferred temperature range for compaction is below the melting point of the polymer, compaction can be performed over a temperature range between the onset of melt and melting. Preferably the UHMWPE powder is compacted at a temperature of between 130° C. and 137° C. It should be noted that at higher compaction pressures the operative temperatures for this step can be somewhat lower than those described above. Compression ratios of from about 2:1 to about 4:1 have been found to yield a well formed, compacted sheet. Compaction in these ranges results in the production of a compacted sheet that is of very uniform density and thickness and suitable for further processing in accordance with the method of the present invention. A compacted sheet exhibiting a density of between about 0.85 g/cm 3 and 0.96 g/cm 3 is preferred as the compacted sheet starting material for the subsequent calendering and drawing processes.
[0029] 17) For proper compression, shearing, and drawing to occur in the rolling station 32 , the friable UHMWPE polyethylene sheet 28 is preferably first preheated by preheater rolls 30 to a temperature near the onset of melt. Calendering is accomplished by the application of pressure with temperatures preferably near the onset of melt. At the first stage drawing unit 40 , drawing is preferably performed at a constant and controlled tension and at a temperature preferably between 140° C. and 158° C. At temperature levels below the previously defined range, drawing of the UHMWPE tape is difficult or impossible or, if drawing occurs, mechanical damage may result in the tape. At temperatures above this range, low tension may result in possible destruction of larger crystals or complete melting and separation of the tape may occur.
[0030] 18) Tension control throughout the calendering and drawing steps is important for controlling the thickness of the final UHMWPE product of the present invention. It is preferable to maintain a constant tension of between 0.5 g/denier and 5.0 g/denier to achieve the desired modulus of the final product. At tension levels below 0.5 g/denier drawing will occur but with some loss of modulus, possible melting, or separation of the tape. At tension levels above 5.0 g/denier the tape is susceptible to damage or breakage.
[0031] 19) With reference to FIG. 2 , the polyethylene sheet 38 exiting the compacting/calendering/drawing process then enters a super drawing unit 44 in which the sheet 38 is heated to the proper temperature for drawing and then drawn an additional amount of 7:1 or greater. The super drawing unit 44 includes a first godet stand 46 , a first hot shoe drawing unit 48 , a first in-line tension sensor 50 , a second godet stand 52 with all rolls steam heated, a second hot shoe drawing unit 54 , a second in-line tension sensor 56 , a third godet stand 58 with all rolls steam heated, a nip roll stand 60 , and a fourth godet stand 62 . At the first 48 and second 54 hot shoe drawing units, the UHMWPE is preferably drawn at a constant and controlled tension and at a temperature preferably between 140° C. and 158° C. The polyethylene exiting the super drawing unit 44 has undergone a total draw ratio of at least 100:1 wherein the draw ratio is defined as the length after stretching divided by the length before stretching, thereby producing a highly oriented ultra high molecular weight polyethylene tape having a modulus of greater than 1,400 gpd. The total draw ratio is a product of the individual draw ratios of each separate drawing stage. As an example with reference to FIGS. 1 and 2 , with a draw ratio of 7:1 in the rolling station 32 , a draw ratio of 3.6:1 in the first stage drawing unit 40 , and a draw ratio of 4:1 in the super drawing unit 44 would equal a total draw ratio of 7×3.6×4 or a total draw ratio of 100:1. The total draw ratio of 100:1 or greater is one critical parameter to meeting the desired molecular orientation and modulus in the final tape product. Hence, the amount of drawing in each individual zone, such as in the rolling or calendering station 32 , the first stage drawing unit 40 (see FIG. 1 ), the first hot shoe drawing unit 48 , and the second hot show drawing unit 54 , can be varied as desired and will still form the high modulus UHMWPE tape according to the present invention, as long as the overall draw ratio is maintained at 100:1 or greater. The highly oriented UHMWPE tape at the exit of the super drawing unit is maintained at a width of at least 1.0 inch and at a thickness of between 0.0015 and 0.004 inch. The highly oriented UHMWPE tape exits the super drawing unit at speeds of 20 meters/minute (m/min) or greater.
[0032] 20) The efficiency of the process for producing high modulus ultra high molecular weight polyethylene tape from the exit of the trimming unit 36 to the final product is quite high, at least 95%, as a result of the tape construction and the resultant minimal amount of breakage. The tape product eliminates stress concentrators and thereby greatly reduces breaks and increases efficiency. The edge trimming is sometimes necessary to remove an uneven edge that is sometimes created at the compaction station 26 . If the edge is ragged and left untrimmed, the uneven edge exiting the compaction station 26 would lead to stress concentrators at the edge of the polyethylene tape, and it is desirable to minimize the stress concentrators or microscopic stress points to maximize the performance of the high modulus UHMWPE tape in the final ballistics products.
[0033] 21) In contrast to the present process wherein UHMWPE powders are compacted to produce non-fibrous UHMWPE tape, prior art processes including compaction of UHMWPE powders produced UHMWPE fibers that were slit to a width of approximately ⅛-inch. As a result of the production of narrow-width fibers, the fibers process exhibited high amounts of breakage and losses as a result of the high level of stress concentrators along the fiber edges. As a result, the prior art fibers process was subject to a very low efficiency, typically around 72% and the amount of drawing to achieve higher modulus was severely constrained by the narrow width of the ⅛-inch product. The process for producing non-fibrous UHMWPE tape of the present invention therefore increases the efficiency substantially over the prior art fibers processes and enables much higher draw ratios to achieve a higher modulus product.
[0034] 22) With reference to FIG. 1 , it should be emphasized that, in comparison to prior art UHMWPE produced from compacting polyethylene powders, slitting of the polyethylene sheet is completely eliminated in the present invention. The edge trim, when necessary, is taken to clean up the edge, but there is no slitting of the sheet. The fact that the tape product of the present invention is not slit creates an important distinction of the tape product over all prior art types of ultra high molecular weight polyethylene as all of the prior art UHMWPE products are fibers. When forming butt-jointed sheets of polyethylene tape for use in forming ballistic armor, the joining of 8 tapes of at least 1.0-inch width each would create a nominal 8-inch wide sheet with only 16 edges susceptible to joint defects. Creating an 8-inch wide sheet with fibrous UHMWPE would lead to an extremely high amount of joints susceptible to defects as the entire periphery of each fiber along its entire length would be susceptible to microscopic stress points. A ballistic panel formed of fibrous UHMWPE would therefore be much more prone to joint failure than would a ballistic panel formed of UHMWPE tape according to the present invention.
[0035] 23) For a specific example or preferred embodiment of the non-fibrous high modulus ultra high molecular weight polyethylene tape of the present invention, with reference to FIGS. 1 and 2 , ultra high molecular weight polyethylene powder having a viscosity average molecular weight of 5,000,000, a crystallinity of greater than 76%, and a heat of fusion of greater than 220 joules/gram, is fed from the raw material hopper 22 with the conveying belt 24 running at 1.3 m/min. A compression force of 25 kgf/cm2 is applied to compress the UHMWPE powder to a compacted friable sheet 28 having a thickness of approximately 0.051 inch. The compacted sheet 28 is heated with preheater rolls 30 and is calendered, compressed, and drawn in rolling station 32 . The friable UHMWPE sheet is converted by the rolling station 32 into a partially oriented UHMWPE sheet 34 that has been drawn approximately 6 times (length out is 6 times the length into the rolling station 32 ). The edges of the partially oriented UHMWPE sheet 34 are then trimmed off at the trimming unit 36 thereby creating a sheet 38 with clean edges. The sheet 38 entering the first stage drawing unit 40 is at a nominal thickness of 0.008 inch, a nominal width of 6.0 inches, and at a speed of 8 m/min. Drawing unit 40 typically draws the UHMWPE sheet an additional 2.5× (2.5 times) adding additional orientation to the polyethylene molecules. The UHMWPE sheet or tape exits the first portion or compacting/calendering/drawing unit 20 of FIG. 1 at a nominal width of 3.5 inches. The super drawing unit 44 of FIG. 2 is currently a separate process in which several ends of tape product from the compacting/calendering/drawing unit 20 of FIG. 1 are further processed. However, the additional product drawing of the super drawing unit 44 could also be performed in line with the compacting/calendering/drawing unit 20 if desired. In the super drawing unit 44 of FIG. 2 , three ends of UHMWPE tape of a nominal size of 3.5 inches each are drawn, under carefully controlled tension and carefully controlled temperature, an additional amount to total approximately 120:1 total draw ratio through the processes of FIGS. 1 and 2 . The final product exiting the super drawing unit 44 of FIG. 2 is a non-fibrous, highly oriented 19,000 denier UHMWPE tape having a nominal width of 1.62 inches, a nominal thickness of 0.0025 inch, a width to thickness ratio of 648:1, and a tensile modulus of 1,600 grams per denier.
[0036] 24) Although in the specific example presented above the denier was 19,000, it should be emphasized that the non-fibrous, highly oriented, high modulus UHMWPE tape of the present invention can be produced in various weights including deniers from 6,000 to 90,000 and higher. Additionally, although specific calender parameters and draw ratios are cited it should be emphasized that the pressure can be varied in the rolling station 32 and the amount of drawing varied among the various drawing stations including at the rolling station 32 , first stage drawing unit 40 , and at the first 48 and second 54 hot shoe drawing units and still produce the non-fibrous, highly oriented UHMWPE tape of the present invention as long as the total draw ratio is maintained at 100:1 or greater. Additionally, in the specific example cited herein the tape width is cited as 1.62 inches, which is dictated by the specific processing equipment used in the example. It should be noted that the non-fibrous, highly oriented UHMWPE tape can be produced at widths of 8 inches or even larger with properly sized equipment. The width to thickness ratio is preferably at least 400:1.
[0037] 25) Having thus described the invention with reference to a preferred embodiment, it is to be understood that the invention is not so limited by the description herein but is defined as follows by the appended claims. | A non-fibrous ultra high molecular weight polyethylene tape having a width of 1-inch or greater and a modulus of 1,400 grams per denier or greater. The non-fibrous UHMWPE tape is obtained by compression molding ultrahigh molecular weight polyethylene powder at a temperature below its melting point and then drawing and stretching the entire resultant compression molded UHMWPE sheet, with no slitting or splitting of the sheet, at a draw ratio of at least 100:1. The UHMWPE tape can be produced in weights of 6,000 to 90,000 denier or greater. The UHMWPE tape of the present invention minimizes the effect of stress concentrators that are prevalent with fibers and thereby enables the tape to be drawn at much higher draw ratios than is possible with fibrous UHMWPE. When used in ballistics panels, the high modulus high molecular weight polyethylene tape of the present invention improves ballistic performance by providing enhanced dissipation of the impact energy of a projectile. | 8 |
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This is a continuation patent application of U.S. patent application Ser. No. 11/513,546, filed Aug. 31, 2006, which is a continuation patent application of U.S. patent application Ser. No. 10/763,863, filed Jan. 22, 2004, which itself claims an earlier filing date from U.S. Provisional Application Ser. No. 60/443,404, filed Jan. 29, 2003, the entire contents of both of which are incorporated herein by reference.
BACKGROUND
[0002] During hydrocarbon exploration and production numerous different types of equipment is employed in the downhole environment. Often the particular formation or operation and parameters of the wellbore requires isolation of one or more sections of a wellbore. This is generally done with expandable tubular devices including packers which are either mechanically expanded or fluidically expanded. Fluidically expanded sealing members such as packers are known as inflatables. Traditionally, inflatables are filled with fluids that remain fluid or fluids that are chemically converted to solids such as cement or epoxy. Fluid filled inflatables although popular and effective can suffer the drawback of becoming ineffective in the event of even a small puncture or tear. Inflatables employing fluids chemically convertible to solids are also effective and popular, however, suffer the drawback that in an event of a spill significant damage can be done to the well since indeed the chemical reaction will take place, and the fluid substance will become solid regardless of where it lands. In addition, under certain circumstances during the chemical reaction between a fluid and a solid the converting material actually loses bulk volume. This must be taken into account and corrected or the inflatable element may not have sufficient pressure against the well casing or open hole formation to effectively create an annular seal. If the annular seal is not created, the inflatable element is not effective.
SUMMARY
[0003] Disclosed herein is an expandable element which includes a base pipe, a screen disposed at the base pipe and an expandable material disposed radially outwardly of the base pipe and the screen.
[0004] Further disclosed herein is an annular seal system wherein the system uses a particle laden fluid and pump for this fluid. The system pumps the fluid into an expandable element.
[0005] Further disclosed herein is a method of creating a wellbore seal which includes pumping a solid laden fluid to an expandable element to pressurize and expand that element. Dehydrating the solid laden fluid to leave substantially a solid constituent of the solid laden fluid in the expandable element.
[0006] Further disclosed herein is an expandable element that includes an expandable material which is permeable to a fluid constituent of a solid laden fluid delivered thereto while being impermeable to a solid constituent of the solid laden fluid.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] Referring now to the drawings wherein like elements are numbered alike in the several figures:
[0008] FIG. 1 is a schematic quarter section view of an inflatable element;
[0009] FIG. 2 is a schematic illustration of a device of FIG. 1 partially inflated;
[0010] FIG. 3 is a schematic view of the device of FIG. 1 fully inflated;
[0011] FIG. 4 is a schematic illustration of another embodiment where fluid is exited into the annulus of the wellbore;
[0012] FIG. 5 illustrates a similar device for fluid from a slurry is returned to surface rather than exhausted downhole; and
[0013] FIG. 6 is a schematic illustration of an embodiment where the inflatable element is permeable to the fluid constituent of the slurry.
DETAILED DESCRIPTION
[0014] In order to avoid the drawbacks of the prior art, it is disclosed herein that an inflatable or expandable element may be expanded and maintained in an expanded condition thereby creating a positive seal by employing a slurry of a fluidic material entraining particulate matter and employing the slurry to inflate/expand an element. The fluidic material component of the slurry would then be exhausted from the slurry leaving only particulate matter within the element. This can be done in such a way that the element is maintained in a seal configuration by grain-to-grain contact between the particles and areas bounded by material not permeable to the particulate matter. A large amount of pressure can be exerted against the borehole wall whether it be casing or open hole. As desired, pressure exerted may be such as to elastically or even plastically expand the borehole in which the device is installed. A plurality of embodiments are schematically illustrated by the above-identified drawings which are referenced hereunder.
[0015] Referring to FIG. 1 , the expandable device 10 is illustrated schematically within a wellbore 12 . It is important to note that the drawing is schematic and as depicted, this device is not connected to any other device by tubing or otherwise although in practice it would be connected to other tubing on at least one end thereof. The device includes a base pipe 14 on which is mounted a screen 16 spaced from the base pipe by an amount sufficient to facilitate the drainoff of a fluidic component of the slurry. A ring 20 is mounted to base pipe 14 to space screen 16 from base pipe 14 and to prevent ingress and egress of fluid to space 22 but for through screen 16 . For purposes of explanation this is illustrated at the uphole end of the depicted configuration but could exist on the downhole end thereof or could be between the uphole and downhole end if particular conditions dictated but this would require drain off in two directions and would be more complex. An exit passage 24 is also provided through base pipe 14 for the exit of fluidic material that is drained off through screen 16 toward base pipe 14 . In this embodiment, the fluid exit passage is at the downhole end of the tool. The fluid exit passage 24 could be located anywhere along base pipe 14 but may provide better packing of the downhole end of the device if it is positioned as illustrated in this embodiment. At the downhole end of screen 16 the screen is connected to end means 26 . Downhole end means 26 and uphole end means 28 support the expandable element 30 as illustrated. As can be ascertained from drawing FIG. 1 , a defined area 32 is provided between screen 16 and element 30 . The defined area 32 is provided with an entrance passageway 34 and a check valve 36 through which slurry may enter the defined area 32 . The defined area 32 to may also optionally include an exit passage check valve 37 . FIG. 4 is an alternate embodiment where the fluidic substance 38 of slurry 18 is not dumped to the I.D. of the base pipe 14 , but rather is dumped to the annulus 42 of the borehole 12 . The escape passage 44 is illustrated at the uphole end of the device however could be at the downhole end of the device as well. Other components are as they were discussed in FIG. 1 .
[0016] The slurry comprises a fluidic component comprising one or more fluid types and a particulate component comprising one or more particulate types. Particulates may include gravel, sand, beads, grit, etc. and the fluidic components may include water, drilling mud, or other fluidic substances or any other solid that may be entrained with a fluid to be transported downhole. It will be understood by those of skill in the art that the density of the particulate material versus the fluid carrying the particulate may be adjusted for different conditions such as whether the wellbore is horizontal or vertical. If a horizontal bore is to be sealed it is beneficial that the density of the particulate be less than that of the fluid and in a vertical well that the density of the particulate be more than the fluid. The specific densities of these materials may be adjusted anywhere in between the examples given as well.
[0017] In one embodiment the particulate material is coated with a material that causes bonding between the particles. The bonding may occur over time, temperature, pressure, exposure to other chemicals or combinations of parameters including at least one of the foregoing. In one example the particulate material is a resin or epoxy coated sand commercially available under the tradename SUPERSAND.
[0018] Slurry 18 is introducible to the seal device through entrance passageway 34 past check valve 36 into defined area 32 where the slurry will begin to be dehydrated through screen 16 . More particularly, screen 16 is configured to prevent through passage of the particulate component of slurry 18 but allow through passage of the fluidic component(s) of slurry 18 . As slurry 18 is pumped into defined area 32 , the particulate component thereof being left in the defined area 32 begins to expand the expandable element 30 due to pressure caused first by fluid and then by grain-to-grain contact of the particulate matter and packing of that particulate matter due to flow of the slurry. The action just described is illustrated in FIG. 2 wherein one will appreciate the flow of fluidic components through screen 16 while the particulate component is left in the defined area 32 and is in the FIG. 2 illustration, expanding expandable element 30 toward borehole wall 12 . Slurry will continue to be pumped until as is illustrated in FIG. 3 there is significant grain-to-grain loading throughout the entirety of defined area 32 of the particulate matter such that the expandable element 30 is urged against borehole wall 12 to create a seal thereagainst. Grain-to-grain loading causes a reliable sealing force against the borehole which does not change with temperature or pressure. In addition, since the slurry employed herein is not a hardening slurry there is very little chance of damage to the wellbore in the event that the slurry is spilled.
[0019] In the embodiment just discussed, the exiting fluidic component of the slurry is simply dumped into the tubing downhole of the element and allowed to dissipate into the wellbore. In the embodiment of FIG. 5 , (referring thereto) the exiting fluidic component is returned to an uphole location through the annulus in the wellbore created by the tubing string connected to the annular seal. This is schematically illustrated with FIG. 5 . Having been exposed to FIGS. 1-3 , one of ordinary skill in the art will appreciate the distinction of FIG. 5 and the movement of the fluidic material up through an intermediate annular configuration 40 and out into the well annulus 42 for return to the surface or other remote location. In other respects, the element considered in FIG. 5 is very similar to that considered in FIG. 1 and therefore the numerals utilized to identify components of FIG. 1 are translocated to FIG. 5 . The exiting fluid is illustrated as numeral 38 in this embodiment the tubing string is plugged below the annular seal element such as schematically illustrated at 44 . Turning now to FIG. 6 , an alternate embodiment of the seal device is illustrated which does not require a screen. In this embodiment the element 130 itself is permeable to the fluidic component of the slurry 18 . As such, slurry 18 may be pumped down base pipe 14 from a remote location and forced out slurry passageway 132 into element 130 . Upon pushing slurry into a space defined by base pipe 14 and element 130 , the fluid component(s) of slurry 18 are bled off through element 130 leaving behind the particulate component thereof. Upon sufficient introduction of slurry 18 , element 130 will be pressed into borehole wall 12 for an effective seal as is the case in the foregoing embodiments.
[0020] In each of the embodiments discussed hereinabove a method to seal a borehole includes introducing the slurry to an element which is expandable, dehydrating that slurry while leaving the particulate matter of the slurry in a defined area radially inwardly of an expandable element, in a manner sufficient to cause the element to expand against a borehole wall and seal thereagainst. The method comprises pumping sufficient slurry into the defined area to cause grain-to-grain loading of the particulate component of the slurry to prevent the movement of the expandable element away from the borehole wall which would otherwise reduce effectiveness of the seal.
[0021] It will further be appreciated by those of skill in the art that elements having a controlled varying modulus of elasticity may be employed in each of the embodiments hereof to cause the element to expand from one end to the other, from the center outward, from the ends inward or any other desirable progression of expansion.
[0022] While preferred embodiments have been shown and described, modifications and substitutions may be made thereto without departing from the spirit and scope of the invention. Accordingly, it is to be understood that the present invention has been described by way of illustrations and not limitation. | An inflatable element utilizing a solid or particulate laden fluid as an expansion media. A fluid component of the solid or particulate laden fluid is exhausted from a defined area of the element to leave substantially only particulate matter therein to maintain the expanded state of the seal. A method for sealing includes pumping a solid laden or a particulate laden fluid to an expandable, pressurized element. A fluid component of the solid or particulate laden fluid is removed from the expandable element with substantially solid material comprised to maintain the expanded element in the expanded condition. | 4 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The invention relates to methods of treating fabrics and fibres and in particular pure cotton and polyester fibres.
[0003] 2. Description of Prior Art
[0004] Natural fibres have played an important role in the textile industry. They are widely used in the high quality garments because of their excellent intrinsic properties. However, a lot of natural fibres are short and cannot be spun into yarn for fabrication and producing garments. Additionally, many used garments made from natural fibres are discarded each year. How to use such recourses has large market potential because natural fibres have excellent intrinsic properties and are environmentally friendly. A lot of research has been done to find a use for natural fibre powder material. Hitherto they have been used to make cosmetic preparations and for making thermoplastic film, but there is no use for them in the textile industry.
SUMMARY OF THE INVENTION
[0005] It is an object of the present invention to provide a use for short or discarded natural fibres and natural fibre powder material within the textile industry in a method of treating fabrics and fibres and in particular pure cotton and polyester fibres.
[0006] According to a first aspect of the invention there is a method of treating fabrics and fibres comprising preparing a solution comprising between 0.1 and 10 percent natural fibre material having an average particle size of less than 500 nano-meters, wetting fabric or fibres to be treated with the solution for a period of between 1 and 60 minutes, and drying the wetted fibres at a temperature of between 80 and 160 degrees Celsius for a period of between 1 and 10 minutes.
[0007] Preferably, the wetted fabric or fibres are further treated by padding with the solution before the drying step.
[0008] Preferably, the fabric or fibres are padded with the solution five times.
[0009] Preferably, the solution comprises 15 percent natural fibre material.
[0010] Preferably, the natural fibre material has an average particle size of less than 300 nano-meters.
[0011] Preferably, the fabric or fibres are wetted with the solution for not less than 15 minutes.
[0012] Preferably, the wetted fabric or fibres are dried at a temperature of 130 degrees Celsius for not less than five minutes.
[0013] Preferably, the fabric or fibres to be treated are selected from a group comprising cotton and polyester fabrics and fibres.
[0014] Preferably, the natural fibre material is a fine wool powder.
[0015] Further aspects of the invention will become apparent from the following drawings and description.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] Embodiments of the invention will now be described by way of example only and with reference to the accompanying drawings which illustrate characteristic of treated fabrics.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0017] A method of treating fabrics and fibres, such as pure cotton and polyester fabrics and fibres, according to the invention comprises preparing a solution of nano scale natural fibre particles, wetting the fabrics or fibres to be treated with the solution and drying the wetted fabrics or fibres in an oven. In the preferred embodiment the natural fibre particles are a super fine natural wool powder.
[0018] Nature wool fibres have a diameter of between 15 and 30 micro meters. These fibres must be pulverised or crushed to nano size super fine natural wool powder for the preparation of the solution. A method of popularising natural fibre into nano-scale particles as described in applicants earlier PCT application published as WO 2004/055250 on 11 Jul. 2004. An alternative method of obtaining nano-scale particles from natural fibre is to use an apparatus for producing fine powder from organic material as described an applicant earlier U.S. patent application Ser. No. 10/354,170. The entire contents of WO 2004/055250 and Ser. No. 10/354,170 are incorporated herein by reference.
[0019] The average particle size of the nano scale natural wool fibre particulate should be less than 500 nano meters, and in preferably less than 300 nano meters. The particulate matter obtained from the pulverising or crushing techniques described in WO 2004/055250 and Ser. No. 10/354,170 may contain larger particles. These larger particles can be removed using a high-speed centrifuge or filtering.
[0020] If a centrifuge is used it should be run at a speed of 1500 to 8000-rpm (preferably 5000-rpm) for 5-15 minutes (preferably 10 minutes). The centrifuge separates the particular matter into upper and lower layers. The upper layer is used for preparation of the solution. The lower layer is returned to the pulverising or crushing process described in WO 2004/055250 and Ser. No. 10/354,170.
[0021] If a filter is used it should have a pore size less than 300 nano meters to remove the large particles.
[0022] The solution is prepared by suspending the super fine natural wool powder in distilled water. The ratio of wool powder to water is in the range 3 to 30 grams per litre. No other agents are required in the solution.
[0023] The fabric or fibres to be treated are wetted with the solution for 30 minutes. They are then padded with the solution five times.
[0024] After the fabric or fibres have been wetted they are dried and cured and in an oven at 130 degrees Celsius for five minutes.
[0025] The treated fibres have improved thermal, air permeability, ultraviolet blocking, liquid transfer, wrinkle recovery and blending properties.
[0026] The thermal properties of the treated fabrics were evaluated using a KES-F7 Thermal Labo II (Precise and Prompt Thermal Prosperity Measurement Instrument), which can evaluate not only the warm/cool feeling (q-max value), but also thermal conductivity and insulation value (keep warm ratio). The change in thermal properties of treated fabrics is shown in the FIGS. 1-3 . FIG. 1 shows that after treatment with the natural fibre solution, the q-max values of the treated cotton and polyester samples are much lower than that of the control fabrics. FIGS. 2 and 3 show that after treatment thermal conductivity of the cotton and polyester fabrics decreased.
[0027] The air permeability of the samples was tested by means of an ASTM D737-1996 using Shirley Development Limited Air Permeability Tester. FIG. 4 shows that superfine wool solution treated polyester and cotton fabrics have lower air permeability than that of the untreated control fabrics, which means that the treated fabrics have higher wind resistance.
[0028] The ultraviolet protection factor (UPF) of treated fabric was tested on a Cary 300 Conc UV-Visible Spectrophotometer, according to Australian/New Zealand Standard AS/NZS 4399:1996. The results are summarized in FIGS. 5 and 6 . The UPF value of both treated cotton and polyester fabric are significantly increased compared with the control samples.
[0029] The liquid water transfer properties on the treated fabric were also changed. FIGS. 7 and 8 show that the original polyester fabric is hydrophobic fabric and liquid does not transfer through it well. After treatment, polyester fabrics had higher one-way transport capacity (OWTC) and overall moisture management capacity (OMMC) than that of the untreated control fabric, showing that liquid can be more easily transfer from the side next to skin to the opposite side. FIGS. 9 and 10 show that treated cotton fabrics have lower OWTC and OMMC than that of the untreated control fabric.
[0030] The wrinkle recovery of treated cotton fabric was determined according to the AATCC Test Method 66-1998 Wrinkle Recovery of Woven Fabrics. FIG. 11 shows that superfine wool treated fabric has greater recovery angle than that of the untreated control angle for both of the warp and weft direction of the fabrics.
[0031] The bending property is important for evaluating fabrics and is one of the components of a hand evaluation system. The bending rigidity of the treated cotton and polyester fabrics is tested by Kato Tech Co., Ltd, Pure Bending Tester KES-FB-2. The result of the testing is shown in FIG. 12 . Treatment did not have much affect on the bending rigidity of the fabrics. This means the treatment does not change the bending rigidity of the fabric.
[0032] Where in the foregoing description reference has been made to integers or elements having known equivalents then such are included as if individually set forth herein.
[0033] Embodiments of the invention have been described, however it is understood that variations, improvement or modifications can take place without departure from the spirit of the invention or scope of the appended claims. | A solution for treating fabrics or fibres consists of between 0.1 and 10 percent natural fibre material suspended in distilled water. The solution is used to wet fabrics or fibres for a period of between 1 and 60 minutes. After wetting the fabrics or fibres are dried at a temperature of between 80 and 160 degrees Celsius for between 1 and 10 minutes. | 3 |
[0001] The invention relates to a transmission, in particular for motor vehicles.
BACKGROUND
[0002] Many types of transmissions for motor vehicles are known in the art. For instance, in what are known as manual transmissions, a clutch may connect the transmission input shaft to a crankshaft of a drive motor, and an output shaft is provided. Between the input shaft and the output shaft, there is a plurality of gearwheel pairs that may be selected by means of a shift lever. In these gearwheel pairs, one of the gearwheels is generally a fixed gearwheel that is firmly connected to the shaft whereas the other gearwheel is a loose gearwheel that is free to rotate on the shaft but connectible for co-rotation therewith by means of a locking mechanism. This may occur by means of the shift lever, a process which is also referred to as engaging a transmission ratio. In this process, the clutch is usually engaged and disengaged by a foot-operated pedal.
[0003] Auto shift gearboxes in which the transmission is actuated as described above by means of an actuator in an automated way have also become known in the art. In such a system, the clutch is also actuated in an automated way by means of an actuator.
[0004] A disadvantage of these transmissions is that when the transmission ratio is changed, there is a period of time in which no transmission ratio is engaged and consequently no driving torque is applied. Thus shifting operations without interrupting the tractive force are impossible.
[0005] For this reason, what are known as double clutch transmissions have become known, which allow transmission ratio changes without interrupting the tractive force. Such transmissions may be actuated by actuators that allow the transmission ratio to be selected and engaged or disengaged as well as the clutch to be operated. These transmissions have two transmission input shafts, which are connectible to a crankshaft of a drive motor by means of two clutches. These transmissions also have an output shaft and a plurality of gearwheel pairs disposed between the two input shafts and the output shaft, allowing a transmission ratio to be engaged simultaneously for each input shaft unless both clutches are engaged at the same time. When the transmission ratio is changed, it is only necessary to disengage one clutch and to engage the other clutch at essentially the same time.
[0006] An advantageous actuating device is known, for instance, from the older German Patent Application DE 10 2013 221 058 of the same applicant. This document discloses an actuating device having two roller assemblies, wherein the transmission ratios are actuated by means of selector forks with contacting elements. The contacting elements engage in grooves of the roller assemblies. A change from one groove to another groove is implemented in a direction-of-rotation-dependent way.
SUMMARY OF THE INVENTION
[0007] Prior art transmissions have been found to have different shifting speeds for shifting into higher and lower gears. This results in different shifting times, which may be considered rather inadequate for dynamic shifting cycles, whereas shifting cycles for selected transmission ratio changes are fast if the dynamic aspect seems less important.
[0008] An object of the invention is to provide an improved transmission compared to the prior art, in particular in terms of transmission ratio change dynamics.
[0009] An exemplary embodiment of the invention relates to a transmission having a first input shaft, a second input shaft, an output shaft, a first clutch, and a second clutch, wherein each one of the input shafts is connectible to the crankshaft of a drive motor by one of the clutches, wherein each one of the input shafts is connectible to the output shaft by means of gearwheel pairs to transmit torque, wherein a respective actuatable selector fork is provided to connect respective groups of two gearwheel pairs to the output shaft to transmit torque, wherein every gearwheel pair is assigned a transmission ratio, wherein a number of transmission ratios that are gradational relative to one another are provided, wherein the two transmission ratios of a group of gearwheel pairs are a first transmission ratio (N) and the one after the next (N+2), with N an integer number, in particular N=1, 2, 3, 4 or 5 etc. As a consequence, to shift down two transmission ratios, i.e. from transmission ratio 3 to transmission ratio 1 and/or from transmission ratio 4 to transmission ratio 2 and/or from transmission ratio 5 to transmission ratio 3 and/or from transmission ratio 6 to transmission ratio 4 and/or from transmission ratio 7 to transmission ratio 5 , no complex shifting cycles need to be carried out because the down-shifting is actuated by a selector fork. Thus a short shifting time is achieved in particular for dynamically relevant shifting cycles.
[0010] In this context, it is particularly advantageous if the transmission ratios of an input shaft have two groups of gearwheel pairs that comprise the transmission ratios N, N+2, N+4, and N+6, with N an integer, in particular N=1, 2, or 3. This allows even downshifting from transmission ratio N to transmission ratio N−4 to be implemented in a particularly fast way.
[0011] In this context, it is advantageous if the transmission ratios of an input shaft have two groups of gearwheel pairs and if these gearwheel pairs comprise transmission ratios 1 , 3 , 5 , and 7 .
[0012] It is further expedient if the transmission ratios of a first input shaft have two groups of gearwheel pairs, with one group of gearwheel pairs comprising transmission ratios 1 and 3 and another group of transmission ratios comprising transmission ratios 5 and 7 .
[0013] It is particularly advantageous if the transmission ratios of a first input shaft have two groups of gearwheel pairs and if these gearwheel pairs comprise transmission ratios 2 , 4 , and 6 .
[0014] In this context, it is further advantageous if the transmission ratios of the reverse gear R are assigned to one of the gearwheel pairs.
[0015] It is particularly advantageous if the transmission ratios of a second input shaft have two groups of gearwheel pairs and if a first group of gearwheel pairs comprises transmission ratios R and 2 and another group of gearwheel pairs comprises transmission ratios 4 and 6 .
[0016] In accordance with a particularly advantageous aspect, transmission ratios 3 , 5 and 2 , 4 , respectively, of the individual groups may be disposed adjacent to one another on the respective input shaft in the arrangements described above. In this way, shifting cycles from 4 to 2 and from 5 to 3 likewise have correspondingly short shifting times.
[0017] In this context, it is advantageous if the gearwheel pairs of at least one of the input shafts or of all input shafts are actuated in pairs by a selector fork, with the selector forks of an input shaft actuated by a respective controller drum.
[0018] In accordance with the invention it is likewise advantageous if a respective controller drum is provided to actuate the gearwheel pairs of an input shaft, i.e. if two controller drums are provided to actuate the transmission in the case of two input shafts and the associated gearwheel pairs thereof.
[0019] In this context, it is particularly advantageous if each one of the controller drums is driven by a respective electric motor. This allows the transmission to be actuated in a particularly quick and energy-efficient way.
[0020] The present invention will be explained in more detail below based on preferred exemplary embodiments in connection with the associated figures.
BRIEF DESCRIPTION OF THE DRAWINGS
[0021] FIG. 1 is a schematic representation of a transmission of the prior art.
[0022] FIG. 2 is a schematic representation of a transmission of the invention.
[0023] FIG. 3 is a view of a detail of a transmission of the invention.
DETAILED DESCRIPTION
[0024] FIG. 1 is a schematic representation of a transmission 1 of the prior art. The transmission 1 includes a first input shaft 2 , a second input shaft 3 , and clutches 4 , 5 for connecting the input shafts 2 , 3 to a non-illustrated crankshaft of a drive motor. The clutches 4 , 5 are disposed in a clutch housing 6 , which is connectible to the crankshaft. Actuation devices 7 , 8 are provided to actuate the clutches 4 , 5 . The actuation devices 7 , 8 are actuatable by a control unit to be able to actuate the one clutch 4 and/or the other clutch 5 . The input shafts 2 , 3 are disposed to be at least coaxial with one another at least in sections, and the actuating devices 7 , 8 are preferably likewise disposed to be coaxial with one another. Gearwheels 9 , 10 , 11 , 12 , 13 , 14 , 15 , 16 of gearwheel pairs 9 / 17 ; 10 / 18 ; 11 / 19 ; 12 / 20 ; 13 / 21 ; 14 / 22 ; 15 / 23 , and 16 / 24 are fixed for co-rotation to the two input shafts 2 , 3 . Gears 9 , 10 , 11 , and 12 are fixed for co-rotation to shaft 3 and gears 13 , 14 , 15 , and 16 are fixed for co-rotation to shaft 2 .
[0025] Gears 17 , 18 , 19 , 20 , 21 , 22 , 23 , 24 are connectible to the output shaft 25 , which is disposed to be parallel to the input shafts 2 , 3 , by selector sleeves 26 , 27 , 28 , and 29 . For this purpose, the selector sleeves 26 , 27 , 28 , and 29 are axially movable by selector forks 30 , 31 , 32 , and 33 , which are to be moved in one direction or in the other direction in this process. The displacement of the selector forks 30 , 31 , 32 , and 33 is implemented by means of the roller elements 34 , 35 , 36 , and 37 , which may be rotated by drive motors 38 , 39 .
[0026] Also, pistons 40 , 41 of piston/cylinder units 42 , 43 may be actuated by the drive motors 38 , 39 to be able to actuate the clutches 4 , 5 .
[0027] The transmission ratios Ü are arranged as follows:
[0028] gearwheel pair 13 / 21 is assigned to the first transmission ratio Ü 1 ,
[0029] gearwheel pair 11 / 19 is assigned to the second transmission ratio Ü 2 ,
[0030] gearwheel pair 15 / 23 is assigned to the third transmission ratio Ü 3 ,
[0031] gearwheel pair 10 / 18 is assigned to the fourth transmission ratio Ü 4 ,
[0032] gearwheel pair 14 / 22 is assigned to the fifth transmission ratio Ü 5 ,
[0033] gearwheel pair 12 / 20 is assigned to the sixth transmission ratio Ü 6 ,
[0034] gearwheel pair 16 / 24 is assigned to the seventh transmission ratio Ü 7 , and
[0035] gearwheel pair 9 / 17 with an intermediate gearwheel 44 is assigned to the transmission ratio of the reverse gear ÜR. In this context, the transmission ratios Ü 1 to Ü 7 and ÜR correspond to the known transmission ratios 1 to 7 and R of a transmission, which are also referred to as gears.
[0036] It can be seen that the transmission ratios of a group of gearwheel pairs 13 / 21 , 14 / 22 and 15 / 23 , 16 / 24 , and 11 / 19 , 12 / 20 , respectively, i.e. Ü 1 , Ü 5 and Ü 3 , Ü 7 and Ü 2 , Ü 6 , respectively, have a transmission ratio leap of 4, i.e. N and N+4. Thus to shift down from N to N−2, two groups of gearwheel pairs need to be involved. For instance, to shift down from Ü 3 to Ü 1 , the group of gearwheel pairs 13 / 21 and 14 / 22 as well as the group of gearwheel pairs 15 / 23 and 16 / 24 need to be involved; in this process, the selector sleeve of gearwheel pair 15 / 23 is actuated in a disengaging way and the selector sleeve of gearwheel pair 13 / 21 is actuated in an engaging way. To shift down from Ü 7 to Ü 5 , both gearwheel pair groups 13 / 21 and 14 / 22 as well as 15 / 23 and 16 / 24 are involved.
[0037] FIG. 2 is a diagrammatic representation of a transmission 101 of the invention. The transmission 101 has a first input shaft 102 , a second input shaft 103 , and clutches 104 , 105 for connecting the first and second input shafts 101 , 102 to a non-illustrated crankshaft of a drive motor. The clutches 104 , 105 are disposed in a clutch housing 106 , which is connectible to the crankshaft. To operate the clutches 104 , 105 , actuating devices 107 , 108 are provided. The actuating devices 107 , 108 are controllable by a control unit to actuate one clutch 104 and/or the other clutch 105 .
[0038] The input shafts 102 , 103 are disposed to be coaxial with one another at least in sections, and the actuating devices 107 , 108 are preferably likewise disposed to be coaxial with one another. Gearwheels 109 , 110 , 111 , 112 , 113 , 114 , 115 , 116 of gearwheel pairs 109 / 117 ; 110 / 118 ; 111 / 119 ; 112 / 120 ; 113 / 121 ; 114 / 122 ; 115 / 123 and 116 / 124 are fixed for co-rotation to the two input shafts 102 , 103 . Gearwheels 109 , 110 , 111 , and 112 are fixed for co-rotation to shaft 103 and gearwheels 113 , 114 , 115 , and 116 are fixed for co-rotation to shaft 102 .
[0039] Gearwheels 117 , 118 , 119 , 120 , 121 , 122 , 123 , 124 are connectible to the output shaft 125 , which is disposed to be parallel to the input shafts 102 , 103 , by means of selector sleeves 126 , 127 , 128 , and 129 . For this purpose, the selector sleeves 126 , 127 , 128 , and 129 are axially movable by selector forks 130 , 131 , 132 , and 133 , which are to be moved in one direction or in the other direction in this process. The displacement of the selector forks 130 , 131 , 132 , and 133 is implemented by the roller elements 134 , 135 , 136 , and 137 , which may be rotated by drive motors 138 , 139 , for instance electric or hydraulic motors. Roller elements 134 , 135 and 136 , 137 , respectively, may be combined to form a respective controller drum.
[0040] Also, pistons 140 , 141 of piston/cylinder units 142 , 143 may be actuated by the drive motors 138 , 139 to be able to actuate the clutches 104 , 105 .
[0041] The transmission ratios Ü are arranged as follows:
[0042] gearwheel pair 113 / 121 is assigned to the first transmission ratio Ü 1 ,
[0043] gearwheel pair 110 / 118 is assigned to the second transmission ratio Ü 2 ,
[0044] gearwheel pair 114 / 122 is assigned to the third transmission ratio Ü 3 ,
[0045] gearwheel pair 111 / 119 is assigned to the fourth transmission ratio Ü 4 ,
[0046] gearwheel pair 115 / 123 is assigned to the fifth transmission ratio Ü 5 ,
[0047] gearwheel pair 112 / 120 is assigned to the sixth transmission ratio Ü 6 ,
[0048] gearwheel pair 116 / 124 is assigned to the seventh transmission ratio Ü 7 , and
[0049] gearwheel pair 109 / 117 with an intermediate gearwheel 144 is assigned to the transmission ratio of the reverse gear ÜR. In this context, the transmission ratios Ü 1 to Ü 7 and ÜR correspond to the known transmission ratios 1 to 7 and R of a transmission, which are also referred to as gears.
[0050] It can be seen in FIG. 2 that the transmission ratios of a group of gearwheel pairs 113 / 121 , 114 / 122 and 115 / 123 , 116 / 124 , and 111 / 119 , 112 / 120 , respectively, i.e. Ü 1 , Ü 3 and Ü 5 , Ü 7 and Ü 4 , Ü 6 , respectively, have a transmission ratio leap of only two, i.e. N and N+2. Thus to shift down from N to N−2, only one gearwheel pair group is involved. This accelerates the shifting cycle, in particular if roller elements are used for actuation. For instance, to shift down from Ü 3 to Ü 1 , only the group of gearwheel pairs 113 / 121 and 114 / 122 is involved; to shift down from Ü 7 to Ü 5 , only the group of gearwheels 115 / 123 and 116 / 124 is involved.
[0051] A respective freewheel 45 , 145 is provided between the respective drive motor 38 , 39 and 138 , 139 , respectively, and the piston.
[0052] FIG. 3 is a sectional view of the arrangement of two roller elements 202 with a gearwheel 224 for driving purposes via a drive unit 225 , wherein the contact elements 210 , 211 of the selector forks 212 , 213 engage in the guide tracks 203 , 204 and are movable in the guide tracks by rotating the roller elements 202 .
[0053] Thus the gearwheel pairs of at least one of the input shafts or of all input shafts may be actuated in pairs by means of one of the selector forks 212 , 213 . The selector forks 212 , 213 of an input shaft may be actuated by a respective controller drum as the roller unit 202 . A respective controller drum as the roller element 202 is provided to actuate the gearwheel pairs of an input shaft, and for two input shafts and the associated gearwheel pairs, two controller drums as the roller elements 202 are provided to actuate the transmission. The controller drums as the roller elements 202 are preferably driven by one electric motor or by respective electric motors.
[0054] In this respect and in particular in terms of the actuation of the clutch, reference is made to the older application DE 10 2013 221 058, whose disclosed content is hereby expressly incorporated in its entirety by reference herein.
LIST OF REFERENCE SYMBOLS
[0000]
1 transmission
2 input shaft
3 input shaft
4 clutch
5 clutch
6 clutch housing
7 actuating device
8 actuating device
9 gearwheel
10 gearwheel
11 gearwheel
12 gearwheel
13 gearwheel
14 gearwheel
15 gearwheel
16 gearwheel
17 gearwheel
18 gearwheel
19 gearwheel
20 gearwheel
21 gearwheel
22 gearwheel
23 gearwheel
24 gearwheel
25 output shaft
26 selector sleeve
27 selector sleeve
28 selector sleeve
29 selector sleeve
30 selector fork
31 selector fork
32 selector fork
33 selector fork
34 roller element
35 roller element
36 roller element
37 roller element
38 drive motor
39 drive motor
40 piston
41 piston
42 piston-cylinder unit
43 piston-cylinder unit
44 intermediate gearwheel
45 freewheel
101 transmission
102 input shaft
103 input shaft
104 clutch
105 clutch
106 clutch housing
107 actuating device
108 actuating device
109 gearwheel
110 gearwheel
111 gearwheel
112 gearwheel
113 gearwheel
114 gearwheel
115 gearwheel
116 gearwheel
117 gearwheel
118 gearwheel
119 gearwheel
120 gearwheel
121 gearwheel
122 gearwheel
123 gearwheel
124 gearwheel
125 output shaft
126 selector sleeve
127 selector sleeve
128 selector sleeve
129 selector sleeve
130 selector fork
131 selector fork
132 selector fork
133 selector fork
134 roller element
135 roller element
136 roller element
137 roller element
138 drive motor
139 drive motor
140 piston
141 piston
142 piston-cylinder unit
143 piston-cylinder unit
144 intermediate gearwheel
145 freewheel
202 roller element
203 guide track
204 guide track
210 contact element
211 contact element
212 selector fork
213 selector fork
224 gearwheel
225 driving stage | A transmission having a first input shaft, a second input shaft, an output shaft, a first clutch, and a second clutch, wherein each one of the input shafts in connectible to the crankshaft of a drive motor by one of the clutches, wherein each one of the input shafts is connectible to the output shaft by means of gearwheel pairs to transmit torque, wherein a respective actuatable selector fork is provided to connect respective groups of two gearwheel pairs to the input shaft to transmit torque, wherein every gearwheel pair is assigned a transmission ratio, wherein a number of transmission ratios that are gradational relative to one another is provided, wherein the two transmission ratios of a group of gearwheel pairs are a first transmission ratio (N) and the one after the next (N+2), with N an integer number, in particular N=1, 2, 3, 4 or 5. | 5 |
BACKGROUND OF THE INVENTION
This invention relates to a building entrance protector box and, more particularly, to a self-grounding protector module for installation in such a box.
Where telephone wires enter a building, there is usually provided a building entrance protector box. The incoming wires, which are typically contained within one or more multi-wire cables, enter a splice chamber in the box, where they are connected to wires which go to a protector field, in a connector chamber of the box, providing protection against lightning, high voltage and high current, and then connections are made to wires which extend through the building to output jacks at various locations in the building.
Installed building entrance protector boxes typically include excess wires for termination of additional building entrance protector boxes to be mounted at a future time. The additional boxes require space above or below the presently installed boxes. However, due to the mounting of other nearby equipment, the required space may not be available. Accordingly, building entrance protector boxes usually have large housings which can be filled with protector modules, each providing protection for twenty five pairs of wires. Modules are added as needed with time until the housing is full. Accordingly, partly filled building entrance protector box housings are used to reserve enough space for modules to be added later. Accordingly, there exists a need for a protector module which is easily added, grounded and wired.
SUMMARY OF THE INVENTION
According to the present invention, a conductive chassis plate is mounted in the protector chamber of the building entrance protector box. A grounding connector is mounted to the chassis plate and a ground conductor connected at one end to the grounding connector is used to ground the chassis plate. Each protector module is mounted to the chassis plate by means of a conductive mounting bracket which is in electrical contact with all of the ground terminals of the module. Accordingly, when a module is mounted to the chassis plate, it is automatically grounded.
BRIEF DESCRIPTION OF THE DRAWINGS
The foregoing will be more readily apparent upon reading the following description in conjunction with the drawings in which like elements in different figures thereof are identified by the same reference numeral and wherein:
FIG. 1 is a perspective view of a building entrance box (without its cover) which may be used with the present invention;
FIG. 2 is a top plan view of the box of FIG. 1 with a first type of protector field installed therein;
FIG. 3 is a cross sectional view taken along the line 3--3 in FIG. 2;
FIG. 4 shows a pair of stacked building entrance boxes with a modular form of protector field installed therein;
FIG. 5 is a perspective view showing the ground connector of the modular protector field of FIG. 4;
FIG. 6 is a top plan view showing the protector panel of the protector field shown in FIG. 4;
FIG. 7 is a cross sectional view taken along the line 7--7 in FIG. 6 showing the protector panel with the addition of ground conductors;
FIG. 8 is a perspective view of the grounding arrangement for the modular protector field of FIG. 4;
FIG. 9 illustrates a frame for the mounting of the box of FIG. 1;
FIG. 10 is an exploded perspective view of a first embodiment of a bracket used for mounting the box of FIG. 1 to the frame of FIG. 9;
FIG. 11 is a perspective view showing the assembled bracket of FIG. 10;
FIG. 12 illustrates the mounting of the box shown in FIG. 1 to the frame shown in FIG. 9 using a pair of the brackets shown in FIGS. 10 and 11;
FIG. 13 is a plan view of a second embodiment of a bracket for mounting the box of FIG. 1 to the frame of FIG. 9;
FIG. 14 is a side view of the bracket of FIG. 13;
FIG. 15 is a cross sectional view taken along the line 15--15 in FIG. 14;
FIG. 16 is a cross sectional view taken along the line 16--16 in FIG. 15; and
FIG. 17 is a partial plan view showing the bracket of FIGS. 13-16 during a stage of its manufacture.
DETAILED DESCRIPTION
Referring now to the drawings, FIG. 1 illustrates a building entrance box, designated generally by the reference numeral 20, which finds utility with the present invention. It is conventional to install such a box 20 at the entrance of a building to provide an interface between a signal transmission media cable entering the building and having a first plurality of filamentary signal transmission elements, and a second plurality of individual filamentary signal transmission elements which are routed through the building. The box 20 has a substantially planar base wall 38 adapted for mounting to a support and a plurality of substantially planar surrounding walls 50, 52, 54, 56 each substantially perpendicular to the base wall 38 so as to define an open enclosure. The open enclosure is divided into a splice chamber 22 and a connector chamber 24. The splice chamber 22 receives the cable and the connector chamber 24 receives the second plurality of individual filamentary signal transmission elements. A connector field is disposed in the connector chamber 24 to which the second plurality of individual filamentary signal transmission elements is terminated. A third plurality of individual filamentary signal transmission elements extends from the splice chamber 22 to the connector chamber 24, with each of the third plurality of individual filamentary signal transmission elements being terminated at one end to the connector field and at the other end to a respective cable element within the splice chamber 22. When the signal transmission media cable is made up of telephone wires, the connector field within the connector chamber 24 includes a protector field having protector blocks for providing lightning, high voltage and high current protection. The third plurality of individual filamentary signal transmission elements will in that case each be terminated at the one end to one end of a respective protector block. Dedicated wires extend from the second ends of the protector blocks to respective connectors at which the second plurality of individual filamentary signal transmission elements are terminated.
As shown in FIG. 2, a signal transmission media cable 26 enters the splice chamber 22. The third plurality of individual filamentary signal transmission elements, or wires, 28 extends from the splice chamber 22 to the connector chamber 24. The wires 28 are terminated at a first end to a bank of connectors 30 to which are spliced the first plurality of individual filamentary signal transmission elements, or wires, 32 making up the cable 26.
A cover plate 34 is secured to the standoffs 36 (FIG. 1) so as to be parallel to the base wall 38 of the box 20 and be disposed over the connector chamber 24. The cover plate 34 has secured thereto a protector field 40 with protector blocks 42, and an output wire connector field 44. The wires 28 are connected to one side of the protector blocks 42 by means of the downwardly depending wire wrap tails 46. Wires (not shown) are connected to the other side of the protector blocks and are then routed below the cover plate 34 to the output wire connector field 44, which includes an array of generally planar insulation displacing connector terminals 48. The second plurality of filamentary signal transmission elements, or wires, (not shown in FIG. 2) which are routed through the building are terminated at the terminals 48.
The base wall 38 is formed with a recess open to the open enclosure defined by the base wall and the surrounding walls 50, 52, 54, 56. As best shown in FIG. 1, the recess marks the dividing line between the splice chamber 22 and the connector chamber 24 and preferably includes an elongated groove 58 extending between the walls 50 and 54, and a pair of recesses 60, 62 open to both the groove 38 and the open enclosure and aligned one with the other across the groove 58. The groove 58 and the recesses 60, 62 all extend to the same depth within the base wall 38.
As best shown in FIG. 3, a separator plate 64 is secured, as by welding or the like, transversely to the cover plate 34. The separator plate 64 extends downwardly from the cover plate 34 toward the base wall 38 to isolate the splice chamber 22 from the connector chamber 24. The separator plate 64 has its lower portion, preferably along its entire length which extends between the walls 50, 54, extending into the groove 58 to a depth less than the depth of the groove 58, with the recesses 60, 62 being on opposite sides of the separator plate 64. The wires 28 are routed into the recess 60, across the groove 58 under the separator plate 64, and into the recess 62, as shown in FIG. 3.
When a box of the type shown in FIGS. 1-3 is used in an outdoor application, moisture can enter the box through the opening provided for the cable 26. This moisture can pass under the separator plate 64 where the wires 28 pass through from the splice chamber 22 to the connector chamber 24 and can condense on the underside of the protector field 40 and the connector field 44. The problem results because the bottom of the protector field 40 and the connector field 44 are flat. If moisture condenses on a flat surface, it can short out the downwardly extending wire wrap tails 46. In the past, to prevent such problems, the underside of the protector field 40 and the connector field 44 have been potted. This is a time consuming and costly procedure, requiring a large amount of potting material. To overcome these disadvantages, potting material 66 is placed in the groove 58 and the recesses 60, 62 to a level higher than the bottom of the separator plate 64. This minimizes the required amount of potting material while effectively minimizing the amount of moisture that can pass into the connector chamber 24. Preferably, the potting material comprises a polyurethane mix. Illustratively, the potting material consists of three parts, all made by BIWAX Corp. The three parts are a resin, a catalyst and an accelerator. Preferably, the resin is BIWAX 622R material; the catalyst is CPD Poly 662C material; and the accelerator is BIWAX 622A material.
As further protection, silicone caulking (or some other suitable material) can be added where the cover plate 34 abuts the walls 50, 52, 54.
FIGS. 4-8 illustrate a building entrance box 20 using modular protector fields. Each module provides protection for twenty five pairs of wires. Modules are added as needed until the box is full. Partly filled boxes are used to reserve enough space for modules to be added later. Accordingly, the modules must be easily added, grounded and wired. As shown, this version of building entrance box includes a substantially planar conductive chassis plate 68 mounted within the open enclosure of the box 20 spaced from and parallel to the base wall 38. The chassis plate 68 is disposed within the connector chamber 24 and has an edge 70 adjacent to the splice chamber 22 and overlying the groove 58 of the base wall 38. When a plurality of boxes 20 are stacked, as shown in FIG. 4, a daisy chain of grounding wires must be provided between the boxes. In the past, this has been accomplished using bare number six gauge solid wire segments. The grounding connectors 72 for prior boxes were typically placed above and below the protector field 40, as shown in FIG. 2. To daisy chain the ground between stacked boxes required that the boxes be precisely aligned so that the stiff number six gauge solid wire could easily be routed from one box to the next. In addition, each box was typically provided with its own flexible ground conductor which is used to provide a ground connection to the input cable entering the box. With stacked boxes, only the flexible ground conductor of one box is used to ground the input cable passing through all the boxes and the flexible ground conductors of the other boxes are left unused. The arrangement of grounding connectors 74 shown in FIGS. 4 and 5 eliminates the aforedescribed problem encountered with the solid number six gauge solid wire and efficiently utilizes the available flexible ground conductors.
As shown in FIG. 5, the chassis plate 68 is bent downwardly along its edge 70 to form a corner. The chassis plate 68 is further formed with an array of openings 76 adjacent the edge 70 and along a line parallel to the edge 70. The grounding connector 74 is installed in the aforedescribed corner by means of headed screws 78 installed through respective openings 76 and into suitably threaded bores in the grounding connector 74, which is a solid rectilinear block of conductive material. Preferably, the screws 78 are located at opposite ends of the grounding connector 74 and between the screws 78 are bores holding set screws 80 accessible through respective openings 76. In addition, the grounding connector 74 is formed with bores 82 extending at right angles into the set screw bores, the bores 82 being accessible through openings 84 in the downwardly bent portion of the chassis plate 68. The downwardly bent portion of the chassis plate 68 extends into the groove 58 of the base wall 38 and the grounding connector block 74 fits in the recess 62 of the base wall 38. It is noted that when using the chassis plate 68 with modular protector fields, the aforedescribed potting in the groove 58 and recesses 60, 62 is not utilized.
Each box 20 is supplied with a flexible ground conductor 86 secured at one end to the upper one of the headed screws 78, when viewed as in FIG. 4. When the cable 26 is installed in the box 20, the other end of the flexible ground conductor 86 is secured to a conductive grounding clip 88 on the cable 26, as shown in the upper box in FIG. 4. When a plurality of boxes 20 are stacked, as shown in FIG. 4, the connection to the ground clip 88 is sufficient to provide a ground connection for the entire cable 26 going to all of the boxes 20. Therefore, it is unnecessary to connect the flexible ground conductor 86 of the lower box 20 to the cable 26. Instead, the lower flexible ground conductor 86 is routed into the splice chamber 22 of the lower box 20, into the splice chamber 22 of the upper box 20, and is connected to the grounding connector 74 of the upper box 20 by the lower headed screw 78. A local ground wire 90, which may be a number six gauge solid wire, is then connected to the grounding connector 74 of the lower box 20 by one of the set screws 80, as shown in FIG. 5, and may then be routed to a suitable local ground within the building.
Illustratively, each modular protector field 91 provides protection for twenty five pairs of modules and up to four modules can be installed in a single box 20. It is required that the modules 91 be easily added, grounded and wired, with the input and output wires from all of the modules being separated so that they cannot short, and with the modules resisting shorting due to condensation without requiring potting. To satisfy these requirements, each protector module 91 includes an insulative protector panel 92, as best shown in FIGS. 6 and 7. The protector panel is a generally rectilinear block with a pair of opposed parallel major surfaces 94, 96 and four minor surfaces 98, 100, 102, 104 orthogonal to the major surfaces 94, 96. Formed in the panel 92 are sockets 106 which extend between the surfaces 94, 96 and orthogonally thereto. The sockets 106 are arrayed in groups, illustratively with five sockets to a group, where each group of sockets corresponds to the terminal arrangement of a protector block 42. The groups of sockets 106 are preferably arranged in a five-by-five array so that each protector panel 92 can accommodate twenty five protector blocks for twenty five telephone line pairs. Each of the sockets 106 holds a respective connector terminal 108 adapted to receive a mating terminal of a protector block. Of the five terminals in each group, four are provided with wire wrap tails 110 extending to the underside of the panel 92. These four connector terminals are the two input and two output connector terminals for each protector block. The fifth connector terminal 112 in each group is between the pair of input connector terminals and the pair of output connector terminals and functions as a ground connector terminal. Instead of a wire wrap tail, the end of the ground connector terminal 112 extending underneath the panel 92 is formed with a U-shaped clip 114, the function of which will be described hereinafter.
Grounding and mounting of each protector module 91 is accomplished by providing a conductive ground bar 116, five conductive ground rods 118, and a conductive mounting bracket 120. As best shown in FIG. 8, the ground bar 116 is a generally C-shaped piece of conductive sheet material which is bent so that its legs 122 overlie end portions 124 (FIG. 6) of the protector panel 92 and its connecting portion 126 is adjacent the minor surface 98 of the protector panel 92. Along the bottom edge of the connecting portion 126 are five U-shaped clips 128 which are each aligned with a row of the clips 114 of the ground connector terminals 112. For assembly, the ground bar 116 is placed adjacent the protector panel 92 with the legs 122 overlying the end portions 124 and the connecting portion 126 adjacent the minor surface 98. Screws (not shown) are then inserted through the openings 130 in the connecting portion 126 and into the protector panel 92 through its minor surface 98 to securely hold the ground bar 116 to the panel 92. With such mounting, the openings 132 in the legs 122 are aligned with the openings 134 in the end portions 124 of the panel 92. Each conductive ground rod 118 is then passed through an aligned row of clips 114 of ground connector terminals 112 and a clip 128 of the connecting portion 126. The clips 114, 128 are then deformed, as by pliers or the like, to be securely in contact with a respective rod 118 and are then soldered to the respective rod 118. Accordingly, all of the ground connector terminals 112 are in secure electrical contact with the ground bar 116.
The mounting bracket 120 is then placed over the aforedescribed assembly. The mounting bracket 120 is formed from conductive sheet material and is bent into a rectilinear shape to overlie the protector panel 92. The bracket 120 is formed with an opening 136 exposing all of the sockets 106 of the panel 92. As best shown in FIG. 8, the side wall 138 of the bracket 120 is formed with an opening 140 at one end and below the level of the panel 92 (when the panel 92 is installed, as will be described). Although not shown in FIG. 8, the opposing side wall of the bracket 120 is also formed with an opening corresponding to the opening 140 and diagonally across the bracket 120 from the opening 140. These openings allow bundles of wire to enter and exit the module 91 for connection to the wire wrap tails 110 below the panel 92. The pair of openings 140 are so situated on the opposing side walls that when the module 91 is rotated 180° about an axis orthogonal to the major surfaces 94, 96 of the panel 92, each of the openings 140 occupies the position previously occupied by the other of the openings 140.
The bracket 120 is provided with threaded studs 142 extending downwardly from the upper side of the bracket 120 and aligned with the openings 132 of the ground bar 116 and the openings 134 of the panel 92 end portions 124. Accordingly, when the assembled panel is installed into the bracket 120, the studs 142 extend beyond the bottom of the panel 92 and may have nuts (not shown) installed thereon to securely mount the assembled panel 92 to the bracket 120 and provide good electrical contact between the ground bar 116 and the bracket 120. The side wall 138, as well as the opposing side wall, is bent to form an outwardly extending mounting flange 144 on each side of the bracket 120. The mounting flange 144 is formed with a mounting hole for receiving an upwardly extending mounting stud secured to the chassis plate 68. A nut 148 threaded onto this stud 146 completes the mounting of the module 91 to the chassis plate 68 with secure electrical contact between the mounting bracket 120 and the chassis plate 68, thereby automatically grounding the ground connector terminals 112 of the panel 92.
All of the wires which are connected to the wire wrap tails 110 corresponding to the inputs of the protector blocks 42 are bundled together into a first cable which extends out through one of the openings 140, and all of the wires which are connected to the wire wrap tails 110 corresponding to the outputs of the protector blocks 42 are bundled together into a second cable which extends out through the other of the openings 140. Accordingly, the input wires are isolated from the output wires for each module 91. As shown in FIG. 4, the modules 91 are oriented on the chassis plate 68 so that when they are mounted in the upper of the two rows, the input cables 150 extend out the lower of the openings 140 and the output cables 152 extend out the upper of the openings 140. Conversely, when a protector module 91 is mounted in the lower row, its input cable 150 extends out the upper of the openings 140 and its output cable 152 extends out the lower of the openings 140. Thus, the input cables 150 of the protector modules 91 are routed from connectors 151 in the splice chamber 22 above the chassis plate 68 and between the two rows of protector modules 91. At the same time, each output cable 152 is routed between its module 91 and the closer one of the walls 50, 54 to a connector (not shown) in another layer (not shown) of the box 20. Thus, the input cables 150 and the output cables 152 of all of the modules 91 are isolated from each other. To provide additional isolation, the box 20 is formed with a pair of divider walls 154 which extend into the open enclosure each from one of the walls 50, 54. The divider walls 154 are along the plane separating the splice chamber 22 from the connector chamber 24. These divider walls 154 extends sufficiently into the open enclosure that their distal ends each butts up against a respective module 91, as best shown in FIG. 4, thereby closing off the space between that module and the respective wall 50, 54 from the splice chamber 22 to further insure isolation between the output cables 152 and the input cables 150.
Since it is disadvantageous to use potting on the protector modules 91 to prevent moisture condensation from shorting the terminals, some other way must be found to provide such protection. Moisture condenses on the plastic of the protector panel because, during temperature cycling, the temperature of the plastic lags behind the ambient temperature, allowing condensation of humidity in the ambient. To prevent such condensation, or at least to prevent the bridging of terminals by any such condensation, the bulk body of the panel 92 is minimized to thin out the plastic geometry of the panel 92. A thin geometry has a lowered temperature differential with the ambient temperature. This lowers the amount of condensation. Further, the panel block 92 is recessed from both of its major surfaces 94, 96 around each of the sockets 106 to increase the electrical path between each socket and all other sockets on the panel 92. Thus, in effect, the panel 92 can be considered to be a central planar plate having pairs of coextensive cylinders extending in opposite directions away from the plate, with each of the sockets 106 extending within a respective pair of opposed cylinders and through the central plate.
FIG. 9 illustrates a typical frame for mounting and stacking building entrance boxes. The frame includes a horizontal top member 156 and a horizontal bottom member 158 which are parallel to and spaced from each other. Joining the top and bottom members 156, 158 are left and right vertical mounting beams 160, 162, each having an array of internally threaded mounting holes 164. When a plurality of boxes 20 are stacked, they must be vertically aligned in order to pass input cables through aligned splice chambers and align the output wires through aligned wiring guides. However, at any given installation, the horizontal spacing between the vertical mounting beams 160, 162 can vary. FIGS. 10 and 11 illustrate a first embodiment of a bracket assembly 165 which allows a box 20 to be installed to the frame of FIG. 9 in predetermined alignment to the mounting beam 162, to accommodate variability in spacing between the beams 160, 162. Thus, the bracket assembly 165 includes a first bracket member 166 and a second bracket member 168. The first bracket member 166 has a C-shaped cross section when viewed orthogonal to its longitudinal axis and is preferably closed at a first end 170. The second bracket member 168 is also generally C-shaped in cross section with both ends closed and is sized to fit for sliding longitudinal motion within the interior of the first bracket member 166, as best seen in FIG. 11.
The second bracket member 168 is formed with a pair of open longitudinal slots 172 and the first bracket member 166 is formed with a pair of threaded posts 174 which are received each within a respective one of the slots 172. Nuts 176 and washers 178 engage the posts 174 to secure the bracket member 168 to the bracket member 166 with the overall length of the bracket assembly 165 being selectively variable. The bracket member 166 has a pair of elongated slots 180, 182 at its opposite ends, the slots 180, 182 being elongated in a direction orthogonal to the length of the bracket member 166. Similarly, the bracket member 168 has a pair of elongated slots 184, 186 (FIG. 12) at its opposite ends, also elongated in a direction orthogonal to the length of the bracket member 168. As best seen in FIG. 12, the bracket assembly 165 is mounted to the frame by a first screw 188 which extends through the slot 180 and into a threaded mounting hole 164 of the mounting beam 162 and a second screw 190 which extends through the slot 186 of the bracket member 168 and into a threaded mounting hole 164 of the mounting beam 160. This arrangement provides a predetermined alignment between the bracket member 166 and the mounting beam 162 and another predetermined alignment between the bracket member 168 and the mounting beam 160, while allowing variation of the alignment between the bracket members 166, 168.
The bracket member 166 is formed on its exterior, which is away from the mounting frame, with a threaded post 192 and with threaded openings 194. The spacing between the post 192 and the openings 194 corresponds to the spacing between mounting holes 196, 198 in the base wall 38 of the box 20. Thus, the post 192 extends through the mounting hole 196 and has a nut 200 and washer 202 installed thereon, and a screw 204 extends through the mounting hole 198 into an appropriate one of the threaded openings 194. It is noted that there are a pair of vertically displaced threaded openings 194 in each of the bracket members 166. The upper one of these threaded openings 194 is for use with the upper mounting hole 198 of the box 20 and the lower one is for use with the lower mounting hole 198 of the box 20, as best seen in FIG. 12. The slots 180, 186 allow for vertical adjustment of the bracket assembly 165 to insure that it is aligned with the mounting holes 196, 198 of the box 20. Since the post 192 and the openings 194 are fixed on the bracket member 166, the box 20 is always precisely aligned with the bracket member 166, which is precisely aligned with the mounting beam 162. Accordingly, when a plurality of boxes 20 are mounted to the frame by the aforedescribed bracket assembly, they are always precisely vertically aligned. Another function of the vertical slots 180, 186 is to eliminate a gap between stacked boxes 20.
FIGS. 13-17 illustrate another embodiment of a bracket 206 for mounting a box 20 to the frame shown in FIG. 9. The bracket 206 is similar to the bracket member 168, having a slot 180 at its closed end. However, there are several slots 186 at its open end, each corresponding to a different fixed spacing between mounting beams 160, 162. The bracket 206 is formed with weakened portions 208 outboard of the slots 186. Preferably, each of the weakened portions 208 consists of a V-shaped groove 210 formed in the material of the bracket 206, which is preferably metal sheet stock, along with apertures 212 formed in each corner of the C-shaped cross section of the bracket 206. As shown in FIG. 17, the weakened portion 208 is preferably formed before the bracket 206 is bent into its C-shape by forming the V-shaped groove 210 across the width of the bracket 206 while still flat and punching the apertures 212 at the intersections of the groove 210 and the subsequent bend lines 214. After a technician has determined the proper length of the bracket 206, the bracket 206 is cut with a cutter along the groove 210 at both ends up to the apertures 212. The bracket 206 is then bent back and forth until it snaps along the groove 210 between the apertures 212. Accordingly, the bracket 206 can be separated along a weakened portion 208 without requiring sawing of the bracket. Thus, excess length of the bracket, which would otherwise stick out beyond the mounting beam 160 and be potentially injurious, can be removed.
Accordingly, there has been disclosed an improved building entrance box and mounting structure therefor. While an exemplary embodiment of the present invention has been disclosed herein, it will be appreciated by those skilled in the art that various modifications and adaptations to the disclosed embodiment may be made and it is intended that this invention be limited only by the scope of the appended claims. | A building entrance box providing an interface between a signal transmission media cable having a first plurality of filamentary signal transmission elements and a second plurality of individual filamentary signal transmission elements. In a first embodiment, moisture infiltration is reduced by providing potting material in a transition region between a splice chamber of the box and a connector chamber of the box. In another embodiment, a plastic protector panel is specifically shaped to reduce condensation and to reduce the effects of any condensation. Modular protector panels mounted in the box are automatically grounded when mounted to a conductive chassis plate and are so arranged that input and output wires are isolated from each other. Mounting of stacked boxes in a predetermined alignment is effected by a first embodiment of a bracket assembly having a variable overall length but a fixed horizontal alignment, and by a second embodiment of a bracket which is breakable by an installer to achieve a desired bracket length. | 7 |
RELATED APPLICATION
[0001] This patent application is a divisional of U.S. patent application Ser. No. 09/892,922, filed on Jun. 26, 2001, titled “Wrapper Playlists on Streaming Media Services”, commonly owned herewith, and hereby incorporated by reference.
TECHNICAL FIELD
[0002] This disclosure relates to networked client/server systems and to methods of delivering requested content in such systems. More particularly, the subject matter relates to systems and methods for delivering client requested content to the client along with additional content.
BACKGROUND
[0003] When a client requests a piece of content such as digital video, audio, or some other content from a server, the client typically provides a global address to the content in the form of a Uniform Resource Locator (URL). The server then accesses the addressed content and sends or “streams” it to the client in the form of a continuous digital data stream.
[0004] There are various file data formats for streaming digital media content and composite media streams. “Advanced Streaming Format” (ASF) is an example of such a data file format. ASF (sometimes referred to as WINDOWS Container Media Format) specifies a way in which multimedia data content is stored, streamed, and presented by a variety of tools, servers, and clients of a number of different multimedia vendors. ASF provides a storage and transmission data file format that encapsulates multimedia data types (e.g., images, audio, and video) as well as embedded text (e.g., a URL) and also allows for synchronizing these objects within a digital data stream. (Further details about ASF are available from Microsoft Corporation of Redmond, Washington).
[0005] Regardless of which of a number of different streaming file data formats is used, an individual data stream includes a sequence of digital data sets or units. The units represent an image, sound, or some other stimuli that is perceived by a human to be continuously varying. The client renders the units individually, in sequence, to reproduce the original stimuli. For example, an audio data stream comprises a sequence of sample values that are converted to a pitch and volume to produce continuously varying sound. A video data stream comprises a sequence of digitally specified graphics frames that are rendered in sequence to produce a moving picture.
[0006] In the simplest case, a client requests a single streaming media content file, to reproduce, or “play” a single piece of content such as a song or a video. Alternatively, the client may request a playlist, or “playlist file” that includes a number of different references to individual streaming media content files. Each playlist file includes information such as information to reference specific pieces of content, an order in which to play the referenced content, and other information (e.g., whether to play certain pieces of referenced content more than one time). In other words, a playlist file not only references media content, but also describe how pieces of media content are combined.
[0007] Playlists do not normally contain the actual media data, but rather particular references (i.e., a URL) to stored media data. As a result, a playlist file is typically small in size, generally only contains text, and is typically easy and computationally inexpensive to modify. (A reference to a single piece of media content may appear in any number of different playlist files).
[0008] A playlist is typically created in predetermined format. The Synchronized Multimedia Integration Language (version. 2.0), referred to as “SMIL” is an example of such a predetermined format. SMIL is an extension of the World Wide Web Consortium (W3C) standard Extensible Markup Language (XML). SMIL provides syntax and structure to define both high-level instructions and data corresponding to the content referenced by a playlist. (The specification for SMIL is well understood in the computing industry).
[0009] A playlist can be implemented on a client computer or on a server computer. When a client implements a playlist, the playlist is typically downloaded from a server. The client interprets the downloaded playlist file to present a series of requests to the server, for every piece of content represented in the playlist. A server, upon receipt of a media content request from a client, is generally not aware that the client is requesting media content that is referenced in a client implemented, or “client-side” playlist file. This is because use of a client-side playlist is indistinguishable from a client requesting a server to play one or more respective pieces of media content one-after-the-other.
[0010] A server implemented playlist, or “server-side” playlist is maintained by a server and is not downloaded to a client. To access media content represented in a server-side playlist, a client typically selects a URL that identifies both a server and a particular playlist file. Responsive to receiving a request from the selection of such a URL, the identified server accesses the requested playlist and streams, or “plays” the media content referenced by the playlist to the requesting client, one piece of media content at a time.
[0011] Regardless of whether a playlist is implemented on a server or on a client, a playlist can play a substantially important role in building a business based on advertising, source branding, service branding, and/or other revenue basis. For example, a playlist file can allow a content provider (e.g., an Internet radio station) to embed, or combine an advertisement, a brand name, and/or other content such as multimedia content previews, radio-station identifiers and/or the like with scheduled media content. Every time that a content provider chooses to modify an advertisement, branding information, and/the like, that is embodied in a playlist, the content provider must typically modify the playlist to excise the old content to incorporate the new content. Or, the content provider can remove the old playlist and create a completely new playlist to reflect the change(s). Such playlist modifications and may be brought about for any number of reasons such as changes in business methods, regulatory constraints, audience demographics, and/or the like. It can be appreciated that a content provider such as a radio or television station may have any number of playlists (e.g., one playlist, one-hundred playlists, one thousand playlists, or more) that need to be modified, and or created to reflect such changes. Thus such playlist media content changes typically require a substantial amount of administrative overhead.
SUMMARY
[0012] Systems and methods for combining streaming media content items for streaming to a client computer across a network are described. In one aspect, a playlist is maintained on a server computer. The playlist includes at least one reference to a streaming media content item and at least one placeholder. A request for a requested streaming media content item is received at the server computer from a client computer over a network. The server computer modifies the playlist to create a modified playlist by replacing at least one placeholder with a reference to a streaming media content item. This is accomplished such that the modified playlist includes at least one reference to the requested streaming media content item and at least one reference to at least one further streaming media content item. The streaming media content items referenced by the modified playlist are provided to the client computer over the network.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] FIG. 1 is a block diagram that illustrates aspects of an exemplary system to deliver additional content along with requested content from a server to a client.
[0014] FIG. 2 is a block diagram that illustrates aspects of an exemplary playlist wrapper data structure that refers to one or more content items.
[0015] FIG. 3 is a block diagram that illustrates aspects of an exemplary playlist wrapper data structure or playlist that refers to one or more content items.
[0016] FIG. 4 is a block diagram that illustrates aspects of an exemplary copy of a playlist wrapper data structure, or playlist that refers to one or more content items.
[0017] FIG. 5 is a block diagram that illustrates aspects of a modified playlist wrapper data structure or playlist that refers to one or more content items along with a client requested content item.
[0018] FIG. 6 is a flowchart that illustrates aspects of an exemplary methodology for a server to stream content items to a client.
[0019] FIG. 7 is a block diagram that illustrates aspects of an exemplary server computer to deliver additional content along with requested content to a client.
DETAILED DESCRIPTION
[0020] The following description sets forth a specific embodiment of a server component and methodology that incorporates elements recited in the appended claims. The embodiment is described with specificity in order to meet statutory requirements. However, the description itself is not intended to limit the scope of this patent. Rather, the inventors have contemplated that the claimed subject matter might also be embodied in other ways, to include different elements or combinations of elements similar to the ones described in this document, in conjunction with other present or future technologies.
[0000] Exemplary System Environment
[0021] FIG. 1 shows a client/server network system 100 and environment. Generally, the system includes one or more network server computers 102 and multiple network client computers 104 . The computers communicate with each other over a data communications network 106 such as the Internet. The data communications network might also comprise intranets, local-area networks and private wide-area networks. The system has associated data storage media 106 .
[0022] In one embodiment, server 102 is a streaming media content server that receives URLs or other references that indicate streaming media content, files, and/or sources. For example, the URL might identify an ASF (.asf) file. A variety of requests from the client are typically received by server 102 , and might identify requested content in a variety of different forms other than the URL form. Furthermore, some requests might not be processed in accordance with the technique described below. However, at least one subset of the received requests includes requests to one or more different content items that will be processed in accordance with the described technique.
[0023] In response to receiving the content request, the server 102 identifies or creates a data structure, or content template that refers to one or more other content items. In the described embodiment, the content template comprises a playlist. The playlist or other type of data structure can be created in a number of different data formats. SMIL provides an example of a suitable format.
[0024] The data structure acts as a wrapper or content template because the data structure specifies content that will wrap or frame at least a subset of the content sent by a server 102 to a client 104 .
[0025] After identifying the appropriate base data structure, the server 102 modifies the data structure to reference the requested content item by inserting the requested URL into the playlist's sequence of URLs. In most cases, this modification will be performed on a copy of the base data structure. A copy of the base data structure is a duplicate playlist. After the base playlist has been modified in this manner, server 102 provides the content items referenced by the modified data structure or playlist to the client 104 .
[0026] FIG. 2 shows an exemplary data structure 200 to reference one or more items of content. The data structure includes a sequence of one or more references 202 to content items. In the described implementation, the references are URLs. Additionally, the data structure includes a placeholder 204 , or flag that identifies a particular point in a sequence where the reference to the client requested content is to be placed. The placeholder 204 can be located at any position with respect to the references 202 .
[0027] There can be any number of placeholders 204 in the data structure 200 , each placeholder identifying a particular point in a sequence where the reference to the client-requested content is to be placed. If there is more than one placeholder, the total number of placeholders is analogous to a repeat count of how may times the client requested content will be referenced in the data structure. Optionally, the number and position of each placeholder is indicated in the client's request for the content item.
[0028] Although the implementation that is described above has been applied to playlists and streaming media, there are other types of content that might benefit from this approach. For example, the client's request might be for any other type of a document or file such as a Web page (e.g., an HTML document). In this case, the data structure 200 can be represented in the file/document/Web page specification with a placeholder indicating where the requested content, or reference to the content is to be inserted.
[0029] It can be appreciated that other types and combinations of content besides streaming media files are also possible such as bitmaps, JPEGs, MPEGs, and/or the like.
[0030] FIG. 3 is a block diagram that shows an exemplary base playlist 206 that references one or more items of streaming media content. The playlist is one example of a data structure 200 of FIG. 2 . In this implementation, the playlist references streaming media content items by identifying the content items with respective URLs 208 . The playlist also includes a placeholder 210 , or flag to identify a particular point in a sequence where a reference to client requested content is placed. The placeholder can be located at any position with respect to the one or more references or URLs.
[0031] FIG. 4 is a block diagram that shows an exemplary copy 212 of a base data structure 206 or playlist. A copy of a base data structure 206 or playlist is a duplicate data structure or playlist. The copy/duplicate is modified to reference client requested content item(s). Because playlist 212 is a copy of playlist 206 , playlist 212 includes streaming media content references 208 and placeholder 210 .
[0032] A client plays a temporary copy 212 of the wrapper playlist file 206 , so modifying the temporary copy for one client request will not affect any other concurrent or future client requests. Thus, a server is able to apply a same wrapper playlist to any number of different clients that request any number of different original URL's. This is because each requesting client will play their own requested URL in a private copy of the wrapper playlist.
[0033] A URL 214 represents an item of content requested by a client. In this example, the client's content request refers to streaming media content file “newstuff.asf”. Server 102 modifies playlist 212 to reference the requested content item. This modification is illustrated in FIG. 5 .
[0034] FIG. 5 is a block diagram that shows an exemplary playlist 212 after it has been modified. Specifically, the server 102 has inserted a URL 214 into the playlist 212 at the location identified by a placeholder 210 . A server can use this technique to “wrap” other content items around a client-requested content item. The client 104 does is not required to do anything special to receive the other content items. This is because the server automatically translates the client's request for a particular content item into a request for the particular content item and the other content items.
[0035] To illustrate this, consider a playlist that includes the HTML instruction sequence shown in Table 1.
TABLE 1 EXAMPLE OF A PLACEHOLDER IN A WRAPPER PLAYLIST <HTML> <SEQ> <MEDIA src=“http://advertisements/ advertisement1.asf“/> <MEDIA src=“%url%”/> <MEDIA src=“http://advertisements/advertisement2.asf“/> </SEQ> </HTML>
[0036] A placeholder 214 in the above HTML sequence is identified by “% url %”. The server replaces every occurrence of the string “% url %” with a URL requested by the client. For example, consider a playlist that includes the HTML sequence shown in Table 2.
TABLE 2 EXAMPLE OF WRAPPING OTHER URLS AROUND A A CLIENT REQUESTED URL <HTML> <SEQ> <MEDIA src=“http://advertisements/ advertisement1.asf”/> <MEDIA src=“http://serverName/FeatureMovies/BigActionMovie.asf”/> <MEDIA src=“http://advertisements/advertisement2.asf“/> </SEQ> </HTML>
[0037] Note that the “% url %” placeholder has been replaced with a client requested URL 214 (http://serverName/FeatureMovies/BigActionMovie.asf).
[0038] In these examples, the playlists of Tables 1 and 2 are illustrated using the SMIL data format. However, the SMIL format is used for illustration purposes only, and a wrapper playlist can be generated and/or modified using instructions and/or data represented in one of a number of other multimedia integration formats.
[0039] Using a playlist structure and technique as described, allows a server to add advertisements, previews of coming attractions, or other content to a playlist sequence without having to modify an original playlist, or change a URL that corresponds to the original playlist. A data structure or playlist is not restricted to placing advertisements before a requested URL. Such playlists can be used to specify that a client will receive any stream of content that can be described by the playlist language, and that the original requested URL may appear anywhere and any number of times in this sequence of content. Moreover, as discussed above, any other playlist attributes that can be applied to content, such as repeat count and/or the like, can also be applied to the original requested content reference (e.g., a URL).
[0040] Furthermore, a data structure such as this allows an administrator to specify an advertising policy by editing the content of the playlist. The policy can easily be changed, by simply editing the base playlist. As a result, the discussed problem of configuring an advertising policy is turned into a much simpler problem of authoring an advertising template or playlist to frame or wrap all content. Authoring content is a well-understood problem and many existing tools for authoring Web content can help with this task.
[0041] In some cases, a server may store a standard playlist that is applied to all incoming client requests for content items. In other implementations, a collection of base playlists can be stored for use with different types of requests. Requests can be distinguished, for example, by a storage location of the referenced content, by a file name or extension indicated in the request, and/or by a variety of other distinguishing factors.
[0042] As discussed above, base data structures or wrappers can be useful for other types of servers besides streaming media servers. For example, a Web server typically serves Web pages that contain multiple references or URLs specified in a format such as HTML (hypertext markup language). A document such as this can be used as a template or wrapper according to the novel procedures discussed above, by including a placeholder indicating where embedded content should be located. When a client requests a Web page specification by supplying a URL reference, the server inserts this URL reference into the wrapper, in place of the placeholder, and then serves the resulting Web page.
[0043] To illustrate this, consider that a client requests a URL, for example, “http://server/doc1.htm”. The Web server responds by making a temporary copy of a “wrapper” HTML document. The Web server then modifies the temporary copy by inserting the originally requested URL (“http://server/doc1.htm”) into the contents of the wrapper document.
[0044] The “wrapper” HTML document may place banner advertisements and other helpful links around the originally requested content. When the modified temporary copy of the wrapper html document is presented to the user, the contents of the original URL “http://server/doc1.htm” might then appear in the middle of the wrapper document.
[0000] Exemplary Procedure
[0045] FIG. 6 is a flowchart diagram that shows an exemplary procedure 600 to stream data from a server to a client. At block 610 , the procedure receives a request from a client for one or more content items. At block 612 , the procedure identifies a data structure that refers to one or more further content items. At block 614 , the procedure modifies the data structure to reference the requested content items. At block 616 , the procedure provides the requested content items (block 610 ) referenced by the modified data structure (block 614 ) to the requesting client (block 610 ).
[0000] Exemplary Computer Environment
[0046] FIG. 7 shows components of computer 700 that forms a suitable environment for a server computer 102 of FIG. 1 . The components shown in FIG. 7 are only examples, and are not intended to suggest any limitation as to the scope of the functionality of the subject matter; the subject matter is not necessarily dependent on the features shown in FIG. 7 .
[0047] Generally, various different general purpose or special purpose computing system configurations can be used. Examples of well known computing systems, environments, and/or configurations that may be suitable for use with the subject matter include, but are not limited to, personal computers, server computers, hand-held or laptop devices, multiprocessor systems, microprocessor-based systems, set top boxes, programmable consumer electronics, network PCs, minicomputers, mainframe computers, distributed computing environments that include any of the above systems or devices, and the like.
[0048] The functionality of a computer is embodied in many cases by computer-executable instructions, such as program modules that are executed by the computer. Generally, a program module includes routines, programs, objects, components, data structures, etc. that perform particular tasks or implement particular abstract data types. Tasks might also be performed by remote processing devices that are linked through a communications network. In a distributed computing environment, program modules may be located in both local and remote computer storage media.
[0049] The instructions and/or program modules are stored at different times in the various computer-readable media that are either part of the computer or that can be read by the computer. Programs are typically distributed, for example, on floppy disks, CD-ROMs, DVD, or some form of communication media such as a modulated signal. From there, they are installed or loaded into the secondary memory of a computer. At execution, they are loaded at least partially into the computer's primary electronic memory. The subject matter described herein includes these and other various types of computer-readable media when such media contain instructions programs, and/or modules for implementing the steps described below in conjunction with a microprocessor or other data processors. The subject matter also includes the computer itself when programmed according to the methods and techniques described below.
[0050] For purposes of illustration, programs and other executable program components such as the operating system are illustrated herein as discrete blocks, although it is recognized that such programs and components reside at various times in different storage components of the computer, and are executed by the data processor(s) of the computer.
[0051] With reference to FIG. 7 , the components of computer 700 may include, but are not limited to, a processing unit 720 , a system memory 730 , and a system bus 721 that couples various system components including the system memory to the processing unit 720 . The system bus 721 may be any of several types of bus structures including a memory bus or memory controller, a peripheral bus, and a local bus using any of a variety of bus architectures. By way of example, and not limitation, such architectures include Industry Standard Architecture (ISA) bus, Micro Channel Architecture (MCA) bus, Enhanced ISA (EISAA) bus, Video Electronics Standards Association (VESA) local bus, and Peripheral Component Interconnect (PCI) bus also known as the Mezzanine bus.
[0052] Computer 700 typically includes a variety of computer-readable media. Computer-readable media can be any available media that can be accessed by computer 700 and includes both volatile and nonvolatile media, removable and non-removable media. By way of example, and not limitation, computer-readable media may comprise computer storage media and communication media. Computer storage media includes volatile and nonvolatile, removable and non-removable media implemented in any method or technology for storage of information such as computer-readable instructions, data structures, program modules, or other data. Computer storage media includes, but is not limited to, RAM, ROM, EEPROM, flash memory or other memory technology, CD-ROM, digital versatile disks (DVD) or other optical disk storage, magnetic cassettes, magnetic tape, magnetic disk storage or other magnetic storage devices, or any other medium which can be used to store the desired information and which can be accessed by computer 710 .
[0053] Communication media typically embodies computer-readable instructions, data structures, program modules or other data in a modulated data signal such as a carrier wave or other transport mechanism and includes any information delivery media. The term “modulated data signal” means a signal that has one or more if its characteristics set or changed in such a manner as to encode information in the signal. By way of example, and not limitation, communication media includes wired media such as a wired network or direct-wired connection and wireless media such as acoustic, RF, infrared and other wireless media. Combinations of any of the above should also be included within the scope of computer readable media.
[0054] The system memory 730 includes computer storage media in the form of volatile and/or nonvolatile memory such as read only memory (ROM) 731 and random access memory (RAM) 732 . A basic input/output system 733 (BIOS), containing the basic routines that help to transfer information between elements within computer 700 , such as during start-up, is typically stored in ROM 731 . RAM 732 typically contains data and/or program modules that are immediately accessible to and/or presently being operated on by processing unit 720 . By way of example, and not limitation, FIG. 7 illustrates operating system 734 , application programs 735 , other program modules 736 , and program data 737 .
[0055] Such application programs 735 include server component 738 , which responds to client requests for content by providing the requested content and additional content to the client. Aspects of an exemplary methodology of server component 738 were described above in reference to FIGS. 7-6 .
[0056] The computer 700 may also include other removable/non-removable, volatile/nonvolatile computer storage media. By way of example only, FIG. 7 illustrates a hard disk drive 741 that reads from or writes to non-removable, nonvolatile magnetic media, a magnetic disk drive 751 that reads from or writes to a removable, nonvolatile magnetic disk 752 , and an optical disk drive 755 that reads from or writes to a removable, nonvolatile optical disk 756 such as a CD ROM or other optical media. Other removable/non-removable, volatile/nonvolatile computer storage media that can be used in the exemplary operating environment include, but are not limited to, magnetic tape cassettes, flash memory cards, digital versatile disks, digital video tape, solid state RAM, solid state ROM, and the like. The hard disk drive 741 is typically connected to the system bus 721 through an non-removable memory interface such as interface 740 , and magnetic disk drive 751 and optical disk drive 755 are typically connected to the system bus 721 by a removable memory interface such as interface 750 .
[0057] The drives and their associated computer storage media discussed above and illustrated in FIG. 7 provide storage of computer-readable instructions, data structures, program modules, and other data for computer 700 . In FIG. 7 , for example, hard disk drive 741 is illustrated as storing operating system 744 , application programs 745 , other program modules 746 , and program data 747 . Note that these components can either be the same as or different from operating system 734 , application programs 735 , other program modules 736 , and program data 737 . Operating system 744 , application programs 745 , other program modules 746 , and program data 747 are given different numbers here to illustrate that, at a minimum, they are different copies. A user may enter commands and information into the computer 700 through input devices such as a keyboard 762 and pointing device 761 , commonly referred to as a mouse, trackball, or touch pad. Other input devices (not shown) may include a microphone, joystick, game pad, satellite dish, scanner, or the like. These and other input devices are often connected to the processing unit 720 through a user input interface 760 that is coupled to the system bus, but may be connected by other interface and bus structures, such as a parallel port, game port, or a universal serial bus (USB). A monitor 791 or other type of display device is also connected to the system bus 721 via an interface, such as a video interface 790 . In addition to the monitor, computers may also include other peripheral output devices such as speakers 797 and printer 796 , which may be connected through an output peripheral interface 795 .
[0058] The computer may operate in a networked environment using logical connections to one or more remote computers, such as a remote computer 780 . The remote computer 780 may be a personal computer, a server, a router, a network PC, a peer device or other common network node, and typically includes many or all of the elements described above relative to computer 700 , although only a memory storage device 781 has been illustrated in FIG. 7 . The logical connections depicted in FIG. 7 include a local area network (LAN) 771 and a wide area network (WAN) 773 , but may also include other networks. Such networking environments are commonplace in offices, enterprise-wide computer networks, intranets, and the Internet.
[0059] When used in a LAN networking environment, the computer 700 is connected to the LAN 771 through a network interface or adapter 770 . When used in a WAN networking environment, the computer 700 typically includes a modem 772 or other means for establishing communications over the WAN 773 , such as the Internet. The modem 772 , which may be internal or external, may be connected to the system bus 721 via the user input interface 760 , or other appropriate mechanism. In a networked environment, program modules depicted relative to the computer 700 , or portions thereof, may be stored in the remote memory storage device. By way of example, and not limitation, FIG. 7 illustrates remote application programs 785 as residing on memory device 781 . It will be appreciated that the network connections shown are exemplary and other means of establishing a communications link between the computers may be used.
[0000] Conclusion
[0060] Although various implementations of the described subject matter have been described in language specific to structural features and/or methodological operations, it is to be understood that the subject matter defined in the appended claims is not necessarily limited to the specific features or steps described. Rather, the specific features and operations are disclosed as exemplary forms of implementing the claimed subject matter. | Systems and methods for combining streaming media content items for streaming to a client computer across a network are described. In one aspect, a playlist is maintained on a server computer. The playlist includes at least one reference to a streaming media content item and at least one placeholder. A request for a requested streaming media content item is received at the server computer from a client computer over a network. The server computer modifies the playlist to create a modified playlist by replacing at least one placeholder with a reference to a streaming media content item. This is accomplished such that the modified playlist includes at least one reference to the requested streaming media content item and at least one reference to at least one further streaming media content item. The streaming media content items referenced by the modified playlist are provided to the client computer over the network. | 8 |
FIELD OF THE INVENTION
The present invention relates to a device for longitudinally guiding a motor vehicle, including a sensor system for locating preceding vehicles, a regulator that regulates the speed of the vehicle to a setpoint speed, either in a free driving mode or in a following driving mode, the setpoint speed depending on the distance from a preceding vehicle, as well as an interface to a navigation system that provides information concerning the route traveled, and a limiting device for limiting the setpoint speed based on the information provided.
BACKGROUND INFORMATION
Such devices for longitudinally guiding a motor vehicle are also known as ACC (adaptive cruise control) systems and typically have a radar sensor as a sensor system which can be used to measure the distances and relative speeds of preceding vehicles. This method makes it possible to follow a vehicle traveling directly ahead, the so-called target object, at a suitable distance or, more precisely, in a suitably selected time interval. In free driving mode when no target object is present, the speed is regulated to a setpoint speed, which in the systems in use today is specified by a desired speed selected by the driver.
In specific conditions, for example when driving in tight curves, it is possible that the regulation may not be adapted to the current situation so that the curve is taken at an excessively high speed. The driver is then forced to intervene in the longitudinal guidance and temporarily deactivate the ACC system.
In German Patent Application Nos. DE 198 21 803 and DE 199 31 161, longitudinal guidance systems are described having a connection to a navigation system which is also present in the vehicle so that the route information supplied by the navigation system, in particular the information readable from a digital map concerning the curvature of the section of roadway directly ahead, can be included in the speed regulation.
SUMMARY OF THE INVENTION
In the present invention, the connection of the longitudinal guidance system to the navigation system is configured in such a way that the system behavior as a whole is more transparent and plausible for the driver.
According to the present invention, this is achieved in that the limiting device is designed to deactivate automatically when changing from free driving mode to following driving mode and activate automatically when changing from following driving mode to free driving mode.
This mode of functioning is based on the consideration that the host vehicle in following driving mode is able to drive along the section of roadway ahead at the same speed at which the target object also drives along the same section of roadway. Deactivating the limiting device then has the advantage that the distance from the target object is kept constant and unnecessary deceleration and acceleration events that are contrary to the driver's intuition and increase fuel consumption are avoided. Experience shows namely that in following driving mode, the driver primarily bases his evaluation of his own speed on the distance from the vehicle ahead and experiences fluctuations of this distance for which he finds no plausible explanation to be unsettling. For that reason, the acceptance of the system may be significantly increased if the limiting device is active only in free driving mode.
Since it is only possible to determine the roadway curvature with limited precision using the route information supplied by the navigation system, it is expedient to program the limiting device in such a way that it considers a specific safety allowance in calculating the limiting value for the setpoint speed. Since the limiting device is active only in free driving mode, this safety allowance has no effect in following driving mode in which it would likely be experienced as unsettling.
If the target object is lost, for example when the preceding vehicle turns off or changes to an adjacent lane, the system goes into free driving mode and the limiting device activates automatically so that travel continues at an adapted speed.
According to an advantageous refinement of the present invention, there are specific exceptions to the rule that the limiting device should only be active in free driving mode. In particular, the limiting device should, by way of exception, also be active in following driving mode when there are definite indications that the expected route of the host vehicle deviates from the route of the target object and the speed adapted to the route of the host vehicle is significantly lower than the expected speed of the target object. A typical example is the situation in which the host vehicle approaches an intersection or bifurcation and the driver announces an intention to turn off by setting his turn signals (blinkers) while the target object travels straight ahead. A more general criterion for exception exists when it is apparent that the route of the host vehicle differs from the route of the target object and the speed at which the route of the target object may be traveled is higher by a specific threshold value than the speed at which it is possible to travel on the route of the host vehicle. The speeds at which the different routes may be traveled may be determined using the data supplied by the navigation system, in particular using the particular roadway curvatures.
If the route guidance function of the navigation system is activated, the assumption that the driver of the host vehicle will follow the route calculated by the route guidance function makes it possible to predict the route of the host vehicle.
If there is a plurality of possible routes for the host vehicle, for example ahead of an intersection or bifurcation, the limiting device preferably operates in free driving mode so that it calculates a limiting value for the setpoint speed for each possible route and selects the highest of these limiting values for limiting the setpoint speed.
In this way, the limiting device is constantly in a defined state even if the expected route is unclear, and therefore may be active even if no information is present concerning the route the driver is expected to select. When approaching an intersection or fork in the road, the mode of functioning of the limiting device is then based on the assumption that the driver will select from the various conceivable routes the one allowing the highest speed. It is not necessary for this assumption always to be accurate; however, it creates the precondition for the limiting device to be active in the first place when the route is unknown and thus makes it possible to adapt the speed automatically on sections of roadway on which the route is clear. In doing so, it is deliberately accepted that the driver must occasionally actively intervene in the longitudinal guidance, specifically when he selects from a plurality of possible routes the one that only permits traveling at a lower speed. In such situations, which occur only sporadically in any case, the driver must, however, assume that the limiting device is unable to accurately predict the adapted speed and he must therefore be prepared to actively intervene in the longitudinal guidance. The associated loss of comfort must simply be accepted. The advantage that the function of the limiting device is available in all other situations prevails.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a block diagram of the longitudinal guidance device.
FIG. 2 shows a sketch of a traffic situation for illustrating the mode of operation of the device.
FIG. 3 shows a flow chart for elucidating the mode of operation of the device according to a modified embodiment
DETAILED DESCRIPTION
FIG. 1 shows an ACC system 10 , the basic design and function of which is presumed to be known and will therefore only be outlined briefly here.
A radar sensor 12 having angle resolution installed in the front of the vehicle supplies ACC system 10 with locating data (distances, relative speeds, and azimuth angles) of the objects located. The measured data are updated cyclically. In a tracking module 14 , the prevailing measured data are compared with the measured data from previous measurement cycles, thus making it possible to track the movements of individual objects.
A path prediction module 16 is used to estimate the anticipated path of the host vehicle. Therefore, in the simplest case only yaw rate w of the host vehicle is analyzed, this yaw rate being measured with the help of a yaw rate sensor 18 , a determination of road curvature in the section of road on which the host vehicle is driving at the moment being made possible in conjunction with the driving speed of the host vehicle.
On the basis of the predicted path, a driving tube, within which the vehicles that may be used as the target object for the adaptive cruise control must be situated, is determined. In the simplest case, this driving tube is a strip having a certain standard width following the predicted path.
A plausibility check is then performed on the objects located and tracked in tracking module 14 in a plausibility check module 20 , i.e., a probability of an object being inside the driving tube is calculated for each object. This takes into account the fact that the locating data, in particular the transverse position data, have certain error tolerances that increase with an increase in object distance. If the probability that the object is within the driving tube is above a certain threshold, the object is “plausibilized,” i.e., it is treated like a relevant object that is in one's own lane. Of the objects thereby plausibilized, ultimately the object having the smallest distance is then selected as the target object for the adaptive cruise control.
In a regulator 22 , the actual adaptive cruise control is then performed on the basis of the locating data on the target object by intervening in the drive system and, if necessary, also intervening in the brake system of the vehicle, so that the target object is tracked with a time gap that is selectable by the driver within certain limits. If no target object is present, the system is in free driving mode and normally the speed is regulated based on a desired speed selected by the driver.
ACC system 10 described here has an interface to a navigation system 24 of the vehicle. This navigation system contains a road map stored in digital form and ascertains the instantaneous position of the host vehicle with the help of a GPS system (global positioning system), so that information about the road type (highway or rural road) and about exit ramps, intersections, junctions, curves and the like yet to come is also available in the ACC system.
In particular, the curvature of the section of roadway lying directly ahead may be determined from the data stored in the digital map. This information may be used on the one hand to improve the path prediction in prediction module 16 . However, in free driving mode in particular, it may also be used to improve the longitudinal guidance of the vehicle. While applying a maximum transverse acceleration, which, depending on the vehicle type, is still experienced as comfortable, the roadway curvature may be used to calculate an upper limiting value for the speed at which the section of roadway in question should be traveled. If this limiting value is lower than the desired speed, it is expedient to modify the speed regulation so that it is based on the limiting value instead of the desired speed.
In addition, the data supplied by the navigation system may also be used to decide if the section of roadway ahead is a highway outside of built-up areas or a street within a city or town so that the applicable legal maximum speed may be selected as a limiting value for the road type in question. The same applies in cases in which an “intelligent” navigation system supplies information concerning speed limits that may exist.
However, if a plurality of possible routes is available ahead of an intersection, bifurcation, or fork in the road, which is also identifiable from the data of the navigation system, specific assumptions must be made concerning which route the driver is expected to follow so that the system shows defined behavior in every situation. For this reason, the device shown in FIG. 1 has a module 26 which detects such route ambiguities using the data of navigation system 24 . In order to eliminate or at least limit such ambiguities, module 26 additionally receives signals from a state sensor 28 which indicates the present state of the turn signal (blinker) of the host vehicle. If, for example, a possibility for turning off to the right exists and the right blinker is set, it may be concluded from this that the driver intends to turn off to the right and consequently the route turning off to the right is significant for determining the limiting value for speed. If, however, neither the right nor the left blinker is set, the situation remains ambiguous since it is not clear if the driver actually intends to drive straight ahead or has only forgotten to set the blinker. It may be possible to eliminate the ambiguity by analyzing the driver's steering behavior. For this purpose, module 26 in the example shown also receives the signal of yaw rate sensor 18 .
If the guidance function is active in navigation system 24 , in order to eliminate the ambiguity, it may also be assumed that the driver will follow the route calculated by the guidance system. In the example shown here, however, the route calculated by the guidance system will not be considered. In another embodiment, the limiting device may also be programmed in such a way that it is only active in free driving mode when the expected route of the host vehicle is known, for example, when the guidance function is active.
If a target object is selected and followed in a following driving situation, it is a reasonable assumption for the purposes of the adaptive cruise control that the host vehicle will follow the path of the target object. This assumption is based on the path prediction in prediction module 16 .
In free driving mode, the aforementioned speed limiting value is calculated in a limiting device 30 which receives from module 26 the roadway data of all possible routes still remaining after the most extensive elimination of ambiguity. In addition, limiting device 30 receives from plausibility check module 20 the information as to whether a target object has been selected or not. If a target object is selected, i.e., in following driving mode, limiting device 30 remains inactive and the adaptive cruise control based on the target object occurs in regulator 22 independently of the data supplied by navigation system 24 .
In free driving mode, limiting device 30 calculates a separate limiting value for each of the possible routes, each based on the roadway curvature applicable to the route in question. Limiting device 30 then selects the highest of the limiting values calculated in this manner and compares it with the desired speed selected by the driver. The lower of the two values compared with one another is then transferred to regulator 22 as the setpoint speed.
FIG. 2 illustrates the mode of operation of the device described above based on an example.
A vehicle 32 which is fitted with the device according to FIG. 1 approaches an intersection 36 on a right-of-way street 34 . Vehicle 32 thus has three possible routes 38 , 40 and 42 available to it, which differ in the curvature of the roadway. Routes 38 and 42 may only be traveled at a significantly lower speed than route 40 .
ACC system 10 is in following driving mode and follows a preceding vehicle 44 , which is just crossing intersection 36 , as a target object. As long as nothing is known concerning the route of vehicle 32 , the assumption is valid that the target object will continue to be followed. Regulator 22 thus regulates the speed of vehicle 32 in such a way that vehicle 44 is followed at a suitable time interval. Even if road 34 should have tight curves in its further course and vehicle 44 reduces its speed, regulator 22 would essentially keep the time interval between the target object and vehicle 32 constant, since limiting device 30 is not active.
In the situation shown in FIG. 2 , module 26 now detects that the driver of vehicle 32 activates his right turn signal, from which it is concluded that vehicle 32 will follow route 42 and thus turn off to the right. Alternatively, this could also be detected from the fact that the guidance system of navigation system 24 has calculated route 42 .
Module 26 now prompts prediction module 16 to correct the path prediction so that the target object is no longer in the predicted driving tube. Consequently plausibility check module 20 discards the target object so that the system shifts into free driving mode. Accordingly, limiting device 30 is activated so that the setpoint speed for regulator 22 is limited in such a way that the turning maneuver may be performed at an adapted speed. If the driver of vehicle 32 travels straight ahead contrary to expectation, the target object is detected again and the system returns to following driving mode and deactivates limiting device 30 .
In a modified specific embodiment, the speed limiting values for the three possible routes 38 , 40 and 42 have already been calculated before the situation shown in FIG. 2 . Even before vehicle 44 has reached intersection 36 , the system is able to detect that the speed of the target object is too high for routes 38 and 42 and from this it is able to conclude that the target object will follow route 40 , i.e., will deviate from its own route 42 . In this case, limiting device 30 may already be activated although the system temporarily remains in following driving mode. The limiting device does not then completely cancel the adaptive cruise control but instead only the setpoint speed is limited from increasing so that vehicle 32 is slowed down for the turning maneuver and also does not approach the target object too closely if this target object should decelerate its travel.
FIG. 3 shows a slightly modified mode of functioning of the device in a flow chart which, however, is in result equivalent to the mode of functioning described above.
In step S 1 it is decided if ACC system 10 is in following driving mode (Y) or in free driving mode (N). If the system is in following driving mode, regulator 22 calculates a following driving setpoint acceleration as a setpoint acceleration in step S 2 using the data concerning the target object supplied by tracking module 14 , the following driving setpoint acceleration ensuring that the target object is followed at the specified time interval.
In step S 3 , module 26 then checks while still in following driving mode if a bifurcation or intersection 36 is present in the area ahead of vehicle 32 or if vehicle 32 will turn off. If this is the case, a free driving setpoint acceleration is calculated in step S 4 which decelerates the vehicle in such a way that its speed is at most equal to the calculated limiting value during the turning maneuver. The minimum from the thus calculated free driving setpoint acceleration and the following driving setpoint acceleration from step S 2 is then selected as a final setpoint acceleration.
In free driving mode, however, in step S 5 , limiting device 30 calculates a desired setpoint acceleration as well as free driving setpoint accelerations for each of the possible routes. The desired setpoint acceleration is the acceleration necessary to maintain or reattain the desired speed selected by the driver. The free driving setpoint accelerations are dependent on the roadway curvature and/or other roadway characteristics of the route in question. In calculating them, limiting device 30 uses roadway data supplied by navigation system 24 for the routes considered possible by module 26 . In step S 6 , limiting device 30 then calculates as a setpoint acceleration the minimum from the desired setpoint acceleration and the maximum of the free driving setpoint accelerations.
In step S 7 , regulator 22 then outputs either the setpoint acceleration calculated in step S 2 or S 4 or the setpoint acceleration calculated in step S 6 to the drive and/or brake system of the vehicle.
In contrast to the exemplary embodiment described earlier, this exemplary embodiment does not take into account the setpoint speed but instead the setpoint acceleration. However, in this case also, the free driving setpoint accelerations are calculated in steps S 4 and S 5 in such a way that a limiting value for speed is first determined for each route using the roadway curvature, and the setpoint acceleration is then calculated in such a way that the actual speed on reaching the section of roadway in question corresponds to the limiting value. The limiting values are thus contained implicitly in the free driving setpoint accelerations and the setpoint accelerations calculated in steps S 4 and S 6 imply a limiting of the setpoint speed. | A device for longitudinally guiding a motor vehicle includes a sensor system for locating preceding vehicles, a regulator that regulates the speed of the vehicle to a setpoint speed, either in a free driving mode or in a following driving mode, the setpoint speed depending on the distance from a preceding vehicle, as well as an interface to a navigation system that provides information concerning the route traveled, and a limiting device for limiting the setpoint speed based on the information provided. The limiting device is designed to deactivate automatically when changing from free driving mode to following driving mode and activate automatically when changing from following driving mode to free driving mode. | 1 |
BACKGROUND OF THE INVENTION
[0001] (a) Field of the Invention
[0002] The invention relates to a digital display device, particularly to a digital television display device.
[0003] (b) Description of the Related Art
[0004] In modern life, display control technology has become indispensable for daily life. Accompanying with the technology improvement and the opening of media, the channel that can be received by the display device (such as: the television) is also becoming more various.
[0005] Currently, there are basically two types of digital display control technologies. The first type is the frame rate conversion, that is, the data of at least one frame is buffered by the frame buffer and is displayed after processing. Therefore, the timing control of the output image signal is completely irrelevant to the input image signal. However, the chip area increases due to the large storage capacity of the frame buffer and thereby the cost increases. The second type is the frame synchronization, that is, the data of less than one frame is buffered by the line buffer and is displayed after processing. Since the buffered image data is less than one frame, the frame rates of the input frame and the output frame must be maintained at a specific relation in order to avoid the line buffer overflow or underflow. Therefore, the output image signal timing has specific relations with the input image signal timing. In order to establish the specific relation between the output image signal and the input image signal frame rate, a display vertical synchronization (DVS) signal is generally initiated according to an input vertical synchronization (IVS) signal. The method according to the prior art resets the DVS signal and then outputs the DVS signal according to the IVS signal.
[0006] During channel switching, since the video signal timing of the two channels are irrelevant with each other, the frequencies and the phases of the IVS signals of the two channels are most likely not the same. Please refer to FIG. 1 , where the IVS signal of the channel 1 is not synchronizing with the IVS signal of the channel 2 . However, the frame synchronization technology resets the DVS signal according to the IVS signal. The channel switching may result in such DVS signal timing shown in FIG. 1 . Since the DVS signal format (that is, the frame timing) resulting from Such phenomenon cannot meet the required timing of the panel, the panel cannot display normally.
[0007] Therefore, an invention for solving the above-mentioned problems is needed urgently.
BRIEF SUMMARY OF THE INVENTION
[0008] One object of the invention is to provide a display control device and method thereof to solve the above-mentioned problem.
[0009] One object of the invention is to provide a display control device and method thereof to fulfill the trend that the television signal source technology of the future becomes more diversified.
[0010] The display control device according to one embodiment of the invention comprises a first measuring circuit, a second measuring circuit, a determining circuit, a timing controller, and a clock generator. The display control device utilizes the phase deviation and the frequency deviation between the output signal and the input signal caused by channel switching to provide converting time acceptable by a display device and to achieve the objective of balancing the data stream transmission.
[0011] By the above-mentioned description, the image can be smoothly switched during channel switching no matter what kind of frequency and phase period are used by the channel. In other words, the above-mentioned problem is greatly improved by the present invention and therefore the present invention is a novel invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] FIG. 1 shows a signal synchronizing timing chart during channel switching in the prior art;
[0013] FIG. 2 shows a block diagram of the display control device according to one embodiment of the present invention;
[0014] FIG. 3 shows a timing chart illustrating the phase compensation of the display control device and method according to one embodiment of the present invention;
[0015] FIG. 4 shows a functional black diagram of the clock generator of the display control device according to one embodiment of the present invention; and
[0016] FIG. 5 shows a schematic diagram illustrating the linear frequency switching of the clock generator of the display control device according to one embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0017] Although the present invention has been fully described by way of examples with reference to the accompanying drawings, it Should not be construed as any limitation on the range of implementation of the invention. It should be understood by those who are skilled in the art that hardware manufacturers may use different names for the same element. Thus, in this application and the following claims, the elements are distinguished by their functionalities but not what is called.
[0018] FIG. 2 shows a block diagram of the display control device according to the present invention. As shown in FIG. 2 , the display control device 200 comprises a first measuring circuit 201 , a determining circuit 202 , a second measuring circuit 203 , a timing controller 204 , and a clock generator 205 .
[0019] The first measuring circuit 201 detects the frequency of an IVS signal. The second measuring unit 203 detects the phase difference between a DVS signal and the IVS signal. The determining circuit 202 generates a first control signal and a second control signal according to the IVS frequency data and the phase difference data between the IVS and the DVS. The first control signal indicates the setting of the display clock and the second control signal indicates the setting of the display timing. The determining circuit 202 can be implemented by a look up table (LUT) or a logic circuit generated from hardware. The clock generator 205 generates a proper display clock (DCLK) signal according to the setting of the first control signal. Usually, the clock generator 205 can be implemented by a phase-locked loop. The timing controller 204 receives the second control signal (usually comprising: the number of horizontal lines, the number of pixels of the horizontal line, and the reset signal) and the DCLK signal to generate the DVS signal, the display horizontal synchronization (DHS) signal, and the display enable (DEN) signal. Usually, the timing controller 204 can be implemented by a pixel counter and a line counter. The pixel counter counts the number of pixels of the horizontal line according to the DCLK signal and outputs the DHS signal when the count of the pixel counter reaches the number of pixel of the horizontal line. The line counter counts the number of horizontal lines according to the DHS signal and outputs the DVS signal when the count of the line counter reaches the number of horizontal lines of the display frame.
[0020] In another embodiment, the first measuring circuit 201 can also measure the frequency data of an input horizontal synchronization (IHS) signal and an input enable (IEN) signal so that the determining circuit 202 can generate more precise control signals. Similarly, the second measuring circuit 203 can also measure the phase difference data of the IHS/DHS and the IEN/DEN so that the determining circuit 202 can generate more precise control signals.
[0021] In another embodiment, the first measuring circuit 201 can also measure the frequency data of the IVS, IHS, IEN, DVS, DHS, and DEN so that the determining circuit 202 can generate more precise control signals.
[0022] Since the vertical synchronizing signal is related to the horizontal synchronizing signal, the first measuring circuit 201 can only measure the frequency data of the IHS to replace the frequency data of the IVS; and the second measuring circuit 203 can only measures the phase difference between the IHS and the DHS to replace the phase difference between the IVS and the DVS.
[0023] FIG. 3 illustrates the timing diagram of the display control device after channel switching according to one embodiment of the present invention. Initially, the second measuring unit 203 measures the phase difference between the IVS and the DVS to provide the measurement result to the determining circuit 202 . Based on the phase difference between the IVS and the DVS, the determining circuit 202 determines and sets the corrections (such as line number, pixel number, clock frequency and so forth) of the display clock and the display timing. By performing adjustment and compensation of a phase correction X repeatedly, the phase deviation between the IVS of the input terminal and the DVS of the output terminal is gradually adjusted and corrected to be within the range acceptable by the system.
[0024] Of course, the related display timing, after correction, still has to meet the requirements of the panel. That is, each of the newly corrected display timing during the correction period also has to meet the requirements of the panel. One of implements is to employ the concept of progressive linear frequency switching for performing the adjustment and correction of the frequency deviation between the signals.
[0025] Please refer to FIG. 4 . FIG. 4 illustrates the block diagram of the clock generator 205 of the display control according to one embodiment of the present invention. The clock generator 205 further comprises a re-synchronizer 401 , a phase-locked loop 402 (PLL), a phase swallower 403 , a sigma delta modulator 404 , and a frequency divider 405 . The re-synchronizer 401 can be implemented by a flip-flop and the rest of circuit components are well known to those who are skilled in the art and detail description will be omitted. By utilizing the re-synchronizer 401 , the sigma delta modulator 404 and the phase-locked loop with the phase swallow technology, the frequency of the display clock (DCLK) can be increased or decreased, progressively. Therefore, the phase lock loop 402 is controlled by adjusting the level of variation of the first control signal so as to switch frequency progressively and thus the linear frequency switching failure phenomenon induced by the large jitter generated by the drastic frequency switching at the receiving end can be avoided. Therefore, the frame rate can be smoothly switched during the channel switching and this is exactly the concept of linear frequency switching. Please refer to FIG. 5 . FIG. 5 shows the frequency variation of the clock generator 205 of the present invention.
[0026] The other detail characteristics of the method can be learned from the above-mentioned description by those who are skilled in the art and will not be described in further detail.
[0027] Although the present invention has been fully described by way of examples with reference to the accompanying drawings, it should not be construed as any limitation on the implementation of the present invention. Various equivalent changes and modifications of the shape, scope, characteristics, and spirit as described by the claims of the present invention are to be encompassed by the scope of the present invention. | The invention discloses a display control device and method thereof. The display control device and method thereof utilize the phase deviation and the frequency deviation between the output signal and the input signal caused during channel switching to provide converting time acceptable by a display device and to achieve the objective of balancing the data stream transmission. | 7 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to utilitarian and aesthetic sink constructions for use in a kitchen, bathroom or any other facility in which an attractive sink would be normally installed. The sink construction includes a stainless steel bottom combined with a counter top and vertical wall constructed from a polymer based solid surface sheet material. More particularly, the invention relates to the manner in which the components of the solid surface sheet material are connected to each other and the stainless steel bottom is secured to the solid surface sheet material wall in order to provide a secure mounting and a positive seal, together with a very attractive appearance. The present invention is an improvement over the sink construction disclosed in International Industrial Design Reg. No. DM 033,437, dated Jul. 3, 1995, and published in the International Design Bulletin (Issue No. July 1995).
2. Description of the Prior Art
Sink constructions including a rigid bowl of stainless steel, porcelain and various other materials are well known and are normally installed in a counter top constructed of solid surface sheet material in order to support the sink from the solid surface sheet material and also to seal the periphery of the bowl or bottom of the sink to the solid sheet material. FIGS. 4 and 5 in the accompanying drawings, illustrate the prior art sink construction disclosed in the aforesaid International Industrial Design Reg. No. DM 033,437, dated Jul. 3, 1995, and published in the International Design Bulletin (Issue No. July 1995). This prior art sink construction includes a stainless steel bowl secured to the bottom edge of a vertical wall constructed of polymer based solid surface sheet material, in particular a thermoplastic sheet material available from DuPont under the name CORIAN®.
The periphery of the bowl in this prior art construction is provided with an outwardly extending horizontal flange and an upstanding vertical flange at its outer edge for engaging the bottom edge and lower outer surface of the vertical wall. The vertical wall comprises two segments interconnected by butt type vertical joints adheringly sealed together to form the vertical wall. A sealant and adhesive material is disposed between the contacting surfaces of the flanges on the sink bowl and the abutting contacting vertical edge and horizontal bottom surfaces of the vertical wall components in order to seal and connect the bowl to the bottom of the vertical wall.
The prior art does not disclose, however, a sink structure having the desired strength and sealing characteristics of the present invention. More specifically, the prior art does not include a sink structure in which the components of a polymer based vertical wall are interconnected by a tongue and groove joint combined with an appropriate adhesive and sealant. The prior art also does not disclose a connection between a stainless steel, or other type metal, bottom or bowl and the lower edge of a polymer based vertical wall of the sink construction which ensures an anchored interconnection and seal.
SUMMARY OF THE INVENTION
The sink construction of the present invention includes the mounting of a sink having a bottom bowl and an upwardly curved peripheral wall in supported relation to a horizontally disposed counter top constructed from a polymer based solid surface sheet material by the use of a vertical peripheral wall preferably made from the same polymer sheet material as the counter top. The vertical wall has its upper edge connected with the horizontal counter top of sheet material and its lower edge connected to an outwardly extending flange on the upper edge of the periphery of the bottom bowl. The bottom bowl is preferably constructed of stainless steel, or other formed or molded material. The vertical wall component is preferably constructed in two components each extending approximately one half of the periphery of the bottom bowl and one half of the periphery of the opening in the horizontal counter top of sheet material. The vertical juncture between the two components of the vertical wall are mechanically connected and sealed in relation to each other by a tongue and groove connection and an appropriate adhesive and sealant material.
The periphery of the sink bowl is provided with an outwardly extending generally horizontal flange at its upper edge. The lower edge of the vertical wall is provided with a peripheral recess around its inner edge. The recess is generally rectangular in cross-section with an upper wall and an outer wall. The recess receives the flange on the bowl with an adhesive and sealant between the flange on the bowl and the upper or horizontal wall of the recess. The remainder of the recess below the flange on the bowl is filled with a sealant and adhesive. The outer wall of the recess is sloped or inclined downwardly and inwardly toward the bowl at an angle to provide a wedge-shaped configuration between the outer wall of the recess and the upper vertical side wall of the bowl. By this construction, the inward slope of the outer wall of the recess securely anchors the sealant and adhesive material which fills the recess below the flange on the bowl thereby providing an effective mechanical connection between the sealant and adhesive material, the bowl flange and the recess. In this manner, a secure mounting for the bowl from the vertical wall and an effective seal between the bowl and the vertical wall are achieved.
Accordingly, it is an object of the present invention to provide a sink construction including a multi-piece vertical wall fabricated from polymer based solid surface sheet material with vertical junctions between the vertical wall components formed by a tongue and groove mechanical connection which receives a sealant and adhesive to effectively connect the vertical wall components and effectively seal the vertical wall components along their vertical junctions.
Another object of the invention is to provide a sink construction in which the bottom edge of the vertical wall includes an inner peripheral recess which opens downwardly and inwardly for receiving, retaining and sealing therein an outwardly, horizontally extending flange on the upper peripheral edge of the sink bottom bowl.
A further object of the invention is to provide a sink construction in accordance with the preceding objects in which the recess configuration at the bottom of the vertical wall more effectively secures the bowl flange to the wall bottom edge by filling the recess below the flange with adhesive and sealant material to thereby anchor and seal the flange in the recess.
Still another object of the present invention is to provide a sink construction having a vertical wall fabricated from polymer based solid surface sheet material and a sink bottom constructed of stainless steel, or other differentiating metal or distinctive material, which is securely fastened to the bottom edge of the vertical wall and which provides a strong seal against leakage of water or other liquids in the sink.
These together with other objects and advantages which will become subsequently apparent reside in the details of construction and operation as more fully hereinafter described and claimed, reference being had to the accompanying drawings forming a part hereof, wherein like numerals refer to like parts throughout.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a sink incorporating the structure of the present invention.
FIG. 2 is a horizontal sectional view on an enlarged scale taken along section line 2--2 on FIG. 1 illustrating the tongue and groove connection between vertical wall components of the sink construction.
FIG. 3 is a vertical sectional view on an enlarged scale taken along section line 3--3 on FIG. 1 illustrating the connection between the sink bowl and the vertical wall of the sink construction and the reinforced connection between the vertical wall and the counter top.
FIG. 4 is a sectional view similar to FIG. 2 but illustrating prior art sink structure.
FIG. 5 is a sectional view similar to FIG. 3 but illustrating prior art sink structure.
DESCRIPTION OF THE PREFERRED EMBODIMENT
In describing the preferred embodiments of the present invention as illustrated in the drawings, specific terminology will be resorted to for the sake of clarity. However, the invention is not intended to be limited to the specific embodiment illustrated in the drawings and the terminology selected; it being understood that each specific term includes all technical equivalents which operate in a similar manner to accomplish a similar purpose.
Referring to FIGS. 1-3, a preferred embodiment of the sink construction of the present invention is generally designated by reference numeral 10 and includes a horizontally disposed sheet material counter top in the form of a panel 12 having a vertical wall 14 connected thereto at the periphery of an opening 16. A faucet 18 and associated control structure is provided in association with the sink in a well known manner. At the lower end of the vertical wall 14 is a sink bottom or bowl 20 having a drain structure 22 incorporated therein in a conventional and well known manner. The present invention involves the construction of the vertical wall 14, the connection between the counter top 12 and wall 14 and the connection between the lower end of the vertical wall 14 and the sink bowl or bottom 20, especially for the particular materials employed for the present invention to provide a strong and well sealed sink structure having a pleasing aesthetic appearance.
In this regard, the vertical wall 14 is preferably constructed of the same polymer based solid surface sheet material as the counter top 12; whereas, the sink bowl or bottom 20 is preferably constructed of a contrasting material such as stainless steel, copper, porcelain, or other rust resistant metals or other contrasting materials, such as molded plastic. As shown in FIG. 2, the vertical wall 14 preferably includes two vertical wall components 30 joined along two vertical joints or seams 38. However, wall 14 may include more than two components 30, and may even be formed as a single component. The seam edge surfaces are provided with a groove 40 in one edge surface and a tongue or feather 42 on the opposite edge surface so that the tongue 42 is telescopically received within the groove 40. The tongue 42 and groove 40 provide an increased static and mechanical stability and also increase the adhesion area by approximately 75% by providing an additional adhesion area along the surfaces of the tongue 42 and the groove 40. The adhesion areas between the wall components 30 are glued together with an adhesion and sealant material in the form of a two component adhesive.
The counter top panel and the vertical wall components are preferably fabricated from solid CORIAN® sheet material from DuPont, or other similar thermoplastic or other polymer sheet products. The CORIAN® material can be provided in various available designs and colors with various available surface appearance characteristics so that the sinks including the vertical wall components are inconspicuously integrated into the counter top or working surface of the same material.
As illustrated in FIG. 3, the sink bowl 20 includes a bottom wall 24 having an upwardly curved peripheral wall 26 which extends vertically as at 27 and terminates in an outwardly extending horizontally disposed flange 28. The vertical wall 14 is provided with a generally rectangular recess 32 in the bottom edge thereof with the recess extending from the inner surface 34 of the vertical wall 14 toward the outer surface 35. However, the recess 32 terminates inwardly of the outer surface 35 in an inclined downwardly extending outer wall 36 which inclines slightly downwardly and inwardly toward the curved portion 26 of the bottom bowl 20. The degree of inward taper of outer wall 36 of recess 32 is preferably about 7°, although this may vary somewhat between as low as 5° to as much as 30°, and even more, depending on the size of the recess, the materials employed, the depth to which the recess is filled and other factors. The width of the recess 32 along its upper wall from the inner surface 34 of the vertical wall 14 toward the outer surface of the wall 14 is preferably about the same dimension as the flange 28.
A suitable adhesive and sealant material 44 is oriented between the top surface of the flange 28 and the upper wall of the recess 32 to sealingly adhere the bowl 24 to the vertical wall 14. The remainder of the recess 32, below the flange 28 and between the outer recess wall 36 and the upper vertical edge 27 of the bowl wall 26 is filled with a self-leveling silicone 46. The silicone in the recess 32 interacts with the slope or incline on the outer wall 36 of the recess 32 to lock the components together in a secure and positive sealing arrangement. The polymerized silicone acts as a stamped rubber seal between the lower end of the wall components 30 and the peripheral edge of the bowl 24 to provide an absolute water tight joint between the bowl or bottom 24 and the vertical wall 14. While it is preferred that the silicone 46 fill the recess 32 to the bottom edge 33, such complete filling is not always necessary, it being intended that the silicone 46 be at sufficient depth in conjunction with the inclined wall 36 and the bowl wall 27 to structurally anchor flange 28 in the recess 32.
FIG. 4 illustrates a prior art joint between the vertical wall components 50 which are provided with a butt joint 52 in which the joining edges are straight and planar and the edges are joined by a two part adhesive and sealant 54. Thus, the structure as illustrated in FIG. 2 provides an additional mechanical and static stability by the tongue and groove connection and also includes an additional adhesive connection area around the periphery of the tongue 42 and the groove 40, respectively, as compared to the prior art structure shown in FIG. 4. Hence, the wall component interconnection of the present invention provides a more effective and permanent connection between the wall components 30 as compared to the prior art wall components 50.
FIG. 5 illustrates a prior connection between a vertical wall component 50 and an upwardly curved peripheral wall 26' having a horizontal peripheral flange 28' on the upper edge and a vertical flange 29 at the outer edge of the flange 28'. The bottom edge of the vertical wall 50 engages the upper surface of the flange 28' and the inner surface of the upstanding flange 29. An adhesive and sealant 54 is provided between the engaging surfaces of the flanges 28' and 29 and the bottom edge of the wall 50 and a portion of the outer wall surface of the wall 50 adjacent its bottom edge. The adhesive and sealant 54 retains and seals the bottom bowl 24' with respect to the vertical wall 50. The manner of securing and sealing the bottom bowl 24 to the wall components 30, as illustrated in FIG. 3, provides a more effective mechanical connection and a more effective seal between the sink bottom 20 and the vertical wall 14.
As illustrated in FIG. 2, the upper outer surface of the vertical wall 14 is provided with a plurality of lateral outwardly extending reinforcement or support members 31 which are secured to the wall 14 and underlie, engage and reinforce the counter top 12 adjacent opening 16. The counter top 12 is secured to both the top edge of the vertical wall 14 and the reinforcement members 31 which extend at least partially throughout the length of each side of vertical wall 14 but do not extend completely around the periphery of the vertical wall 14. The support members 31 thus provide increased stability when the vertical wall and sink are undermounted in relation to the polymer based sheet material of the counter top 12.
When assembling the sink of the present invention with a counter top in which the counter top 12 and vertical walls 14 are constructed of the same thermoplastic solid surface sheet material, such as CORIAN® sheet material, the wall components 30 of the vertical wall 14 are first cut with a circular saw or the like from the solid sheet material in the prescribed rectangular sizes. The abutting side edges are routed to form the tongue 42 and groove 40, and the recess 32 is routed in the bottom edge 33 such that the recess outer wall 36 is sloped or inclined, preferably about 7°. The wall components are shaped as necessary to form the prescribed corners in the wall 14. The side edges of the wall components 30 are preferably first sanded or abraded and then assembled by applying a suitable sealant 38 to the abutting edges, tongue 42 and groove 40. If desired, these areas can first be prepared with a primer. Once the vertical wall 14 has been formed by sealing together the side edges of the wall components 30, the lateral outwardly extending reinforcement or support members 31 are secured to the top edge of the wall 14. Preferably, the support members 31 span the adhered side edges of wall components 30 to provide reinforcement for the vertical joints or seams at the upper edge of the wall assembly.
The wall assembly 14 is then inverted with the bottom edge 33 uppermost for assembly of the bottom or bowl 24 of stainless steel or the like. The top surface area of the flange 28 is preferably sanded or roughened, such as by use of a grinding lathe, to abrade the surface in order to provide a better adhesion with the adhesive and sealant material 44. The areas to be glued including the flange 28 on the stainless bottom and the recess 32 in the side wall components 30 are preferably first prepared with a primer. After drying of the primer, the flange 28 on the stainless steel bottom 20 and the recess 32 in the vertical wall components 30 are glued together with a suitable adhesive and sealant material. When polymerization or drying of the adhesive and sealant between the top surface of flange 28 and the upper wall of recess 32 is finished, the remainder of the recess is then filled with a self-leveling silicone 46. After polymerization/drying of the silicone, the connection of the flange 28 in the recess 32 serves as a reinforcement for the vertical joints or seams between the wall components 30 at the lower edge of the wall assembly. Further, the overall sink assembly is now ready to be undermounted in the opening in the counter top 12.
The areas to be glued or secured by adhesive in accordance with the present invention are preferably first prepared by the application of a primer for the adhesive with the primer being a solvent containing primer with a silicone resin base. The surfaces to be bonded must be dry, free of dust, grease and other contaminants. A cleaner may be used prior to application of the bonding materials, and an optimum bonding surface is achieved by means of roughening or sand blasting the surfaces. After the surfaces to be glued have been primed and after the primer has dried, the surfaces to be glued, including the vertical wall components and the stainless steel bottom, are glued together with a self-leveling silicone sealant/adhesive on the base of a solvent free acetic acid cross-linking silicone rubber which cures at room temperature, and under the influence of humidity becomes a permanently flexible material. The curing starts first on the surface of the silicone and creates a dry skin after a few minutes. The deep curing of the silicone rubber is effected at a speed of approximately 2 mm/24 hrs. In accordance with the present invention, when utilizing CORIAN® sheet material for the counter top 12 and the vertical wall 14, with a stainless steel bottom or bowl 24, a suitable solvent-containing primer with a silicone resin base is DELO-PRE® 3003 marketed by DELO Industrieklebstoffe GmbH & Co. KG of Landsberg, Germany. A suitable adhesive/sealant is DELO-GUM® 2301, also marketed by DELO Industrieklebstoffe GmbH & Co. KG.
When polymerization/drying of the adhesive between the top surface of the flange 28 and the upper horizontal surface of the recess 32 is finished, the unfilled portion of the recess having the inclined slope on the outer wall 36 is filled with self-leveling silicone similar to the silicone adhesive previously discussed but which is distinguished by a very high temperature resistance. The self-leveling silicone sealant/adhesive cures at room temperature and under influence of humidity becomes a permanently flexible material and the curing of the high temperature resistant silicone rubber is under the same conditions as the adhesive material. When polymerization is completed, the specific silicone in the groove or recess acts as a stamped rubber seal ensuring absolute water tightness. A particularly suitable silicone for filling the recess in accordance with the present invention is also marketed by DELO Industrieklebstoffe GmbH & Co. KG under the name DELO-GUM® 2301-WS.
The foregoing is considered as illustrative only of the principles of the invention. Further, since numerous modifications and changes will readily occur to those skilled in the art, it is not desired to limit the invention to the exact construction and operation shown and described, and, accordingly, all suitable modifications and equivalents may be resorted to, falling within the scope of the invention. | A sink construction for use in a kitchen, bathroom or any other facility in which an attractive sink would be normally installed. The sink construction includes a sink bowl bottom combined with a vertical wall, with the vertical wall and counter top preferably constructed of the same material. The vertical wall includes at least one seam with connection including a tongue and a groove. The vertical wall is connected to the counter top assisted by laterally extending support members beneath the counter top. The sink bowl is secured within a downwardly and inwardly opening recess on the lower inner edge of the vertical wall by a filler material that engages a lateral flange at the top of the sink bowl. | 4 |
BACKGROUND OF THE INVENTION
This invention relates to control of the inflation of tandem, inflatable formation packers disposed on a string of casing in a well bore which traverses earth formations, and more particularly, to a system for sequentially actuating tandem arranged inflatable formation packers so that the packers are inflated in a sequence from the bottom packer upwardly in a well bore.
In completion of oil wells, one completion system involves the use of a number of inflatable formation packers disposed lengthwise along a string of casing disposed in a well bore. In operation, the supporting casing is filled with fluid as is the annulus between the packers and casing and the well bore. When it is desired to inflate the formation packers, pressure is supplied through the fluid in a casing which acts upon an enclosed internal space of the formation packers and expands them radially outward into contact with the wall of the well bore. Obviously, when the inflatable packers expand, the fluid that originally occupies the annular volume between the packers and well bore is displaced. The displacement of the fluid in the annular volume may (1) move upwardly to displace fluid upwardly in the casing well bore annulus, (2) move downwardly and enter permeable intervals between the packers, (3) enter permeable intervals adjacent to or between the packers, (4) initiate and flow into fractures adjacent to, between or below the packers, and/or, (5) become trapped in borehole irregularities preventing complete inflation of the packers. Only movement of the fluid upwardly in the annulus is desirable as the interaction of trapped fluids with the borehole adversely affects the formations and operation of the packers.
Heretofore, there has been no effective control of the packer inflation where multiple packers are utilized. For example, inflation of the top packer first can form a flow restriction that completely prevents upward movement of the displaced fluid. Random inflation of the packers traps annular fluid along the packers if they inflate at different rates.
Thus, the purpose of the present invention is to inflate the packers in a predetermined manner so that upward movement of the fluid in the annulus between the borehole and the packer or casing occurs first at the lowermost inflatable packer and by sequentially inflating the packers in an upward direction thereby facilitating a complete unhampered inflation of the packers and upward flow of fluid and thereby minimizing the risk of well damage by virtue of trapped fluid.
Heretofore, it has been proposed to obtain sequential inflation of packers by sequential operation of pressure differentially actuated valves disposed in tandem packers where the pressure operated valves are set to open sequentially in response to pressure beginning with the lowermost packer first. This pressure responsive system has application under certain downhole conditions. In many instances, however, downhole pressure, under normal operating conditions, cannot be directly monitored at the surface and data from the surface pressure measuring devices must be combined with the expected hydrostatic pressures to estimate the pressure that is acting on a given valve at a given depth within the well bore. Thus, there is considerable room for inaccuracy in this system and errors resulting from inaccurate surface readings and/or unexpected hydrostatic forces often exceed the margin of error. That is, the error in the actual pressure exceeds the difference between the pressure settings of pressure operated valves in different packers resulting in the simultaneous opening of two or more pressure valves in two or more packers and the resulting failure of the packer system to sequentially operate. Also, in some cases the number of packers that may be run in tandem in a well bore is limited because the pressure differential required to open the valve in uppermost packer cannot be effectively attained in the casing.
THE PRESENT INVENTION
In the present invention, the fluid access valves in the packers which admit fluid to inflate the packers can be opened simultaneously. Sequential inflation of packers is attained by controlling the flow rate of inflation fluid to each packer so that the inflation flow rate to a lower packer is substantially greater than the flow rate to the next above packer so that the packers inflate sequentially from the bottom packer upwardly. Thus, by controlling the flow rate, the time of inflation of each packer is controlled so that the packers can be inflated sequentially.
The embodiment of the present invention involves a series of tandem connected inflatable packers up to 40 feet in length and coupled in a casing string. Each of the packers has a valving system to selectively control access of fluid within the casing to the interior of the inflatable packer element of a packer. The valving system may be of any conventional type in which a valve opens in response to pressure within the casing. The valves of the packers can be opened contemporaneously or with selectivity beginning with the bottommost packer.
The control of inflation is obtained by controlling the rate of inflation of each packer from the bottom up so that the lowermost packer element inflates first and the next above packer inflates next and so forth in an upward sequence of inflation. The rate of inflation is controlled by controlling the flow of fluid to each packer. This may be accomplished by any flow rate device such as flow orifices or flow rate valve.
A flow rate valve embodiment illustrates a pressure operated adjustable valve where the flow rate is controlled as a function of pressure.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 illustrates a series of tandem inflatable packers in a well bore;
FIG. 2 illustrates a typical inflatable packer construction;
FIG. 3 illustrates a typical valve inflation system for an inflatable packer;
FIG. 4 illustrates schematically tandem packers with flow rate controllers; and
FIG. 5 illustrates a valve construction which is pressure operated.
DESCRIPTION OF THE INVENTION
Referring now to FIG. 1, a borehole 10 traversing earth formations 11 is illustrated. The borehole 10 is initially filled with drilling mud and in a completion operation, a number of inflatable packers 12, 13 and 14 are coupled in a drill string or casing or pipe 15 so that the packers can be located adjacent to formations which are to be completed when disposed in the borehole 10. The inflatable packers 12, 13 and 14 are made in appropriate lengths which can range up to forty feet in length.
Each of the inflatable packers typically includes from top to bottom (See FIG. 2) an upper connecting sub 18, an upper collar 19, a central tubular mandrel 20, a lower valve collar 21 and a lower connecting sub 22. The subs 18 and 22 are connectable by collars to a section of casing pipe. The bore 23 through a packer is uniform and matches the bore of a casing or pipe 15. A tubular, elastomer constructed, inflatable packer element 24 surrounds the mandrel 20 and is sealingly connected to the upper collar 19 and lower valve collar 21. The valve collar 21, as will be explained later, contains valve members 25 which selectively admit fluid from the bore 23 to the interior of the inflatable element 24 for inflation of the element 24 into contact with the wall of a well bore and to limit and contain fluid admitted to the interior of the inflatable element 24.
Referring again to FIG. 1, the assembly of casing pipe 15 and inflatable packers 12, 13, 14 are positioned in a borehole 10 and cement in fluid form is displaced through the casing or pipe 15 and into the annulus 28 between the borehole 10 and the entire assembly on the casing 15. After the cement is displaced in the annulus to a point above the uppermost packer 14, the valves 25a-25c in the respective valve collars of the packers 12, 13 and 14 are actuated and the packers 12, 13 and 14 are inflated in sequence beginning with the lowermost packer 12. As the packer 12 is inflated the fluid in the annulus 28 is moved upwardly as packers 13 and 14 are not yet inflated. After packer 12 is inflated, the packer 13 is fully inflated moving the fluid in the annulus upwardly. After fully inflating packer 13, the packer 14 is fully inflated and moves the fluid in the annulus upwardly. As can be appreciated, the flow of fluid in the annulus 28 is always in an upward direction and is not adversly applied to the formations adjacent to or below a packer. After the packers are fully inflated and the cement set up, a perforating gun (not shown) can be lowered through the casing to complete the earth formations by placing them in fluid communication with the casing.
The valve collar 21 and packer element 24 are illustrated schematically and disproportionally in FIG. 3 where in the wall of the collar 21 contains a shear valve 30, a check valve 31 and a limit valve 32.
The shear valve 30 is comprised of a cylindrically shaped valve element 33 which is slidably disposed in a bore 34. The valve element 33 has a sealing element 35 at one end which is adapted in a closed position of the valve to sealingly engage a valve seat 36 and close off an access bore 37. The access bore 37 extends between the mandrel bore 23 and the valve bore 34. In the access bore 37 is a filter 38. The access bore 37 is initially closed by a hollow, knock-off plug 42 which projects into the mandrel bore 23. The valve element 33 has a smaller diameter pin element 39 at one end which extends through an opening in a closure cap 40. A spring member 41 is mounted on the pin element 39 and is disposed in the bore 34 between the cap 40 and the valve element 33 to normally bias the valve element 33 to a closed position with the sealing element 35 engaging the valve seat 36. The valve element 34 may also carry O-ring seals for straddling a fluid communication passage 48 in a closed position of the valve 30. Initially, the shear valve 30 is in a closed condition and a shear pin 43 with a predetermined shear value cooperates with the cap 40 to releasably lock the valve element 33 in a closed position. The spring member 41 is thus initially in an extended position.
When the knock-off plug 42 is broken (by dropping a member through the mandrel bore 23) fluid under pressure in the mandrel bore 23 is increased to a point where the shear pin 43 shears and the valve element 33 is moved to an open position and the spring member 41 is compressed. This is the position shown in FIG. 3. When the pressure in the mandrel bore 23 is less than the spring force, the valve 30 will close.
The check valve 31 is comprised of a valve bore 45 which receives a slidable valve element 47 having a sealing element 46 on one end which is adapted in a closed position of the valve to sealingly engage a valve seat 49 and close off the fluid communication passageway 48. The passageway 48 extends between the valve bore 45 and the valve bore 34 so that when the shear valve 30 is open, fluid is applied to the end of the valve element 47. The valve element 47 has a smaller diameter pin element within the valve bore which is slidably received in a hollow bore of a cap member 44 and a spring element 50 is disposed between the valve element 47 and cap member 44 to normally bias the valve element 47 to a closed position on the valve seat 49. The check valve 31 is shown in an open position where the pressure in the passageway 48 exceeds the spring force of the spring element 50.
The limit valve 32 is comprised of a valve bore 53 which receives a slidable valve element 54 which has spaced apart sealing members 55, 56. The sealing members 55, 56 are interconnected by a cylindrical pin 57 so that an annular flow passage is formed between the sealing members 55, 56. A pin member 58 extends rearwardly of the sealing member into a bore in a closure cap member 59. A sealing element 61 on the end of the sealing member 55 is adapted to engage a valve seat 62 and close a first bore or passageway 63 which extends through the collar body to the interior space 65 between the mandrel 20 and packer element 24. A second bore or passageway 64 extends through the collar body to the interior space between the mandrel 20 and packer element 24 and to the annular flow passage between sealing members 55, 56 on the valve element. In the position shown, fluid can pass via the passageways 48, 66 and 64 to inflate the packer element 24 and when the pressure in the packer element reaches a predetermined value, the valve element 54 is shifted to the right so that O-rings on the valve element 54 straddle the passageway 66 and entrap the pressure in the packer element.
With the foregoing description in mind, one structural embodiment for a controlling flow rates is schematically illustrated in FIG. 4 wherein a lower section of two inflatable packer means 70, 71 are supported by a tubular casing 72 and valve collars 73, 74. The valve collars 73, 74 respectively attached to inflatable elements 75, 76. The inflation spaces between the respective inflatable elements 75, 76 and the casing 72 are connected by valve and passageway systems 77, 78 to the access plugs 79, 80 disposed in the inner bore of the casing 72. The valve and passageway systems 77, 78 may be as illustrated herein or may be combination of valves or other types of inflation control means as is well known in the art so long as there is a pressure valve responsive in each of the valve and passageway systems with appropriate predetermined pressure operational valves for release so that each of the valve systems is timed to open at nearly the same time or from the bottom packer upwardly. It is contemplated that the valves in the upper packer means can have different values of pressure operation but the operation of the valves are not a critical factor as the flow rate of inflation is the material factor.
The flow rate of inflation in the packer 71 is controlled by a flow choke C1 in the passageway system 78 and the flow rate of inflation in the packer 70 is controlled by a flow choke C2 in the passageway system 77 so that the flow rate of the fluid to inflate the lowermost packer element 76 is greater than the flow rate of the fluid to inflate the next above packer element 75.
The choke C1 and C2 may be simple orifices for sizing the diameter of flow passages in the passageway system. Alternatively, the travel of a valve, such as valve 33, can be limited so that the end of a valve cooperates with a passageway opening to limit or control the flow rate. Still other ways of controlling flow rate can be used such as using different diameters for the openings at the knock-off plugs 79, 80.
Referring to FIG. 5, a variable choke system is schematically illustrated. In this system an inlet flow passage 90 in a valve collar extends from the interior of the casing to the variable choke system and an outlet flow passage 91 extends from the variable choke system to the interior space of the inflatable packer element. Between the inlet flow passage 90 and outlet flow passage 91 is a transverse cylindrical bore 92 which carries a spool type piston 93 with end piston members 94, 95 which connect to a conically shaped valve element 96.
The effective pressure areas of the pistons 94 and 95 are equal and a spring 98 is employed to urge the spool piston 93 towards one end of the passage 92 and fully open the communication of the inlet passage 90 to the outlet passage 91. In the inlet passage 91 is a flow orifice 100 which provides a constant pressure loss for fluid flow so that the pressure P1 above the orifice 100 is greater than the pressure P2 below the orifice 100. A first flow passage 101 connects the inlet passage 90 at a location above the orifice 100 to supply the pressure P1 to the effective seal area of piston 94. A second flow passage 102 connects the inlet passage 90 at a location below the orifice 100 to supply the pressure P2 to the effective seal area of piston 95.
The characteristics of the valve are:
P.sub.2 =P.sub.1 -V.sup.n (PL) (1)
Where
P 1 is the inlet pressure above the orifice
P 2 is the inlet pressure below the orifice
n is usually a value of two (2)
V is the inlet fluid velocity and (PL) is the pressure loss constant of the orifice.
The position of the flow rate valve is determined by the relationship
(P.sub.1 -P.sub.2)A=(SK)L (2)
Where
A=is the piston cross section
(SK) is the spring constant and L is the travel length of the piston.
With the foregoing values, the orifice 100 can be different in each packer and the inflation rate is automatically controlled in each packer means. Likewise, the shape of spool piston 93 can be different in each packer and the inflation rate differently controlled. Also, the spring constant can be different in each packer and the inflation rate differently controlled.
It will be apparent to those skilled in the art that various changes may be made in the invention without departing from the spirit and scope thereof and therefore the invention is not limited by that which is enclosed in the drawings and specifications, but only as indicated in the appended claims. | In a completion of an oil well where the well bore traverses the earth formations, a multiple series of inflatable packer elements are employed with each packer element having a defined sequential dependency of inflation to inflate the lowermost packe first then to inflate the packers in a sequence from the lowermost packer upwardly. | 4 |
The application is a continuation of Ser. No. 877,973, filed June 24, 1986, now U.S. Pat. No. 4,703,803.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention pertains to the stimulation of wells to improve the permeability of such wells to the flow of fluids. The invention is especially useful in improving the flow of hydrocarbons from wells which have suffered from formation damage due to clay deposits.
2. Description of the Prior Art
It is well known that oil production in siliceous sub-terranean formations, over the useful life of a well, usually decreases with time. To reestablish a higher flow of oil, one of the first methods usually employed is pumping. Frequently, however, after a period of time, even pumping will not make the well economical. Unfortunately in many wells such flow reduction occurs long before the oil, or other fluid in the reservoir reached by the wellbore, has become depleted. Low permeability frequently results from the deposition of clay and other finely divided material in the pore structure or flow passages of the formation. Clay particles, capable of forming such undesirable deposits, generally exist throughout the formation and are carried by the oil and deposited in the flow passages leading to the wellbore. Formation damage can also be caused by the swelling of the clay upon contact with foreign liquids injected for well development or stimulation purposes. Formation damage of the above types is often referred to as clay deposits, clay dispersions, particle plugging, clay swelling, etc., which hereinafter will simply be referred to collectively as "pore deposits."
It is known that pore deposits can be solubilized more or less by treatment with mineral acid solutions, for example, hydrochloric acid and hydrofluoric acid. Aqueous solutions containing about 2 to 6 weight percent hydrofluoric acid and 5 to 15 weight percent hydrochloric acid, sometimes referred to as "mud acids" have been used to treat damaged formations in hopes of restoring to the formation its initial permeability. Mud acids have also been used to treat formations which are naturally tight.
Unfortunately, hydrochloric acid is usually not effective in solubilizing the more tenuous pore deposits such as those deposits that are mainly siliceous in composition. By the term "siliceous" as used herein is meant silica and/or silicate. By the term "siliceous material" as used herein is meant silica-containing and/or silicate-containing materials. Examples of siliceous materials are sandstone and certain clays. Non-limiting example of clays which are silicates, usually aluminosilicates are attapulgite, bentonite, chlorite, halloysite, illite, kaolinite, montmorillonite, and various mixtures of the aforementioned substances. It is known that hydrofluoric acid will solubilize siliceous material readily; however, because of its high reactivity hydrofluoric acid, unmixed with other mineral acids such as hydrochloric acid, generally is not used to increase oil production. Other serious problems also exist with the use of hydrofluoric acid. For example, since the rate of reaction of hydrofluoric acid with siliceous materials is very rapid, most of the acid is spent within a zone of about one or two feet or less radially from the wellbore. In formations having high formation temperatures the acid becomes spent at even shorter distances from the wellbore thereby causing the acidizing operation to be even less effective.
Since the mineral content of the matrix of many formations is usually sandstone or silica or a similar siliceous material, hydrofluoric acid can dissolve the matrix itself as well as the undesirable pore deposits in the matrix. As a consequence hydrofluoric acid can cause permanent damage to the formation by the dissolving of the pore structure or matrix itself, or by allowing the precipitation of reaction products and/or creation of fines within the pores of the formation. To prevent permanent damage from occurring the concentration of hydrofluoric acid is usually adjusted so that no more than minor damage to the formation can occur. As a consequence, clay deposits distant from the wellbore do not come in contact with hydrofluoric acid-containing acidizing compositions generally used for dissolving siliceous matter and thus such distant deposits are not dissolved. It is well recognized in the oil producing industry that it is difficult to dissolve only the pore deposits and especially those deposits more than two feet from the wellbore. Nonetheless even utilizing hydrofluoric acid concentrations as low as 0.1%, permanent damage to some formations can occur.
As mentioned earlier another problem associated with acidizing with formation containing hydrofluoric acid is that since the cleaned-out area is usually within a two-foot radius or less of the wellbore, loss of permeability can reoccur within a very short period of time after the treated well is put back on production since the deeper pore deposits are not removed. Thus, it is generally accepted that if deep pore deposits are to be solubilized by hydrofluoric acid, a large quantity and flow rate of acid must be used and since the acid can react with all siliceous material, there is a very high risk that permanent damage will result to the formation.
For these reasons, there have been various attempts to slow up the rate of reaction of hydrofluoric acid so that it can penetrate deeper into the formation and solubilize deeper pore deposits without causing serious damage to the formation adjacent to the wellbore. Unfortunately, many of these attempts, as will be described and further discussed below, still fall short of effectively increasing the permeability of the formation in those zones much farther than the usual two feet from the wellbore.
U.S. Pat. No. 1,990,969 discloses a well stimulation process which produces hydrofluoric acid directly in the subterranean formation. In particular, a quantity of hydrochloric acid is first pumped into the well which is then followed by a quantity of sodium fluoride. The hydrochloric acid and the sodium fluoride react in the formation to produce hydrofluoric acid and sodium chloride. The hydrofluoric acid reacts with the silica material in the pores to dissolve it thereby increasing the permeability of the formation to the flow of oil. The patentee alleges that in his process the hydrofluoric acid is not required to be handled at the surface or continuously in the tubing of the wellbore, but rather produced from precursor reagents within the subterranean formation itself. The "alternate and separate slug" or "two slug" method as disclosed in U.S. Pat. No. 1,990,969 also has disadvantages. First damage to the wellbore can occur because at the interface of the alternate slugs, hydrofluoric acid can be generated and can attack the well tubing itself, thereby decreasing the useful life of such tubing. Secondly, mixing of the reactants within the porous formation is not always uniform and hence not always complete, thereby causing some regions to have high hydrochloric acid concentrations and other regions to have high sodium fluoride concentration. Such regions will not be exposed to effective hydrofluoric acid concentrations and consequently will be largely unaffected by the treatment. Thirdly, the permeability tends to be increased only in a region very close to the wellbore due to the high reactivity of the treating solution. Consequently, deep pore deposits will not be solubilized to the extent desired. Thus, any improvement in oil production will be most likely for only a relatively small period of time.
Others have attempted to improve the distribution of the reactants into the formation over a greater distance by slowing the rate of reaction between hydrofluoric acid and the formation. U.S. Pat. No. 3,889,753 discloses a well stimulation method for dissolving silica or clay around the wellbore. The method involves contacting the siliceous material with an aqueous solution of a fluoride salt, a weak acid, and a weak acid salt in proportions that form in situ a significant but low concentration of hydrogen fluoride. However, while such acidizing mixtures may provide some improvement they still are too reactive to reach and solubilize deep pore deposits.
Ostensibly in order to overcome this difficulty some have returned to the alternate but separate slugs approach discussed earlier. U.S. Pat. No. 4,056,146 discloses a well stimulation method in which alternate slugs of hydrochloric acid and ammonium bifluoride or ammonium fluoride, or mixtures thereof, are alternately and separately introduced into the wellbore. The reagents react and produce hydrofluoric acid. Unfortunately these reagents still react too fast and the hydrofluoric acid produced is spent before it can penetrate deeply into the formation.
In order to obtain deeper penetration of the reagents into the formation, U.S. Pat. No. 4,136,739 varied the injection sequence by injecting, between the two alternate and separate reagent slugs, a hydrocarbon liquid such as diesel oil. In particular, an aqueous solution of an ammonium salt of hydrofluoric acid such as ammonium fluoride is injected in a first slug into the formation. This is then followed by a separate slug of diesel oil, which in turn is followed by a third and separate slug of hydrochloric acid. The patentee contends that in this way hydrofluoric acid is generated at a deeper distance from the wellbore than with the usual two slug method. The problem with this method is that mixing of the reagents in situ, because of the interdisposed diesel oil, becomes even more difficult and less effective. Furthermore, the reactants, when they are mixed, react quickly and produce a relative high concentration of hydrofluoric acid which is too reactive to penetrate deeply into the formation.
In many of the alternate and separate slug methods, the steps are repeated a number of times in order to better distribute the reagents on a more uniform basis into the formation. This switching back and forth can lead to operator error which in turn can result in regions in the formation having a higher concentration of one reagent and little, if any, of the other reagent, thereby providing no solubilization of the pore deposits in such regions. Unfortunately, the difficulty with the alternate and separate slug methods is that it is difficult to provide an equal distribution of each reagent to all parts of the formation zone unless the amount of each slug is very small. As can be appreciated, the smaller the slug amount the greater the number of slug cycles required to introduce the required quantity of reagents into the formation. As slug amount is decreased and the number of cycles increased, the more apt the reagents are to react and form hydrofluoric acid before penetrating deeply into the formation thereby increasing the possibility of both formation damage and well casing damage, and producing little, if any, solubilization of the deeper pore deposits.
The difficulty of mixing reagents in situ was avoided in U.S. Pat. No. 4,418,118 by mixing the acidizing composition at the surface prior to injecting into the formation. The reaction rate of hydrofluoric acid on silica and silicates is said to be retarded. The method relies on the reaction of a mineral acid other than hydrofluoric acid with certain fluoride compounds to produce hydrofluoric acid. The fluoride compounds disclosed have the formula:
(T.sup.+3).sub.n (M.sup.+1).sub.z (F.sup.a).sub.y
and include their hydrates. The cation T is zirconium, cobalt or chromium. M is either hydrogen or ammonium, and z is 0 to 4. The constants satisfy the formula:
3n+z=ay.
The only fluoride compounds disclosed are chromium fluoride, cobalt fluoride, ammonium zirconium hexafluoride or (NH 4 ) 2 ZrF 6 , and hydrogen zirconium hexafluoride or H 2 Zr 4 F 6 . In order to produce hydrofluoric acid it is taught that sufficient mineral acid, other than hydrofluoric acid, is required to produce an acidic composition with a pH no greater than 2. It is further taught that the actual pH is ordinarily much less than 2 and is often expressed in negative values. It is stressed that the only real limitation on the operability with respect to acidity caused by the mineral acid is the upper pH limit of 2 and that this can be achieved with an acid (ostensibly a mineral acid other than hydrofluoric acid) concentration of about 0.1 percent acid by weight of acidic composition. This method has the disadvantage of requiring a reaction between a mineral acid and a fluoride compound to produce hydrofluoric acid while requiring a strongly acidic solution since the upper limit of the pH is 2 and ostensibly in actual practice a pH much less than 2 or even negative values must be utilized if the treatment is to have any real effect on increasing the permeability of the formation.
Another known method depends upon the hydrolysis of fluoboric acid (HBF 4 ) to produce hydrofluoric acid in situ in the formation. While some improvement in dissolving deeper pore deposits may occur in some subterranean formations the reaction rate is still too high for the more sensitive formations; see Journal of Petroleum Technology, August 1981, pages 1491 to 1500.
In all of these prior art methods, the reactants are still ostensibly too reactive to penetrate deeply into the formation and solubilize the deeper pore deposits. Accordingly, there remains a need for a process which retards the rate of reaction of hydrofluoric acid in the formation but at the same time provides sufficient hydrofluoric acid to the various parts of the formation without a dependence on mixing of the reagents within the formation as the hydrofluoric acid is consumed. What is therefore needed is to have a very small amount of the reactant, hydrofluoric acid, present at all times without the need to rely on its formation in situ by the mixing of alternate and separate slugs of precursors, or even by the mixing within a single slug of reagents the interreaction of which might be altered by mineral matter and/or brine in the formation. In general, it is believed that the prior art acidizing solutions utilizing hydrofluoric acid have too high a reactivity and hydrofluoric acid concentration to effect solubilization of the deeper pore deposits. The present invention offers a solution to these problems by the very slow in situ formation of very small amounts of hydrofluoric acid, by hydroysis of a fluoride compound without the necessity to react the fluoride compound with a mineral acid or any other reagent thereby minimizing the uncontrollable effect of varying mineral matter and brine encountered in the subterranean formation being acidized. The present invention therefore allows deeper penetration of the treating fluid into the formation to solubilize deeper pore deposits without causing significant damage to the matrix structure of the formation.
SUMMARY OF THE INVENTION
Injection of one or a series of acidic solutions down a well and into a subterranean formation with the objective of improving the permeability of the formation and hence the flow rate of fluid, for example petroleum, natural gas, water, or other fluids into or out of the well is commonly termed matrix acid stimulation. Frequently concentrated solutions, e.g., 5 to 30% hydrochloric acid, or mixtures such as 12% hydrochloric acid 3% hydrofluoric acid termed mud acid are used to stimulate the formation. Unfortunately the use of these concentrated acid solutions can cause reduction in the permeability of certain subterranean formations for a variety of reasons, including very rapid reaction with the formation leading to reaction product precipitation and release of fine particles. For such sensitive formations, which include high clay containing rock, a more gentle acidizing agent is required.
This invention comprises the slow hydrolysis of hexafluorotitanate anion or TiF 6 - , to produce low concentrations of hydrofluoric acid (HF) which is then used to slowly dissolve siliceous matter which restricts the flow of fluids in the formation. This invention also comprises the slow hydrolysis of hexafluorotitanate anion-containing compound without the necessity of reacting the hexafluorotitanate with an acid, including an acid other than HF, to produce HF. The equilibrium constant for the hydrolysis of hexafluorotitanate anion to HF is about 1.4×10 -6 , see Kinetics of the Hydrolysis of the Hexafluorotitanate Ion in Aqueous Solution of 0° and 25° C., Russian J. Phy. Chem., Vol. 46, pages 1334-1336, which is hereby incorporated herein by reference. Therefore the concentration of HF in solution at equilibrium is very small. The kinetics of the hydrolysis of hexafluorotitanate anion are also slow about 1 to 2 hours at 25° C. This invention comprises the reaction of an aqueous solution containing hexafluorotitanate anions with siliceous materials to slowly dissolve such materials. When subterranean formations containing siliceous materials are contacted with the acidizing solutions of this invention the very slowly produced hydrofluoric acid, because of its very low concentration, will react slowly with the formation, and preferentially with the more reactive siliceous clay deposits in or adjacent the pores of the formation. The acidizing solution therefore will travel deeply into the formation thereby improving the permeability of the formation for considerably longer distances from the wellbore than could be achieved by more concentrated hydrofluoric acid solutions.
Accordingly, in accordance with the practice of the present invention, there is provided a composition and method for slowly dissolving siliceous material comprising forming an aqueous acidizing composition comprising (i.) water and (ii.) a first substance selected from the group consisting of hexafluorotitanate-containing compounds, hydrates of such compounds, and mixtures thereof which are operable for producing without the presence of an acid in said aqueous composition other than hydrofluoric acid, hydrofluoric acid by reaction or hydrolysis of hexafluorotitanate anions produced from the first substance with water, wherein the concentration of the first substance in the aqueous composition is from about 0.0001 molar to about the solubility limit of the first substance in water. The method further comprises contacting siliceous material with the aqueous composition to slowly dissolve the siliceous material. The method is particularly useful where the siliceous material is contained in a subterranean formation, and especially where the siliceous material is siliceous mineral matter adjacent to the walls of, or in, the pores of the subterranean formation. In one embodiment the first substance is selected from the group consisting of ammonium fluotitanate or (NH 4 ) 2 TiF 6 , sodium fluotitanate or Na 2 TiF 6 , hydrates of ammonium fluotitanate, hydrates of sodium fluotitanate, and mixtures thereof. The first substance hydrolyzes in the aqueous acidizing composition to produce the hexafluorotitanate anion which then hydrolyzes by the following reaction:
TiF.sub.6.sup.- +H.sub.2 O=2HF+TiOF.sub.4.sup.-
In one embodiment the concentration of the first substance used to form the aqueous acidizing composition is from about 0.01 to about 1.3 molar and has a pH greater than 2. In another embodiment the concentration of the first substance used to form the aqueous acidizing composition is from about 0.05 to about 0.75 molar and has a pH of at least about 2.2. In still another embodiment the concentration of the first substance is from about 0.1 molar to about 0.5 molar. In still another embodiment the pH of the aqueous solution is about 2.6 or higher. In yet another embodiment the pH of the aqueous solution is from about 2.2 to about 3.8. In one embodiment the pH of the aqueous solution is from about 2.6 to about 3.7. In another embodiment the pH of the aqueous solution is from about 2.6 to about 3.5.
In a subterranean formation which contains siliceous materials, usually both the pore deposits and the matrix of the formation contain siliceous substances. Fortunately the siliceous material which comprises the pore deposits is usually more easily solubilized than the siliceous material which comprises the matrix. One embodiment of this invention comprises injecting the above-described aqueous acidizing compositions of this invention into a wellbore, the mixture being operative for slowly dissolving the more readily dissolvable siliceous material as found adjacent to or in the pores of the subterranean formation. In a preferred embodiment of this invention the mixture is substantially free of mineral acid other than hydrofluoric acid since a mineral acid is not required by this invention to produce hydrofluoric acid from the hexafluorotitanate-containing compounds by hydrolysis. However, it is not necessary for the acidizing composition to be free of a mineral or organic acid since the hexafluorotitanate-containing compound of this invention is operable for producing HF by hydrolysis whether or not an acid is present and reaction of the hexafluorotitanate with an acid (e.g. an acid other than HF) is not required to produce HF by hydrolysis of the hexafluorotitanate of this invention. The method further comprises allowing the mixture to flow deeply into the subterranean formation away from the wellbore and allowing the mixture to react with the siliceous material which is responsible for the low permeability of the formation and to slowly dissolve such siliceous material, thereby increasing the permeability of the formation over a greater distance from the wellbore than the permeability of the more distant parts of the formation would be increased by acidizing with compositions having higher hydrofluoric acid concentration. It is to be understood that the increased permeability is achieved by the slow in situ hydrolysis of the hexafluorotitanate-containing compound and by slowly producing a very low concentration of hydrofluoric acid from the hexafluorotitanate-containing compound.
The method is especially useful for subterranean zones which are hydrocarbon producing zones such as oil and natural gas producing zones.
In one embodiment of this invention the formation is treated with an effective amount of a sequestering or chelating agent to prevent the production of precipitates in the formation. Such treatments with a sequestering agent can be as a separate step before and/or after the step of acidizing the formation with the hexafluorotitanate-containing compounds of this invention. Alternately the sequestering agent can be combined in the same step with the hexafluorotitanate-containing compounds of this invention. Citrate sequestering agents are effective for preventing precipitation of reaction products, especially insoluble aluminum salts and iron-containing compounds. The ammonium salt of citric acid is preferred over the sodium salt since the former lessens the chance of insoluble sodium compounds from being formed. It should be understood, however, that the purpose of the sequestering agent is to prevent the production of detrimental precipitates in the formation and not for reacting with the hexafluorotitanate-containing compounds of this invention for purposes of forming HF by said reaction.
In one embodiment the concentration of citrate ion is from about 0.01 to about 1 molar. In another embodiment the concentrate of the citrate ion is from about 0.05 to about 0.5 molar and preferably from about 0.1 to about 0.2 molar. In compositions containing citric acid, the pH of the acidizing composition may be as low as about 2.2 whereas if a citrate is used the pH of the acidizing composition may be as low as about 2.6. Although citric acid is usually cheaper than a citrate, and sodium citrate is usually cheaper than ammonium citrate, ammonium citrate is preferred in very sensitive formations because it reduces the formation of sodium-containing precipitates and does not lower the pH of the acidizing composition as much as citric acid.
The method is particularly useful where the siliceous material in the subterranean zone comprises clay. Non-limiting examples of clay minerals for which this method can be advantageously applied is attapulgite, bentonite, chlorite, halloysite, illite, kaolinite, montmorillonite, a mixed-layer of the aforementioned clays, and various mixtures thereof. Furthermore, because of the very small concentration of hydrofluoric acid provided by this invention, the method can be employed in formations having elevated temperatures without incurring commercially significant damage to the formation. For example the acidizing composition and method of this invention can be used in siliceous material having an elevated temperature between 65° C. and 125° C. or higher without causing significant damage to the strength of the siliceous material. This means that subterranean hydrocarbon-producing formations having elevated temperatures can be acidized using the composition and method of this invention without serious reduction in the compressive strength of the treated formation. This invention therefore improves the permeability of a formation over greater distances from the wellbore than acidizing systems employing acidizing formulations having a pH of 2 or lower which can cause serious damage in some formations.
This invention is particularly useful in formations which are too sensitive for acidizing with other acidizing compositions.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a graphical representation of the rate of dissolution of bentonite in various acidizing compositions compared to the sodium fluotitanate acidizing composition of this invention.
FIG. 2 is a graphical comparison of the rate of dissolution of clay from siliceous rock using 0.05M sodium fluotitanate where the rock is prereacted with a sequestering agent and where the reaction is conducted under an inert atmosphere.
FIG. 3 is a graphical representation of depth of penetration of the reactive acidizing compositions of this invention as compared to hydrofluoric acid and fluoboric acid.
FIG. 4 is a diagram showing the permeability in a core sample after each step of a five step sequential treatment utilizing a 0.2M sodium fluotitanate acidizing solution.
FIG. 5 is another diagram showing the permeability of a core sample which contained 7% CaCO 3 after each step of a five step sequential treatment utilizing a 0.1M ammonium fluotitanate acidizing solution.
FIG. 6 is a graph showing the permeability of a Somatito core sample after each step of a seven step sequential treatment utilizing a 0.1M ammonium fluotitanate acidizing solution.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Seven small ground samples of Wyoming bentonite, ground and screened through no. 200 mesh, U.S. Sieve Series were reacted at 25° C. over several periods of time with the following aqueous acidizing solutions:
(1) 0.1M ammonium bifluoride (NH 4 HF 2 )
(2) 0.1M hydrofluoric acid (HF)
(3) 0.1M sodium monofluorophosphate (Na 2 PO 2 F) with the solution pH adjusted to 4
(4) 0.05M ammonium fluoride (NH 4 F) - 0.05M HF mixture
(5) 0.1M fluoboric acid (HBF 4 )
(6) 0.1M Na 2 PO 2 F with the solution pH adjusted to 7
(7) 0.05M sodium fluotitanate (Na 2 TiF 6 )
The amount of silicon dissolved as a function of reaction time for the seven experiments is shown in FIG. 1. The data presented in FIG. 1 shows that the sodium fluotitanate solution dissolved bentonite much more slowly than the other acidizing formulations.
A sample of the Wyoming bentonite was analyzed and found to have the following cation content, expressed as %, ppm or ppb by weight of the total cation content in the oxide state,: 2.33% Na, 1.21% K, 1.06% Ca, 1.80% Mg, 3.87% Fe, 18.21 Al, 66.90% Si, 0.263% Ti, 0.046% P, 0.076% Ba and 0.020% Mn, and expressed as parts per million (ppm): 274 ppm Sr, <250 ppm V, 13 ppm Cr, 8 ppm Co, 11 ppm Ni, 8 ppm Cu, <50 ppm Mo, 26 ppm Pb, 62 ppm Zn, <5 ppm Cd, <2 ppm Ag, <4 ppp Au, <25 ppm As, <30 ppm Sb, <100 ppm Bi, <2500 ppm U, <50 ppm Te, <5 ppm Sn, <1200 ppm W, 23 ppm Li, 2.1 ppm Be, <400 ppm B, 125 ppm Zr, 39 ppm La, 65 ppm Ce, <150 ppm Th, and expressed as parts per billion (ppb): 20 ppb Hg; which when totalled amounts to 95.788% of the cation content in the oxide state of the Wyoming bentonite sample.
It has also been found that by treating certain types of siliceous rock with a sequestering or chelating agent before acidizing with the hexafluorotitanate-containing acidizing solution greatly improves the amount of clay removed from the rock. FIG. 2 shows that a 0.05M sodium fluotitanate acidizing solution of this invention dissolves more clays from Talara Zapotal rock when the rock is prereacted with disodium ethylenediamine tetraacetic acid (disodium EDTA) before the rock is reacted with the fluotitanate solution. This is an unexpected and surprising result since it is not believed that pretreatment with sequestering agents improves the clay removing capabilities of other acidizing compositions. Treatment of the rock with hexafluorotitanate-containing compositions under an inert atmosphere was also shown to increase the amount of silicon dissolved over that experience when acidizing in air, but the increase was not as great as that experienced by pretreatment of the rock with EDTA which exhibited silica solubilization over 2.5 times the amount experienced when the control sample was acidized in air.
The Talara Zapotal rock from the Talara, Peru, oil field formation was assayed and found to contain by weight 2% Na, 4% Mg, 17% Al, 64% Si, 3% K, 2% Ca, 2% Ti and 6% Fe. A mineralogical analysis indicated that the rock was by weight 44% plagioclase, 20% quartz, 16% feldspar, 8% illite, 6% chlorite clay, 4% kaolinite and 2% analcime.
Accordingly one embodiment of this invention further comprises reacting the siliceous material with a sequestering or chelating agent so that acidizing with the hexafluorotitanate-containing acidizing compositions of this invention will result in improved solubility of clay contained in the siliceous material. Reacting the siliceous material with a sequestering agent can be carried out as a separate step prior to the acidizing step or combined with the acidizing step. In one embodiment the sequestering agent is selected from the group consisting of citrate ion-containing substances, EDTA and mixtures thereof. In a still further embodiment the siliceous material is reacted with a sequestering agent after the acidizing step to prevent the precipitate of reaction products produced by the acidizing step thereby improving the stability of the acidized formation. In another embodiment of this invention the siliceous material is subjected to an inert environment before acidizing. In a still further embodiment of this invention, a subterranean formation is first subjected to an inert gas, for example nitrogen, prior to acidizing the formation. While not wishing to be bound by theory, it is believed that such inerting or sequestering treatments prevent the iron compounds of the siliceous material from being acidized by the acidizing compositions of this invention and thereby allow the acidizing composition to dissolve more clay.
Based on experimental solubilization data and a computer simulated acidizing program, the extent of penetration of the reactive acidizing solution from the wellbore into a Wyoming bentonite-containing formation was calculated for 0.1M HF, 0.1M HBF 4 and 0.05M hexafluorotitanate-containing acidizing solutions. The calculated results based upon the model program disclosed in Chapter 9, section 9.2, pages 538 to 539 of WELL DESIGN, DRILLING AND PRODUCTION, Prentice-Hall, Inc., which is hereby incorporated herein by reference, are shown in FIG. 3. As can be seen in FIG. 3 the penetration of reactive acidizing composition away from the wellbore is far greater for hexafluorotitanate-containing compositions than for HF and HBF 4 solutions. For example, the calculated penetration of the HF solution is only about 0.6 feet and the HBF 4 solution about 1.2 feet while the sodium fluotitanate is over 11 feet. This calculation was based on the use of a 0.05M sodium fluotitanate acidizing solution conducted at 25° C. Clay stabilization agents can also be used to stabilize ion exchange sites in the mineral matter or clay in the formation. The formation can be contacted with a clay stabilization agent before, or after, or both before and after contacting the formation with the first substance or fluotitanate-containing aqueous composition. Preferably the clay stabilization agent is an aqueous mixture containing a quaternary amine and ammonium chloride. Preferably the quaternary amine is a polymeric quaternary amine. The clay stabilization agent attaches to the ion exchange sites near the surface of the clay particles and prevents the clays from swelling and preferably also forms bridges or linkages with the clay thereby preventing clay particles from breaking off during the acidification step or subsequent oil producing step. The clay stabilization agent keeps the clay in place and reduces formation damage caused by clay swelling, fine particle migration and reprecipitation of fine material.
Preferably ammonium chloride is used with both the clay stabilization agent and the fluotitanate. The purpose of the ammonium chloride is to assist both the clay stabilization agent and the fluotitanate by maintaining the salts which are formed in the solubilized state. Although sodium or potassium chloride can also be used with the stabilization agent or fluotitanate, ammonium chloride is preferred because of the higher solubility of ammonium salts over sodium or potassium salts.
EXAMPLE 1
Low oil recovery from the Talara Field, Peru, was attributed to its very low formation permeability which was determined to range from 0.1 to 5 md with an average of 1 md. Conventional acid stimulation using 3% HF/12% HCl (mud acid) and 15% HCl resulted in failure. Accordingly the formation is considered a good candidate for stimulation using the acidizing compositions and method of this invention. Laboratory data produced from core flow experiments with Talara Zapotal cores demonstrated about 300% permeability improvement as a result of an acidizing program utilizing this invention. The first test utilized an acidizing sequence consisting of the following five steps which are referred to in FIG. 4 and described below. Examples of clay stabilization agents useful in this process are water soluble quaternary ammonium salts such as tetramethylammonium chloride as disclosed in U.S. Pat. No. 3,797,574, or organic cationic or polycationic polymers or copolymers such as quaternary polymers with nitrogen or phosphorous or trivalent or tertiary sulfur such as disclosed in U.S. Pat. Nos. 4,393,939, or 4,366,071, or 4,366,072, or 4,366,073, or 4,366,074, or 4,374,739, or 4,447,342, or 4,460,483, or 4,462,718, or British Patent Specification 1,590,345, or UK Patent Application GB 2,098,196 A, or European Patent Application publication number 0,092,340, or polycationic polymers and copolymer containing two or three quaternary ammonium moieties such as those disclosed in U.S. Pat. Nos. 4,497,596 or 4,536,305, which aforementioned U.S. and foreign patents and foreign patent applications are hereby incorporated herein by reference to any extent deemed necessary for any purpose. Other examples of clay stabilization agents useful in this process are water soluble organic acid salt or mixture of salts having the formula ##STR1## such as those disclosed in U.S. Pat. Nos. 4,536,297 or European Patent Application publication number 0,137,872, or aqueous chlorides such as ammonium chloride as disclosed in U.S. Pat. No. 3,543,856, or inorganic polycationic polymers such as zirconyl chloride or aluminum hydroxy chloride, or water soluble alkali metal halides, alkaline earth metal halides or ammonium halide, which aforementioned U.S. and foreign patent applications are hereby incorporated herein by reference to any extent deemed necessary for any purpose.
The clay stabilization agent used in the experiments represented by FIGS. 4, 5 and 6 is a polymeric quaternary amine stabilization agent sold by Halliburton Services under the trademark CLA-STA II. However it is to be understood that other clay stabilization agents can be used which are operable for stabilizing clay and other fine particles in the formation to be treated. Preferably the clay stabilization agent is polymeric structure that is absorbed on water sensitive clays as ions connected by a chain-like linkage structure. Such ion-linking clay stabilization agents are preferred over agents which are absorbed on cation exchange sites as separate or single ions.
Initially the core of the experiment represented by FIG. 4 was heated to 68° C. (154° F.) and maintained under a pressure of 35 kg/sq cm (550 psig) and then subjected to the following stabilizing-acidizing sequential steps. First the core was treated with a quaternary amine stabilization agent, hereinafter referred to as "QASA,"-NH 4 Cl solution, or QASA/NH 4 Cl solution, to stabilize the clays and other fine particle components of the core. The core was then acidized with a 5% hydrochloric acid solution which preferably contains a corrosion inhibitor, which was followed by restabilization with QASA/NH 4 Cl solution. Next the core was then treated with a 0.2M sodium fluotitanate, 0.15M ammonium citrate or (NH 4 ) 2 HC 6 H 5 O 7 acidizing solution at 68° C. (154° F.) and 35 kg/sq. cm (500 psig), which was followed by a third stabilization treatment with QASA/NH 4 Cl solution. The results as shown in FIG. 4 show an improvement in permeability from about 7.5 md after the first stabilization step to about 20 md after the third stabilization step.
EXAMPLE 2
Another Talara Zapotal core was subjected to a similar five-step sequential treatment as that shown in FIG. 4 except that the fourth step utilized a 0.1M ammonium fluotitanate/(NH 4 ) 2 HC 6 H 5 O acidizing solution instead of the sodium fluotitanate solution used in Example 1. The results, presented graphically in FIG. 5, show an improvement in core permeability from about 75 md after the first stabilization step to about 220 md after the third stabilization step.
EXAMPLE 3
The permeability of a core sample from Somatito Well 9109, having a composition similar to that of the Wyoming bentonite described above, was improved from 0.03 millidarcy (md) to 1.62 md, more than 5000%, by a seven step sequential treatment of this invention conducted at 43° C. (110° F.) and 70 kg/sq cm (1000 psig). The results are shown graphically in FIG. 6. The composition of the treating solutions used for each step and the permeability after each step were as follows:
______________________________________ PermeabilityStep Treating Solution (md)______________________________________(1) QASA/NH.sub.4 Cl 0.03(2) 5% HCl + 0.07% citric acid 0.07(3) QASA/NH.sub.4 Cl 0.09(4) 0.1 M ammonium fluotitanate, 0.98 0.15 M citric acid, 0.2 M NH.sub.4 Cl(5) QASA/NH.sub.4 Cl 1.10(6) 5% HCl + 0.07% citric acid 1.43(7) QASA/NH.sub.4 Cl 1.62______________________________________
EXAMPLE 4
A well having a lower than desired permeability from an isolated 9 m (30 ft.) zone or interval is subjected to a five step sequential matrix acidization process similar to that shown in FIG. 5. The sequence and injection rate are as follows:
______________________________________Step Injected Composition______________________________________(1) 1018 l/m (82 gal/ft) QASA/NH.sub.4 Cl (In a 30 ft. interval this rate corresponds to an injection of 2460 gal.)(2) 1018 l/m (82 gal/ft) 5% HCl(3) 646 l/m (52 gal/ft) 0.1 M ammonium fluotitanate solution(4) 5875 l/m (473 gal/ft) 5% HCl(5) 1018 l/m (82 gal/ft) QASA/NH.sub.4 Cl______________________________________
An incremental improvement of about 5350 l/day (45 bbl/day) is predicted.
EXAMPLE 5
A core from a conglomerate sandstone formation in the Mendoza Contract Area 7559 oil field in Argentina was treated in like manner to the core in Example 3 except for the following changes. The temperature was raised to 104° C. (220° F.) and the pore pressure was held at 127 kg/sq cm (1800 psig) with a back pressure regulator, while an overburden pressure of 155 kg/sq cm (2200 psig) was maintained hydrostatically on the core. This test was conducted using the standard procedure of heat shrinking a Teflon (trademark) plastic sleeve over the entire cylindrical surface of the core so that the cylindrical surface of the core was sealed against the Teflon sleeve. The outside surface of the Teflon sleeve was subjected to the overburden pressure of 155 kg/sq cm. The cylindrical ends of the test core were therefore isolated from the overburden pressure in the usual manner. With the test core in the vertical position the injected solutions were forced to flow upwardly through the test core. The discharge pressure of the solution flowing out of the top of the test core was regulated to a pressure of 127 kg/sq cm. The initial permeability of the core was 2.23 md. The core was then treated with the same sequence of fluids as that of Example 3. After the final treatment, the permeability had increased to 9.11 md or about 4 fold over the initial permeability. No unconsolidation or plugging of the core occurred from the treatment by the principals of this invention.
In contrast to the excellent results described above, a similar core from the same sandstone formation treated with conventional mud acid, i.e. 3% HF/12% HCl, fell apart.
The permeability after each step, the steps are set forth in Example 3, was as follows:
______________________________________Step Permeability (md)______________________________________(1) 2.23(2) 1.95(3) 1.95(4) 4.11(5) 4.11(6) 9.11(7) 9.11______________________________________
EXAMPLE 6
During experiments with treating sandstone cores with solutions of pure sodium fluotitanate, it was found that the aluminum concentration of the filtrate was quite low. To determine if this was due to the precipitation of aluminum-containing compounds such as aluminum fluoride-containing compounds, the following experiments were conducted. A sample of pure chlorite clay was ground to a powder.
Test A: Into a dish at room temperature was added 10 ml of a solution containing 0.45M sodium fluotitanate, 0.156M sodium citrate, 0.1M ammonium chloride, and 15.4 mg of the powdered chlorite clay. This was allowed to stand for 24 hours without agitation.
Test B: For comparison, 150 mg chlorite clay and 10 ml of 6M HCl were also placed in a dish and allowed to stand in the same manner as in Test A.
The mixtures from Tests A and B were filtered and the analysis of the filtrates was as follows:
______________________________________Elemental Concentrations (mg/l) Mole RatioTest Al Si Fe Ca Mn Mg Si/Al______________________________________A 14.9 39.9 21.2 69.5 <12 <10 2.58B 3.8 12.1 15.2 8.55 <12 <10 3.07______________________________________
Not all the chlorite dissolved in either Test A or B. The solids remaining after treating were examined with x-ray diffraction and showed evidence for only the starting materials, chlorite clay, and in the case of Test A sodium fluotitanate resulting from the evaporation of the solution after filtering.
No precipitation of aluminum-containing compounds, or any other compounds, was observed in Test A. These tests show that the citrate ion effectively held aluminum ions in the fluotitanate solution thereby preventing precipitation of reaction products which can reduce the permeability of formations when acidized.
In one embodiment the formulation of the clay stabilization agent/ammonium chloride solution or the QASA/NH 4 Cl solution is from about 0.005 to about 2% by volume clay stabilization agent or QASA and from about 0.5 to about 4% by weight ammonium chloride. The percentage of stabilizer and ammonium chloride will vary depending on the amount of clay in the formation to be treated. Various formulations and uses of QASA is described in Halliburton's publication F-3183 (Revised) which hereby is incorporated herein by reference.
Unless otherwise specified, the preferred formulation of the QASA/NH 4 Cl solution referred to above is as follows:
0.75% by volume QASA
2% by weight NH 4 Cl
In each of the above examples it is preferable that the various hydrochloric acid solutions contain a corrosion inhibitor to protect the piping and tubing of the well and injection system. Any commercially available corrosion inhibitors can be used for this purpose by mixing such inhibitors with HCl containing solutions. Examples of such corrosion inhibitors are Halliburton's inhibitors sold under the trademarks "HAI50," "HAI65" and "HAI75" which are described in Halliburton's publications CS-5073 and CS-5136 which are incorporated herein by reference and Dowell's inhibitor sold under the trademark A200 which is described in the Dowell Stimulation Materials Manual, acidizing-Sec. I-D-1, pages 1 and 2, December, 1981, which is incorporated herein by reference.
Unless otherwise specified, all percentages referred to are by weight.
It is understood that the foregoing detailed description and embodiments shown in the Figures and presented in the Examples are illustrative of the principles of this invention. Other alternatives can be employed. For example, other sequential injection steps can be employed and various other fluids can be used for specific reasons such as stabilizers, removing skin damage adjacent the wellbore, dissolving calcareous materials, causing viscosity increase or thickening, inhibiting corrosion, preventing sludge formation and/or reducing friction. Accordingly the present invention is not limited to that shown and described in the Examples and Figures. | An acidizing composition and method for slowly dissolving siliceous material by the slow production of very low concentrations of hydrofluoric acid is provided by this invention. The continual generation of very low concentrations of hydrofluoric acid is accomplished by the hydrolysis of hexafluorotitanate-containing compounds. The acidizing composition is particularly useful and advantageous for the solubilization of siliceous clay in or adjacent the pores of subterranean hydrocarbon formations thereby increasing the permeability of said formations. Because of the very low concentration of hydrofluoric acid in the acidizing composition solubilization of siliceous clay deposits is possible at relatively large distances from the point of injection into the formation, for acidizing formations which are too sensitive for more reactive acidizing compositions, for acidizing formations containing chlorite clays, and/or for acidizing formations having an elevated temperature including formation temperatures of 125° C. or higher. | 8 |
REFERENCE TO RELATED PATENTS
This application is an improvement over commonly assigned U.S. Pat. No. 5,448,810 granted Sep. 12, 1995.
BACKGROUND OF THE INVENTION
As disclosed in the foregoing patent, metal caskets are expensive because manufacturing and assembling the parts is labor intensive and also requires many manipulative steps to finish and trim the assembled unit to meet consumer satisfaction and acceptance. Normally, steel, bronze or copper is utilized and the sides, ends, lid and bottom are stamped from sheet material and then pressed into the desired configuration. The sides, ends and bottom are welded together and the lid hinged and latched to the sides. The welds and joints are subjected to a grinding operation to enhance their appearance and then the sides, ends and lid are spray painted. The interior of the thusly formed shell is trimmed in one of many styles. Obviously, if any one or more of the assembly steps is eliminated or rendered more efficient, assembly time will be reduced and the cost of manufacturing metal caskets could be significantly reduced.
Another peculiar attribute of present and prior art caskets is that with cutting, stamping, welding, grinding and painting, caskets that should be of the same style or kind coming off an assembly line, will, in fact, not be the same nor identical.
SUMMARY OF THE INVENTION
It is a principal object of the present invention to blank and form the casket sides, ends, bottoms and lids from pre-painted and pre-finished material which are thereafter connected by corner connectors of this invention without the need for welding and grinding.
Another object is to provide a casket of the foregoing type having novel corner connectors for connecting the sides and ends.
A further object is to provide pre-painted and pre-finished casket parts of exact dimensions that may be assembled with mechanical fastening so that each casket is the same; and, consequently, such parts may be shipped at low cost for eventual assembly into identical caskets at another selected location.
Other objects and advantages will become apparent from the following detailed description which is to be taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an exploded perspective view of casket parts including sides, ends, bottom and corner connectors incorporating the teachings of the present invention with a lid shown schematically and fragmentarily;
FIG. 2 is an enlarged fragmentary view showing parts of the side, end and corner connector prior to being connected to form a corner;
FIG. 3 is an enlarged side view of the corner connector of this invention;
FIG. 4 is a bottom view of the corner connector in the direction of the line 4--4 of FIG. 3;
FIG. 5 is a cross-sectional view taken along the line 5--5 of FIG. 3;
FIG. 6 is a cross-sectional view taken along the line 6--6 of FIG. 3;
FIG. 7 is a top view of the corner connector in the direction of the line 7--7 of FIG. 3;
FIG. 8 is a cross-sectional view taken along the line 8--8 of FIG. 3; and
FIG. 9 is a perspective view showing the interior of the corner connector.
DETAILED DESCRIPTION
In the drawings, a metal casket shell 10 according to this invention will include corner connectors of this invention and sides, ends, bottom and lid blanked and formed from pre-painted or pre-finished material. In this connection, cutting, welding, grinding and painting at an assembly or manufacturing plant normally employed in making a metal casket shell need not be performed.
Towards that end, ends 12 and 14, and sides 16 and 18 will be firmly coupled by corner connectors 20. The bottom 22 is connected to the ends 12, 14 and sides 16, 18.
Reference is now made to corner connector 20, which may be advantageously molded from a suitable plastic such as a polycarbonate, but this invention also contemplates connection of metals such as zinc. The connector will be formed with a top part 24, bottom part 26 and central stem 28. A slot 30 will be formed in connector 20 having a shape corresponding to the outline of the end 32 of casket side 18. This slot extends into top part 24, bottom part 26 and central stem 28 and will receive end 32 of casket side 18.
The connector will also be formed with a slot 34 having a shape corresponding to the outline of the end 36 of casket end 12. This slot extends into top part 24, bottom part 26 and central stem 28 and will receive end 36 of casket end 12.
Any suitable enclosing means may be employed for securing the ends 32 and 36 of casket side 18 and casket end 12, respectively, to connector 20 such as adhesive or a mechanical connection employing dowels, screws, rivets, etc. In this regard, the drawings show an exemplary embodiment in which holes 32a and 36a extend from the respective ends 32 and 36 of casket side 18 and casket end 12, respectively. Holes 32a are adapted to align with opening 32b of connector 20 and then a nut and bolt may be used to complete the connection of end 32 to connector 20. Similarly, holes 36a are adapted to align with openings 36b of connector 20 and then a sheet metal screw or nut and bolt may be used to complete the connection of end 36 to connector 20. Holes 32a and 36a may be tapped or internally threaded to receive a threaded screw or bolt or the holes may be replaced by bendable prongs that align with holes 32b and 36b, respectively. As shown in FIG. 2A, prongs 36a', when aligned with openings 36b, are bent or twisted inwardly to complete the connection of end 36' of end 12' to connector 20. If needed, a suitable adhesive may be applied to each bent prong and opening, or any other strategic location, to enhance the connection.
The remaining corner connectors 20', 20" and 20"' are connected to the ends of the associated sides and ends in similar fashion.
Thereafter the base 22 can be connected to the sides and end in any suitable fashion, as for example, in a manner disclosed in U.S. Pat. No. 5,448,810.
Suitable casket hardware may be applied over connectors 20 or the connectors themselves may possess sufficient ornamentation for serving this purpose.
Accordingly, by forming the sides, ends, bottoms and lids with mechanical and adhesive joints as described in the above, the need for welding and grinding is eliminated. This advantageously permits the use of materials that are pre-painted and pre-finished without destroying the outside surface of the casket, which material may be shipped substantially flat thereby minimizing space requirements. Thus, the invention eliminates the need to paint or finish a casket shell in a separate operation, and also permits the assembly of a casket shell at a location remote from that at which the parts are pre-painted and pre-finished.
Thus, the several aforenoted objects and advantages are most effectively attained. Although several somewhat preferred embodiments have been disclosed and described herein, it should be understood that this invention is in no sense limited thereby and its scope is to be determined by that of the appended claims. | A metal casket shell will includes sides, ends, bottoms and lids blanked and formed from pre-painted or pre-finished material. Corner connectors fasten the sides thereby eliminating the need to weld and grind these joints. | 0 |
CROSS REFERENCE TO RELATED APPLICATION
[0001] This application claims the benefit of U.S. Provisional Application No. 60/776,984 filed on Feb. 27, 2006, the contents of which are incorporated herein by reference.
FIELD OF THE INVENTION
[0002] This invention relates to devices for cleaning fluid-containing vessels and more particularly, but not exclusively, to automatic cleaners for swimming pools and components of such cleaners including, but not limited to, bodies, feet, and discs.
BACKGROUND OF THE INVENTION
[0003] Commonly-owned U.S. Pat. No. 4,642,833 to Stoltz, et al. (the “Stoltz Patent”) discloses various valve assemblies useful for automatic swimming pool cleaners. These assemblies typically include flexible, tubular diaphragms surrounded by chambers, with the diaphragms interposed in the fluid-flow paths (i.e. “in-line”) through the cleaners. In response to variation in pressure internally and externally, the diaphragms contract and expand transversely along at least part of their lengths, thereby controlling fluid flow therethrough.
[0004] Commonly-owned U.S. Pat. No. 4,742,593 to Kallenbach (the “Kallenbach Patent”) discloses additional valve assemblies for use with automatic swimming pool cleaners. These assemblies, also typically tubular and of flexible material, too may be interposed in-line, within the fluid-flow paths of such cleaners. According to the Kallenbach Patent:
[0005] The body [of the tubular valve] has an intermediate section between the ends that assumes a substantially collapsed condition over a segment thereof in absence of a pressure differential between the interior and exterior.
[0006] The section preferably is collapsed transversely over a segment. See Kallenbach Patent, col. 1, 11. 28-32.
[0007] International Publication No. WO 02/01022 of Kallenbach, et al. (the “Kallenbach Publication”), entitled “Swimming Pool Cleaner,” details another cleaner in which a valve periodically interrupts a flow of water through the body of the cleaner. Included in the cleaner are a main flow path and a by-pass passage built into the body. See Kallenbach Publication, p. 5, 11. 8-11. Also included in one version is an “annular resilient rolling diaphragm” with an edge “located in sealing engagement with the inner wall of the body.” Id., p. 6, 11. 24-26. However, a dome-shaped valve closure member, rather than the rolling diaphragm, operates to interrupt fluid flow through the main path. Additionally, neither the rolling diaphragm nor the dome-shaped member is interposed in-line in the main water path from the inlet passage of the cleaner to the outlet of the body.
[0008] U.S. Pat. No. 4,351,077 to Hofmann (the “Hofmann Patent”) describes yet another cleaning apparatus in which a valve interrupts fluid flow through the cleaner body. This valve, denoted a “flapper,” oscillates so as periodically to open and close the flow passage through the body. See Hofmann Patent, col. 2., 1. 67 through col. 3, 1. 2. Opposite the flow passage within the body is a so-called “suction communication,” which is closed when the flow passage is open and opens briefly when the flow passage is closed. See id., col. 3, 11. 9-22.
[0009] Each of the Stoltz, Kallenbach, and Hofmann Patents and the Kallenbach Publication discusses “suction-side” cleaners in which a pair of concentric pipes exist, the outer of the pipes being adapted for connection to a flexible hose leading (directly or indirectly) to the inlet, or “suction side,” of a pump. An annular gap between the pipes permits water to flow through the by-pass passage of the cleaner of the Kallenbach Publication toward the flexible hose. A similar gap in versions of cleaners discussed in the Stoltz and Kallenbach Patents offers “suction communication . . . through slots [in a plate] to [a] chamber” defined at least in part by the tubular members of these patents. The contents of the Kallenbach Publication, together with those of the Stoltz, Kallenbach, and Hofmann Patents, are incorporated herein in their entireties by this reference.
SUMMARY OF THE INVENTION
[0010] The present invention provides alternatives to the devices addressed in these earlier efforts, particularly (but not necessarily exclusively) those involving diaphragm valves. Included among features of the present invention are an in-line valve assembly that is periodically repositioned, typically laterally (i.e. from side-to-side) relative to the surface to be cleaned, effectively changing the initial direction of the main fluid-flow path through the cleaner body. Also included as part of the invention is a sealing mechanism that seals against the to-be-cleaned surface on the side of the valve assembly opposite the one toward which the valve is positioned at any given time.
[0011] Additionally, the present invention may incorporate novel apron and foot structure. Unlike conventional aprons and associated footpads, which have circular cross-section, aprons of the invention may be truncated in the normally-forward direction of travel and extend principally transversely beneath the cleaner body. These aprons thus may be wider than they are long, allowing their associated cleaner bodies to approach pool corners more closely before the cleaner discs lose suction with the pool floors. Bearing surfaces of the feet, moreover, may constitute elongated strips of material placed parallel to the normally-forward direction of travel of the cleaners, reducing the likelihood of their engaging obstructions in the pools.
[0012] Discs of the present invention may lack uniform flexibility. Instead, the discs may be least flexible toward the front of the cleaner bodies, reducing the risk of the cleaners sticking in a corner of a pool. Greater flexibility may exist in other areas for improved sealing to the to-be-cleaned surface. Flexibility in the rear part of the discs additionally may improve the ability of cleaners to climb pool walls.
[0013] Innovative discs also may include fins in the forward sections to facilitate movement over obstacles encountered in use. As well, “blocking” tabs may be attached to the discs or barbed, “gripper” material may be placed underneath the finned sections if appropriate. Such tabs or material, in particular, may inhibit undesired backward movement of a cleaner when its operation commences.
[0014] It thus is an optional, non-exclusive object of the present invention to provide alternative automatic swimming pool cleaners and components thereof.
[0015] It also is an optional, non-exclusive object of the present invention to provide in-line valve assemblies for automatic swimming pool cleaners whose position may change in use.
[0016] It is a further optional, non-exclusive object of the present invention to provide repositionable valve assemblies for suction-side automatic pool cleaners.
[0017] It additionally is an optional, non-exclusive object of the present invention to provide sealing mechanisms that seal against a surface on the side of the valve assembly opposite the one toward which the valve is positioned at any given time.
[0018] It is, moreover, an optional, non-exclusive object of the present invention to provide aprons and feet (footpads) with non-circular cross-sections.
[0019] It is yet another optional, non-exclusive object of the present invention to provide feet that are truncated in the normally-forward direction of travel of associated cleaners and extend principally transversely beneath the cleaner bodies.
[0020] It is an additional optional, non-exclusive object of the present invention to provide bearing surfaces that are placed parallel to the normally-forward travel direction.
[0021] It is also an optional, non-exclusive object of the present invention to provide discs with non-uniform flexibility for use with automatic swimming pool cleaners.
[0022] It is a further optional, non-exclusive object of the present invention to provide “blocking” tabs attached to the disc or barbed, “gripper” material underneath sections of the disc to inhibit undesired backward movement of a cleaner when it commences operation.
[0023] Other objects, features, and advantages will be apparent to those skilled in the art with reference to the remaining text and the drawings of this application.
BRIEF DESCRIPTION OF THE DRAWINGS
[0024] FIGS. 1-4 illustrate portions of an automatic swimming pool cleaner of the present invention containing an exemplary valve assembly and sealing mechanism.
[0025] FIG. 5 is a generally bird's-eye view of the automatic swimming pool cleaner of FIGS. 1-4 .
[0026] FIG. 6 illustrates aspects of an exemplary apron of the automatic swimming pool cleaner of FIGS. 1-4 .
[0027] FIG. 7 illustrates an exemplary bearing surface of a footpad of the present invention.
[0028] FIG. 8 is a perspective view of the automatic swimming pool cleaner of FIGS. 1-4 illustrating the act of transitioning from a horizontal surface to a vertical surface of movement.
[0029] FIG. 9 illustrates, somewhat schematically, barbed gripping material attached to the underside of portions of a disc of the present invention.
[0030] FIGS. 10-18 show aspects of an alternate automatic swimming pool cleaner of the present invention.
DETAILED DESCRIPTION
[0031] Well depicted in FIGS. 5 and 8 is an exemplary automatic swimming pool cleaner 10 of the present invention. Cleaner 10 is designed primary for attachment to the inlet, or suction side, of a pump of a swimming pool filtration system. Some or all aspects of the present invention are not necessarily limited to use with suction-side automatic swimming pool cleaners, however, and conceivably could be employed as part of other devices as well.
[0032] Shown in FIGS. 5 and 8 as part of cleaner 10 are body 14 , inner pipe 18 , and outer pipe 22 . Similar to those of the cleaner described in the Kallenbach patent, inner and outer pipes 18 and 22 of cleaner 10 may be concentric, with outer pipe 22 adapted to be connected to a flexible hose leading, ultimately, to the inlet of a pump. Extending from body 14 may be arm 26 , whose end 30 may contain a weight (not shown) functioning, in part, to balance a float (also not shown) typically positioned within body 14 . However any weight need not necessarily be placed within end 30 , and indeed need not necessarily be positioned at any point within arm 26 . In use, arm 26 also may function as a bumper or bearing surface in certain situations.
[0033] Also illustrated in FIGS. 5 and 8 as part of cleaner 10 are apron 34 and disc 38 . Apron 34 may be connected directly or indirectly to footpads 68 , each of which may provide a bearing surface as cleaner 10 traverses a vessel; apron 34 may also serve as an interface connecting disc 38 to body 14 . Although disc 38 too functions, to modest extent, as a bearing surface, it also operates to effect sealing of certain surfaces as body 10 is evacuated by the pump.
[0034] FIGS. 1-4 detail aspects of (nominal) underside 42 of body 14 . Visible in underside 42 is inlet 46 , through which debris-laden water or other fluid may flow into cleaner 10 . In normal use, inlet 46 is adjacent a to-be-cleaned pool surface. Also illustrated in FIGS. 1-4 within inlet 46 is inlet end 50 of valve 54 , through which the debris-laded fluid passes before travelling through inner pipe 18 to the flexible hose and, from there, to some type of filter.
[0035] Valve 54 accordingly is “in-line,” in that it forms part of this main fluid-flow path through body 14 . Any suitable valving mechanism may be employed as valve 54 . Preferably, however, valve 54 is of the diaphragm type, as depicted in the Kallenbach patent or in either of co-pending U.S. patent application Ser. Nos. 10/917,587 and 10/939,579, whose contents also are incorporated herein in their entireties by this reference.
[0036] Existing diaphragm-valve assemblies fix the position of the valve relative to the remainder of the main fluid-flow path during operation. Valve 54 , by contrast, is designed to move periodically, effectively cyclically reorienting a portion of the main fluid-flow path through body 14 . Consequently, rather than maintaining inlet end 50 of valve 54 generally co-linear with the main direction of travel of the cleaner 10 , valve assembly 58 of the present invention periodically repositions inlet end 50 relative to such main travel direction. Presently preferred versions of valve assembly 58 reposition inlet end 50 from side-to-side of such main travel direction, although other motions with lateral components should be substituted instead as beneficial or desired. Further, assembly 58 conceivably periodically could reposition inlet end 50 solely along the main direction of travel (i.e. with no lateral component of motion), although applicants do not currently consider this approach to be especially advantageous.
[0037] Valve assembly 58 may comprise a housing 62 for valve 54 adapted to pivot within inlet 46 . Any suitable mechanism may be employed to effect such pivoting of housing 62 , as long as the mechanism permits continued fluid communication (directly or indirectly) from valve 54 to inner pipe 18 . One or more hinges 64 ( FIG. 11 ) may also be employed to facilitate the pivoting. Each hinge 64 preferably is a one-piece “living” or similar hinge made of flexible material.
[0038] Pivoting of housing 62 is shown in FIGS. 1-3 , which illustrate differing positions of housing 62 and inlet end 50 of valve 54 . FIG. 2 , for example, depicts inlet end 50 positioned generally co-linear with the main direction of travel of cleaner 10 . FIG. 1 , by contrast, depicts inlet end 50 positioned to one side of such main travel direction, while FIG. 3 details inlet end 50 positioned to the other side of such main direction. In certain preferred versions of cleaner 10 , housing 62 pivots through approximately seventy degrees, thirty-five degrees to each side of the main travel direction.
[0039] Generally, inlet end 50 sweeps rapidly from side to side as cleaner 10 travels in a nominal direction. FIGS. 1-3 thus provide snapshots of varying positions of valve 54 as a function of time. Assuming, for example, that FIG. 2 depicts a default, resting position of valve 54 and housing 62 , FIG. 1 might then indicate a subsequent position of valve 54 . Thereafter, valve 54 would return to the position depicted in FIG. 2 before travelling to the position of FIG. 3 , followed by a return to the position of FIG. 2 and then on to the position of FIG. 1 . This cycle of repositioning preferably continues while cleaner 10 is operational, as applicants believe it produces better cleaning results. Nevertheless, if appropriate or desired, cleaner 10 possibly could include a mechanism that could temporarily fix the position of valve 50 along the main direction of travel of cleaner 10 , as shown in FIG. 2 .
[0040] Assembly 58 additionally may comprise one or more sealing surfaces attached to housing 62 . Two such surfaces 66 A and 66 B are depicted in FIGS. 1-3 , with the surfaces being generally parallel to and generally symmetric about the main direction of travel of cleaner 10 when valve 54 is in the position shown in FIG. 2 . When valve 54 is in the position shown in FIG. 1 , surface 66 B may abut and seal against the surface to be cleaned. Conversely, when valve 54 is positioned as shown in FIG. 3 , surface 66 A may abut and seat against the surface to be cleaned.
[0041] In use, valve assembly 58 functions to counteract existing tendencies of flexible hoses to steer, or otherwise influence the movement direction of, the cleaners to which they are attached. If a hose pulls an attached cleaner to the right of a nominal path, for example, housing 62 will pivot so as to point inlet end 50 of valve 54 to the left of the nominal path. Doing so provides more suction power left of the path, effectively counteracting the influence of the hose. Similarly, if the hose pulls cleaner 10 to the left of the nominal path, housing 62 will pivot so as to direct the suction power of valve 54 to the right of the path. In this manner, the position of valve 54 continually conflicts with the movement influence provided by the flexible hose, thereby lessening the effect of such influence.
[0042] Illustrated in various of FIGS. 1-8 is apron 34 , to which one or more footpads 68 may connect. Conventional aprons, which are generally annular in shape, thus have substantially equal lengths and widths. By contrast, apron 34 is substantially wider than it is long. This configuration allows body 14 to be closer to a corner or other transition of a pool before sealing against the pool surface via disc 38 is lost. Consequently, apron 34 facilitates cleaner 10 originating its climbing of vertical surfaces of pools.
[0043] Underside 70 of apron 34 surrounds housing 62 and valve 54 . Underside 70 additionally may be connected to footpads 68 , each of which includes a bearing surface 74 . Preferred versions of surfaces 74 are elongated strips of serrated plastic material placed parallel to the normally-forward direction of travel of the cleaners, reducing the likelihood of their engaging obstructions in the pools. Again preferably (albeit not necessarily), two such surfaces 74 are included as part of two footpads 68 positioned symmetrically about the main travel direction of cleaner 10 . Surfaces 74 may be separate strips of material attached to underside 70 of apron 34 using screws (as shown in FIGS. 1-3 ) or other fasteners; alternatively, they may be molded or otherwise integrally formed as part of apron 34 . Yet alternatively, footpads 68 (together with portions of disc 38 ) may be fitted into channels 76 of a channelled version of apron 34 (see FIG. 11 ).
[0044] Aspects of disc 38 are detailed principally in FIGS. 5 and 8 . Disc 38 may be formed of moldable plastic or other material. Preferably, however, disc 38 lacks uniform flexibility. Instead, disc 38 has lesser flexibility forward of body 14 and greater flexibility elsewhere.
[0045] As depicted in FIGS. 5 and 8 , forward section 78 of disc 38 may, but need not necessarily, constitute an arc-shaped segment of material similar to that described in U.S. Pat. No. 5,421,054 to Dawson, et al., whose contents also are incorporated herein in their entirety by this reference. As initially noted therein, fins 82 may extend radially upward from and outward of a serpentine periphery 82 , with the fins 82 providing sufficient rigidity to disc 38 to enable it to ride over various objects, including many drains, lights, valves, and other nozzles, projecting from internal surfaces of pools. Enhanced rigidity of forward section 78 additionally inhibits its assuming the shape or a corner or other transition within a pool (and thereby sticking in the corner or at the transition) and prevents forward section 78 from folding under itself when departing from vertical surfaces such as walls.
[0046] Connected to any, some, or all of forward section 78 , apron 34 , footpad 68 , or body 14 are mid-section 86 and rear section 90 of disc 38 . Contrasted with forward section 78 , mid-section 86 and rear section 90 are more flexible, as they rarely function as the leading edge of cleaner 10 . This greater flexibility provides improved sealing of disc 38 to the surface to be cleaned. Flexibility of rear section 90 additionally may improve the ability of cleaner 10 to climb pool walls by permitting body 14 to rotate rearward some as generally illustrated in FIG. 8 .
[0047] Because of float placement within some versions of cleaners 10 , the center of gravity of such cleaners 10 is forward of fins 82 . Consequently, when a swimming pool pump is inactive, inner and outer pipes 18 and 22 tend to rest at a low angle to the horizontal, effectively causing cleaner 10 to “lie down.” When the pump is activated, cleaner 10 may attempt to travel backward, undesirably, rather than forward. Accordingly, undersides 94 of tongues 98 from which fins 82 protrude may include barbed gripping material 102 as shown in FIG. 9 . Such material is configured to inhibit backward movement of cleaner 10 in these circumstances, thereby encouraging desired forward movement thereof.
[0048] Alternatively or additionally, one or more tabs 106 may be attached to or integrally formed with forward section 78 of disc 38 . Shown in FIG. 10 , an exemplary tab 106 is adapted to lie flat when cleaner 10 is moving forward so as not to impede such movement. However, should cleaner 10 attempt to travel backward in use, tab 106 will contact (catch) the floor of the pool, in turn forcing forward section 78 upward. As forward section 78 moves upward, rear section 90 will be forced downward, allowing it to adhere to the pool surface temporarily and cease the backward movement. One tab 106 preferably is positioned at rear edge 110 of forward section 78 (opposite fins 82 ), although more tabs 106 may be used and positioned otherwise as needed.
[0049] FIGS. 12-18 , finally, depict an exemplary connecting scheme for footpad 68 A, disc 38 A, and apron 34 A. As detailed particularly in FIG. 12 , each footpad 68 A may comprise one or more upstanding columns 114 , each containing one or more slots 118 so as to define a head 120 . Forward section 78 A of disc 38 A may include openings designed to receive columns 114 , as shown in FIG. 13 . Thereafter, rear section 90 A of disc 38 A may receive selected columns 114 as it is laid over forward section 78 A (see FIG. 14 ), following which one or more mid-sections 86 A of disc 38 A may overlay rear section 90 A (see FIG. 15 ). The assembly 122 comprising footpads 68 A and disc 38 A may then be fitted into channels 76 of apron 34 as detailed in FIG. 16 . The results of such fitting are shown in FIGS. 17-18 , providing a reliable connection scheme for the relevant components.
[0050] The foregoing is provided for purposes of illustrating, explaining, and describing exemplary embodiments and certain benefits of the present invention. Modifications and adaptations to the illustrated and described embodiments will be apparent to those skilled in the relevant art and may be made without departing from the scope or spirit of the invention. | Devices for cleaning vessels, especially swimming pools, are discussed. The devices may include repositionable in-line valves, with the valves typically moving laterally (from side to side) and changing the initial direction of the main fluid-flow path through the valves and corresponding cleaner bodies. Asymmetric feet may be utilized as part of the devices, whose bottom bearing surfaces may include elongated strips of material placed parallel to the normally-forward direction of travel of the devices. Discs of non-uniform flexibility also may be employed, and blocking tabs or gripping material may be used to inhibit undesired backward movement of a cleaner when its operation commences. | 4 |
This is a continuation of application Ser. No. 08/309,487, filed Sep. 22, 1994.
The present invention relates to apparatus and methods for the recovery of cotton seed from the lint for planting purposes and, in particular, to apparatus and methods for the recovery of batch quantities of seed in a reliable manner and without damage to the seed with respect to its suitability for planting purposes.
BACKGROUND
It is a common practice in the art to recover cotton seeds from the lint which remains after the cotton product itself is separated from the crop. The seeds so recovered are used for the production of cotton seed oil and, in some cases, for planting purposes. In cases where the seed is recovered for planting purposes, care must be taken not to damage the seeds such that germination would be impaired. In the recovery of cotton seed from the lint, there are several different methods which are commonly used.
The older and less frequently used method is known as mechanical delinting. This method involves separating the seed from the lint by using saw delinting and/or brush delinting. In the saw delinting method, the lint is cut from the seeds by means of saws, after which the seeds may be dropped through a flame to remove the residual portion of the lint remaining after the saw delinting step.
Another type of mechanical delinting is known as brush delinting. in this method, a series of brushes are rotated against the inner surface of a perforated drum in which the fuzzy seeds are loaded, whereby Eke lint is removed from the seeds mainly by friction.
A mechanical delinting process which is particularly suitable for recovery of seed from lint for planting purposes is disclosed in U.S. Pat. No. 5,249,335--Jones, which is assigned to the same assignee as the present application.
Another approach to the recovery of seed for. planting purposes involves utilizing chemical methods which include the use of hydrogen chloride gas and sulfuric acid. There are several different approaches which have been employed in the use of these chemicals to delint fuzzy cotton seed.
One of these is known as the concentrated sulfuric acid method. In this method, concentrated sulfuric acid is applied to the fuzzy cotton seed. Almost instantly, the acid reacts with the lint and the lint is removed and hydrolyzed into its components. The seed is then rinsed with water to remove the acid and is dried and further processed with seed processing equipment well known in the art.
There are two major disadvantages with the concentrated sulfuric acid method. One is that the rinse water represents an environmental problem and the other is that the process also removes the oil in the seed coat which shortens the shelf life or the time period in which the seed remains viable.
Another chemical method is known as the anhydrous hydrogen chloride gas method. This method involves injecting HCl gas into a closed reaction chamber which contains a charge of fuzzy seed. The HCl gas reacts with the lint on the seed and the seed is then emptied from the reaction chamber into a buffer. In the buffer, the lint is buffed from the seed by means of rotating screens.
A disadvantage of the anhydrous hydrogen chloride gas method is that any of the seeds which have been cracked or otherwise physically damaged or which have openings of any kind in the shell of the seed will be killed by the entry of the gas into the interior of the seed. Also, the gas is hygroscopic and the system can. therefore be used only in an arid or semi-arid environment where the relative humidity is consistently low.
knother chemical method is known as the dilute sulfuric acid method which was developed to avoid many of the disadvantages of the above discussed chemical methods. In this method, a dilute sulfuric acid solution of approximately 10% by weight of sulfuric acid and approximately 0.05% of surfactant (used as a wetting agent) in water is used to dampen the lint on the fuzzy seed. The dampened fuzzy seed is then dried in rotary driers, which are typically about six feet in diameter and about thirty feet long.
As the temperature of the dampened fuzzy seed is increased in the driers, the water in the solution, which has a lower boiling point than the acid, will begin to evaporate from the seed thereby causing the acid which remains on the seed to become more concentrated. As the acid concentration on the fuzzy seed approaches 100%, the lint is abruptly hydrolyzed by the acid and breaks off from the seed in the form of a dry powder. The powder is removed by the heated air stream used in the drying process.
The dilute sulfuric acid methods in use at the present time differ from each other primarily in the methods which are used to apply the dilute acid solution to the fuzzy seed. In the centrifuge method, the cotton seed is first flooded with dilute acid and then partially dried by centrifuging to produce basically a 10% wet pick-up on the seed. In the foam acid system, a foam generator converts the dilute acid solution to foam which is then applied to the seed. Other methods involve the direct application of the dilute acid solution to the seed.
In the dilute acid process as practiced in the prior art, the dilute acid solution is typically added in large amounts to large bulk quantities of fuzzy seed. This is done by flooding, spraying or the like of the dilute acid solution on large bulk quantities of seed as described above and requires relatively severe agitation of the seed to provide for the distribution of the acid solution throughout the seed bulk with resulting trauma to the seed. In addition, such prior art methods of applying the dilute acid solution to the fuzzy seed typically result in the application of excess acid to the seed. When subjected to the drying and hydrolyzation reaction, this excess acid can further damage the seed.
Present dilute acid systems are large, continuous process systems which are configured for continuous product throughput. Such systems have been found to be advantageous in the recovery of seed for planting in large volume commercial applications where relatively harsh conditions are acceptable and where the seed are graded after recovery depending upon the quality thereof. However, such prior art systems are not suitable for use in the recovery of "breeder seed" in relatively small quantities where, in particular, the seeds are from new varieties and therefore very valuable in the process of increasing from just a few seeds to large scale commercial quantities. In these cases, the new seed varieties which have desirable fiber characteristics may also be more easily damaged because the seed coats may be thinner or otherwise subject to damage or because the new seeds may be more vulnerable to impact, heat or other parameters typically encountered in the recovery process.
Such valuable breeder seeds can thus be subject to damage and even the loss thereof when subjected to the recovery conditions typically present in the large commercial delinters of the prior art as described above. For example, such seed may be easily damaged when subjected to vigorous agitation such as used in large commercial delinters such as those described above. The same applies to the high temperatures typically present in the driers used in the dilute acid method.
In such prior art commercial delinters, the dilute acid saturated fuzzy seed are tumbled within a large continuously rotating drum in which heated air is circulated. The saturated fuzzy seed are continuously introduced into the drum at one end thereof and continuously removed at the other end thereof. Drying and hydrolysis and carried out as a continuous process as the seed are agitated and moved axially within the drum from the input end to the exit end where the delinted seed are removed.
The whole process is thus continuous. That is, the dilute acid saturated fuzzy seed are loaded into the drum at one end and are moved axially within the drum while being agitated or tumbled to carry out drying and hydrolysis. The length of the drum and the other parameters related to the delinting process are selected such that the process is completed as the seed reach the exit end of the rotating drum. Thus, the seed are moved axially as well as radially within the drum.
In addition, the configuration and rotational velocity of the drum is such that the seed are pitched or lofted during rotation of the drum to cause them to impact the internal metal surfaces of the drum, thereby causing trauma to the seed. This trauma causes damage to the seed and reduces its suitability for planting purposes.
Accordingly, there has existed a need for a cotton seed delinting system that can be fabricated with a low capital investment and which meets the following criteria:
(a) The ability to delint seed with thin walled seed coats. Such seed is easily damaged when vigorously agitated as is the case with large commercial delinters. In such large commercial delinters, the seed coats tend to crack and fall off the seed, thereby preventing the ability to maintain high quality seed standards.
(b) The ability to delint seed at low temperatures in order to prevent heat damage to the seed. This is of particular importance when dealing with small increase lots developed at the research stage where supplies of the seed are limited.
(c) The ability to delint seed in small quantities which are in an increase program (a program to increase supply) or which are otherwise in limited supply. It has been found to be almost impossible to delint small amounts of cotton seed in continuous flow systems.
(d) The ability to be easily moved from one location to another to permit delinting on site on small land areas which would not accommodate the construction of a large scale fixed installation.
All of the foregoing criteria should be present without significant adverse impact on the environment.
It is a primary object of the present invention to provide a batch delinting system which meets at least the foregoing criteria.
SUMMARY OF THE INVENTION
The present invention provides, in one embodiment thereof, a batch delinting apparatus and method utilizing a dilute acid approach in which unique controls of the process steps are applied and regulated in such a manner as to assure that the seed, including even special varieties in the form of breeder seed, are reliably recovered at a high yield without mechanical or chemical damage to the seed. In one embodiment of the invention, a batch delinting apparatus is provided comprising a supply source of dilute sulfuric acid such as a container means of a selected size for containing a controlled volume of dilute sulfuric acid and surfactant solution and which is instrumented and controlled such that the dilution level of the dilute solution is controlled within the desired range. The supply source of dilute acid solution may also be a mixing apparatus in which supplies of concentrated acid and water and surfactant are continuously mixed through a nozzle at the point of application to the fuzzy seed. Combined with the container means of precisely controlled dilute sulfuric acid solution is a feeding and mixing apparatus which is preferably in the form of an elongated trough having a screw type feeder mounted for rotation in and extending through the lower portion thereof to gently move and combine a feed stream of fuzzy cotton seed with a feed stream of dilute sulfuric acid solution along the trough from one end to the other thereof.
The fuzzy seed and the dilute sulfuric acid solution are fed into the trough at one end thereof and moved through the trough By the screw type feeder while the seed and the dilute acid solution are gently mingled and mixed together to wet the lint with the dilute sulfuric acid solution. This gradual mixing of the two feed streams, one of the dilute acid solution and the other of the fuzzy seed, provides for thorough saturation of the fuzzy seed with the dilute acid solution in a gentle mixing action without applying excess acid to the seed. At the opposite end of the trough from the input end thereof, the lint on the fuzzy seed has thoroughly absorbed and has become substantially saturated with the dilute acid solution and the saturated fuzzy seed is removed from the trough. The surfactant in the dilute acid solution acts as a wetting agent and enhances the absorption process.
The fuzzy seed, which is saturated with dilute acid solution, is removed from the trough and fed into a batch size drying chamber which is preferably in the form of a cylindrically shaped drum. The drum is rotated to tumble the seed while a stream of heated air is directed through the drum to dry the seed and cause a hydrolysis reaction. Seed temperature is controlled by controlling exit air temperature such that the seed temperature does not exceed a level at which heat damage can occur.
The design and flight placement (the direction of the flight pattern of the seed within the chamber) of the drying chamber are selected such that the process is extremely gentle. Features of the present invention which provide such advantages are, among others, close flight placement of the seed in flight within the drying chamber, which minimizes seed agitation, design of the internal configuration of the reaction drum such that the seed cushion each other during rotation of the drum and do not to any significant degree impact the metal structure, and a low rotational speed of the drum to remove the hydrolyzed lint from the seed.
Other objects and advantages of the present invention will be explained in further detail below in connection with the appended drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a block diagram of a batch cotton seed delinting system embodying the present invention;
FIG. 2 is a schematic side view of the reaction chamber of the embodiment of FIG. 1;
FIG. 3 is an end view of the exit end of the reaction chamber of FIG. 2 taken along the plane 3--3;
FIG. 4 is an end view of the entrance end of the reaction chamber of FIG. 2 taken along the plane 4--4 of FIG. 2; and
FIG. 5 is another end view of the entrance end of the reaction chamber of FIG. 2 taken along the plane 5--5.
FIG. 6 is a cross sectional view of the reaction chamber cylindrical drum showing the placement of internal vanes within the drum for directing the flight pattern of the seed within the drum.
DETAILED DESCRIPTION OF THE INVENTION
Referring now to the embodiment of FIG. 1, which shows a block diagram of a batch type cotton seed delinter embodying the present invention, fuzzy cotton seed 11 which is to be delinted is stored in a bulk seed feeder 10. A solution 12 of sulfuric acid, surfactant and water is stored in batch tank 14. The batch tank 14 should have a storage capacity selected to accommodate precise control of the mix of the stored solution and, in a typical case, may be, for example, of a capacity of about one thousand gallons.
The solution 12 typically contains about 10% by weight sulfuric acid, 0.05% by weight surfactant, and the remainder water. It is to be understood that the solution 12 may vary from this composition over a range of constituent components although the amount of acid present should remain in the dilute range, preferably in the range of about 10% or less. The solution 12 is removed from the storage tank 14 by means of a pump 16, which pumps the solution from the tank 14 through line 18 to a discharge line 19. A portion of the solution is recirculated back to the tank 14 through a line 20 which forms a recirculation loop. Recirculation of the solution 12 within the tank 14 assures that homogeneity of the solution is maintained.
The fuzzy seed 11 is removed from the bulk seed feeder 10 by means of a suitable conveyer 22 and lb deposited at an input 24 of an acid applicator 26. In one construction of a batch delinter embodying the present invention as shown in FIG. 1, the acid applicator 26 was formed of a U-shaped trough, about twelve inches wide and about ten feet long having therein about an eight foot length of mixing paddles 28 followed by about two feet of well known auger flighting 30. Positioned at the exit end of the acid applicator 26 is an exit chute 32 for conveying the saturated fuzzy seed from the acid applicator to a reaction chamber 34.
The solution 12 is pumped from the tank 14 through the discharge line 19 to the acid applicator 26 and is introduced to the acid applicator at the input 24 thereof along with the fuzzy seed from the bulk seed feeder 10. Both the fuzzy seed 11 and the dilute acid solution 12 are introduced together as separate feed streams into the acid applicator 26 at the inlet 24 thereof. The acid solution 12 is gradually absorbed by the seed 11 as the two are mixed together and moved through the acid applicator 26 by the mixing paddles 28 and the auger flighting 30.
The separate feed streams of the fuzzy seed 11 and a feed stream of the dilute sulfuric acid solution 12 are fed together into the trough at one end thereof and moved through the trough as described above while the seed and the dilute acid solution are gently mingled and mixed together to wet the lint on the seed with the dilute sulfuric acid solution. The volume flow rates of the dilute acid and fuzzy seed feed streams are selected to provide just enough acid to fully saturate the lint on the seed after thorough mixing along the extended path in the elongated trough of the acid applicator 26. This gradual mixing of the two feed streams, one of the dilute acid solution 12 and the other of the fuzzy seed 11, over the extended flow path through the acid applicator 26 provides for thorough saturation of the fuzzy seed with the dilute acid solution in a gentle mixing action without applying excess acid to the seed.
The concentration of acid in the acid solution 12 is preferably maintained with an upper limit in the range of about 10% or so such that the fuzzy seed 11 is not subjected to a strong acid solution. This is also important for extending and maintaining the length of time over which the delinted seed will remain viable after delinting. The amount of acid solution used in relation to the seed weight is also an important factor to be controlled. In one construction of a batch type delinter embodying the present invention, it was found that the application of about fifty gallons of acid solution per ton of fuzzy seed provided excellent results.
Following application of the acid solution to the fuzzy seed, the seed is fed through the chute 32 into the reaction chamber 34. The process is controlled such that the seed remains in the reaction chamber 34 for a time interval as required for drying and lint hydrolyzation. In one embodiment of the present invention, it was found that a dwell time of the seed in the reaction chamber 34 in the range of about thirty minutes was adequate for this purpose. The exact time in each case will depend upon the amount of saturated fuzzy seed present, the dimensions of the reaction chamber and the particular process parameters which are chosen based on the principles of the invention as set forth herein.
Heated air, which is heated in a heater 36, is introduced into the reaction chamber 34 through an air inlet 37 and circulated though the reaction chamber and into a lint cyclone and collection bin 38 by means of a fan 40. The temperature of the heated air is regulated by a temperature control 36a. Air is removed from the reaction chamber 34 at the opposite end thereof through a duct 42 and delivered to fan 40 from whence it is delivered through a duct 48 to the lint cyclone and collection bin 38. Positioned within the exit duct 42 is a temperature measuring device 42a which measures the temperature of the heated air as it is discharged from the drum and provides a feedback signal for the temperature control 36a for controlling the temperature of the heated air exiting the drum. That is, the exit air temperature feedback signal from the exit air temperature sensor 42a is connected to the air temperature control 36a of the heater 36 to regulate and limit the maximum temperature of the air at the point of exit of the heated air from the drum.
Conditions in the reaction chamber 34, namely the temperature of the heated air in the reaction chamber, the level of seed agitation and the length of time in which the seed remains in the reactor are controlled such that no substantial chemical or mechanical damage is done to the seed in the drying and hydrolysis process. For example, in one construction of a batch type delinter embodying the present invention, the temperature of the exit air at the exit duct 42 from the reaction chamber 34 was maintained at or below about 130° F. to 140° F. while an air volume flow of about 5,000 cubic feet per minute was maintained for seed charges in the range of up to about 4,000 pounds. These conditions assured that the seed temperature never exceeded the exit air temperature of about 130° F. to 140° F. During the drying and hydrolyzation process, the rotational speed of the drum was maintained at a substantially constant speed selected within the range of about 18 to 22 revolutions per minute and preferably less than about 30 revolutions per minute. In addition, the flight pattern of the seed within the drum is further controlled by the internal configuration of the drum such that, during the rotation of the drum, the seed fall back on themselves within the drum and are thus cushioned against direct impact with the interior metal walls of the drum. The manner in which this is accomplished will be set forth in detail below. It was found that the speed of the drum should be maintained substantially constant and that, for the embodiment presented herein, a substantially constant rotational speed of less than about 30 revolutions per minute and preferably within the range of about 18 to 22 revolutions per minute produced good results. It was found that these conditions provided gentle delinting of the fuzzy seed and allowed recovery of batches of virtually undamaged delinted seed suitable for replanting.
The lint on the fuzzy seed is dried and hydrolyzed in the reaction chamber 34 and the hydrolyzed lint is carried off through the discharge duct 42 through the fan 40 to the lint cyclone and collection bin 38. After the lint has been dried and hydrolyzed in the reaction chamber 34 and carried off to the lint cyclone and collection bin 38, the delinted seed is removed from the reaction chamber through a discharge gate 50.
The delinted seed is then processed though a screen air cleaner 52, a gravity separator 54 and a seed treater 56 to a clean seed bulk holding tank 58. The delinted seed, which is now suitable for planting, may then be delivered to a packaging area 60 for packaging for further use.
Flow control devices 51, 53, 55, 57 and 59 may be employed to control the flow at each of the steps just described.
In a particular embodiment of the delinting system illustrated in block diagram form in FIG. 1, the reaction chamber 34 is shown in further detail in FIGS. 2, 3, 4, 5 and 6. With reference to FIG. 2, the reaction chamber 34 comprises an outer housing 72 in which is mounted an open ended cylindrical drum 70. The drum 70 is mounted on a shaft 74 which is supported for rotation at the opposite ends thereof in bearings 76 and 78. The drum 70 is supported on the shaft 74 by means of radial spokes which are not shown in the cross sectional view of FIG. 2. In this embodiment, the acid applicator 26 is mounted above the housing 72 with a discharge chute 80 positioned at the exit end of the acid applicator and connected to the interior of the housing 72 and the drum 70 to feed the acid solution dampened fuzzy seed into the reactor chamber 34. Positioned within the drum 70 are a plurality of radially inwardly extending guide vanes 100, the function of which will be explained below in connection with the descripticn of FIG. 6.
As best seen in FIG. 4, a heated air entrance 82 is positioned adjacent the seed entrance chute 80. At the opposite end of the housing 72 from the chute and the heated air entrance 82, there is positioned a heated air exit 84. Below the heated air exit 84, there is positioned an exit door 86 which is hinge mounted in the housing 70 to permit the removal of nhe delinted seed from the reactor. Directly below the exit door 86, there is positioned a conveyor belt 88 which conveys away the delinted seed discharged from the exit door 86. The axis of rotation of the drum 70 is inclined slightly with respect to the horizontal, preferably less than about 10°, so that the interior surface thereof slopes gently toward the exit end of the drum where the exit door 86 is located. This allows the gradual movement of the seed in the direction of the exit door and facilitates the removal of the delinted seed at the exit door 86.
The drum 70 is continuously rotated during the delinting process by an electric motor 90 connected through a gear box 92 to drive the shaft 74 of the drum 70. The rotational speed of the drum 70 is sensed by a suitable speed sensor (not shown) and the speed is regulated at the desired substantially constant rotational speed by feedback control from the drum speed sensor to the electric motor 90 employing any suitable motor speed control system well known to those skilled in the art. As stated above, the rotational speed of the drum 70 is regulated at a substantially constant speed which, for the particular embodiment presented herein, was selected to be in the range of less than about 30 revolutions per minute and preferably about 18 to 22 revolutions per minute.
The size of the batch quantity which is selected for processing in the drum 70 is such that, in relation to the size of the drum and the parameters of heated air flow, the seed is not crushed or severely impacted in the process of evaporating the water from the dilute acid solution to concentrate the acid and hydrolyze the lint on the fuzzy seed. It has been found that excellent recovery was effected of delinted seed suitable for planting with a drum size of about six feet in diameter and ten feet long, a dilute acid saturated seed charge of up to 4,000 pounds with a heated air volume flow rate of about cubic feet per minute and an exit air temperature of about 130° F. to 140° F.
FIG. 3 shows the exit end of the apparatus of FIG. 2 in cross section along the plane 3--3 of FIG. 2. In addition to the heated air exit 84 and the exit door 86, there is provided an inspection entrance 85 for allowing visual inspection of the interior of the reaction chamber 34.
In the operation of the embodiment of FIGS. 1-5, fuzzy seed to be delinted is first gently saturated with dilute acid solution in the acid applicator 26 and is then introduced as described above into the reaction chamber 34 for drying and hydrolyzation. The flight path of the saturated seed as it is tumbled within the rotating drum 70 of the reaction chamber 34 is selected such that the tumbling action within the rotating drum 70 is extremely gentle. The close flight placement within the rotating drum 70 minimizes seed agitation and assures that the seed cushion each other while being tumbled and that the seed do not to any significant degree impact the metal structure of the drum 70.
FIG. 6 shows a preferred internal configuration of the drum 70 in which guide vanes 100 extending radially inwardly from the outer periphery of the drum to guide the flight path of the seed within the drum 70. In the embodiment illustrated in FIG. 1, in which the radius of the drum is about three feet, the vanes 100 extend radially inwardly about nine inches and there are nine guide vanes 100 which are spaced apart from each other by about 24.5 inch chords. That is, for the particular embodiment illustrated in FIG. 1, where the radius of the drum is about three feet, the guide vanes 100 extend radially inward by an amount preferably less than about one-third of the radius, in this case by about nine inches. The number of guide vanes is nine in the preferred embodiment but can be selected in relation to the radial dimension and other conditions. However, the total number of guide vanes should be less than about twelve to fifteen and preferably about nine as illustrated in FIG. 6.
As shown in FIG. 6 and for the direction of rotation as indicated by the arrow, the seed mass 101 remains essentially intact as it is lifted from the bottom position and toward the upper portion of the rotation and then begins to disperse into discrete seeds and clumps of seeds shown as falling seed 102 in FIG. 6. The dimensions and placement of the guide vanes 100 and the precise rotational control of the rotation of the drum are selected so that there is little movement of the seed as it is being lifted from the bottom position to the Cop of the drum where it is dropped back through the heated air stream. Seed being dropped back from the top position therefore impact back upon themselves to cushion their fall so that direct impact with the metal walls of the drum, which could cause physical impact damage to the seed, is avoided. That is, the falling seed descending from the top of the drum fall back on the seed mass 101 and are thus cushioned against impact with the internal surfaces of the drum 70.
The use of the internal vanes thus avoids random tumbling of the seed within the rotating drum and precisely controls the flight pattern of the drying seed to avoid damage to the seed while the seed is being dried and the lint hydrolyzed.
The apparatus and method of the present invention thus meet the criteria first set forth above and provide a batch type method and apparatus which can economically delint and recover small quantities of valuable seed, such as breeder seed, without damaging the same and which are suitable for replanting purposes. It is to be understood that the embodiments presented herein are for the purpose of providing a full and clear disclosure of the present invention. Various changes and substitutions will occur to those skilled in the art, it being understood that the embodiments presented do not limit in any way the scope of the present invention as defined in the appended claims. | A method and apparatus for recovering cottonseed from the lint in batch quantities for planting purposes. The system utilizes a dilute acid approach and provides for gradual mixing of the fuzzy seed and a dilute acid solution followed by batch drying and hydrolysis in a rotating drum reaction chamber in which heated air at a controlled temperature is circulated. The process conditions and the flight pattern of the fuzzy seed within the rotating drum are controlled to avoid trauma to the seed and thereby assure suitability of the recovered seed for planting purposes. | 3 |
SUMMARY
[0001] An embodiment of the present disclosure includes an apparatus that comprises a slider body of a disk drive. The slider body is electrically coupled to a plurality of end bond pads. A voltage applied to one or more of the end bond pads sets a surface potential of the slider body.
[0002] A method embodiment of the present disclosure includes fabricating a slider body on a wafer, wherein the wafer includes a plurality of end bond pads that are electrically coupled to the slider body. The method further includes establishing a voltage delivery configuration at one or more of the end pads. The voltage delivery configuration is configured to set a surface potential of the slider body.
[0003] Another embodiment of the present disclosure includes a slider body and means for setting a surface potential of the slider body. The slider body is electrically coupled to a plurality of end bond pads and the means for setting surface potential of the slider body does so through use of at least one of the end bond pads.
[0004] The above summary is not intended to describe each embodiment or every implementation. A more complete understanding will become apparent and appreciated by referring to the following detailed description and claims in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0005] FIG. 1 is a schematic representation of a slider in which the various embodiments disclosed herein may be implemented.
[0006] FIG. 2 is a schematic representation of end bond pads on the trailing edge of the slider of FIG. 1 .
[0007] FIGS. 3A-3B illustrate configurations wherein various end bond pads and accompanying circuitry are used to establish slider body surface potential in accordance with disclosed embodiments.
[0008] FIGS. 4A-4C illustrate configurations wherein various end bond pads and accompanying circuitry are used to establish slider body surface potential in accordance with disclosed embodiments.
[0009] FIGS. 5-6B illustrate configurations wherein various end bond pads and accompanying circuitry are used to establish slider body surface potential in accordance with disclosed embodiments.
[0010] FIGS. 7-8 illustrate configurations for bleed resistor balancing in accordance with disclosed embodiments.
[0011] FIG. 9 illustrates a configuration for establishing a potential for metallic features on the air bearing surface of a slider in accordance with disclosed embodiments.
[0012] The figures are not necessarily to scale. Like numbers used in the figures refer to like components. However, it will be understood that the use of a number to refer to a component in a given figure is not intended to limit the component in another figure labeled with the same number.
DETAILED DESCRIPTION
[0013] The embodiments of the present disclosure are directed to systems and methods for setting surface potential of a slider of a disk drive. The systems and methods for setting and/or controlling surface potential can be achieved by making wafer-level changes to the read-write head circuitry, which includes applying a voltage at the end bond pads of the slider wafer.
[0014] The basic components of a hard disk drive (HDD) include a disk that is rotated, an actuator that moves a transducer to various locations on or over the disk, and electrical circuitry that is used to write and read data to and from the disk. Further, an HDD includes a microprocessor that controls most of the operations of the system. The microprocessor utilizes circuitry to encode data so that it can be successfully retrieved from and written to a medium on the disk.
[0015] The transducer translates electrical signals into magnetic field signals that actually record the data. The transducer is usually housed within a small ceramic block called a slider. The slider is passed over the rotating disk in close proximity to the disk. The transducer is used to read data from the disk or write information representing data to the disk.
[0016] Sliders are aerodynamically designed to fly on a cushion of air that is generated due to rotating the disks at high speeds. The slider has an air-bearing surface (ABS) that may include rails and a cavity or depression between the rails. The air-bearing surface is that surface of the slider nearest to the disk as the disk drive is operating. Air is dragged between the rails and the disk surface causing an increase in pressure that tends to force the head away from the disk. Air is simultaneously rushing past the cavity or depression in the air-bearing surface which produces a lower than ambient pressure area at the cavity or depression. The low-pressure area near the cavity counteracts the higher pressure at the rails. These opposing forces equilibrate so the slider flies over the surface of the disk at a particular fly height. The fly height is the distance between the disk surface and the transducing head. This distance is typically the same as the thickness of an air lubrication film. This film minimizes the friction and resulting wear that would occur if the transducing head and disk were in mechanical contact during disk rotation.
[0017] Information in the form of data is stored on the surface of the disks. The data is divided or grouped together on the disks in certain portions or tracks on the disks. In some disk drives the tracks are a multiplicity of concentric circular tracks. Disk drive systems are configured to read and write information that is stored on the disks in one or more of the tracks.
[0018] The transducers are in the form of read/write heads that are attached to the sliders. The transducers read and write information to/from the storage disks when the transducers are accurately positioned over one of the designated tracks on the surfaces of the storage disks. As the storage disks spin, the appropriate read/write head is accurately positioned above the target track where the read/write head is able to store data onto a track by writing information representative of data onto the one of the disks. Similarly, reading data on a storage disk is accomplished by positioning a read/write head above the proper track, and reading the stored material from one of the storage disks. In heat-assisted magnetic recording (HAMR), an energy source, e.g., a laser, is additionally provided upon or within the slider to aid in heating the disk prior to a write operation.
[0019] In order to write on (or read from) different tracks, the read/write head is moved radially across the tracks on the disk to a designated target track. Servo feedback information is used to accurately locate the transducer. The disk drive control system moves the actuator assembly to the appropriate position using the servo information. The servo information is also used to hold the transducer in a steady position during a read or write operation.
[0020] The best performance of the disk drive results when a slider is flown as closely to the surface of a disk as possible. During operation of a disk drive, the distance between the slider and the disk is very small, on the order of several nanometers. The constant demand for increasing hard drive recording density has resulted in a drastic decrease in fly height over the years. Variation in the fly height represents an increasingly complicated source of problems due to head/media intermittent contact. Intermittent contact induces vibrations that are detrimental to the reading/writing quality and may also eventually result in a head crash that causes the loss of data.
[0021] The slider body may be formed from a ceramic wafer. The transducers are built on the wafer using conventional semiconductor processing techniques. The transducers are then encapsulated in an overcoat such as alumina. The wafer is sliced to form rows of individual heads and subsequently lapped to an appropriate dimension and surface finish. The individual heads are then diced from the rows to form individual sliders.
[0022] The interface between the alumina, and the substrate typically includes the closest point between the slider and the disk when the slider is passing over the surface of the disk in transducing relation. As a result, if there is any variation in the fly height, this closest point is a likely contact point between the slider and the disk.
[0023] One source of variation in the fly height results from the differences in thermal expansion between the ceramic substrate and the transducer during operation of the disk drive. Due to intrinsic properties, the ceramic substrate and the transducer expand at different rates as the slider heats up. The differences in expansion cause the transducer to move closer to the disk surface than the substrate that is near the transducer, This change in spacing can affect the fly height of the slider. The varying fly height can cause poor disk drive performance during reading and writing operations. In addition, if the fly height becomes too small, there is likely to be contact between the slider and the disk during operation of the disk drive.
[0024] Other sources of variation in the fly height that can negatively affect the fly-height of the slider are lubricant-slider interaction, such as lube pickup, and electrostatic force. The negative effects of both of these items can be diminished and/or eliminated by controlling the voltage potential of the slider with respect to the potential of the disk. Therefore, controlling the voltage of the slider reduces slider wear and allows for lower flying-heights
[0025] A side view of a slider 102 is illustrated in FIG. 1 . The slider 102 includes a slider body 104 and a transducer portion 106 provided within overcoat 108 at the trailing edge of the slider 102 . The slider 102 is attached via suspension 110 to an arm 112 . The air bearing surface 114 of the slider 102 is shown proximate the surface 116 of a disk 118 . The fly height 120 is also indicated. FIG. 2 illustrates the bond pads 200 on the trailing edge of the slider 102 . These bond pads 200 are directly connected through the overcoat 108 to various components, e.g., reader, writer, heater, and temperature sensor, within the slider 102 . The configuration of FIG. 2 illustrates the current industry standard of nine pads which include bond pads R+ and R− for the reader, W+ and W− for the writer, GND for ground (which defines the ground potential of the slider body 102 ), DETCR+ and DETCR− for the temperature sensor (in this instance a dual-ended temperature coefficient of resistance sensor), and HTR 1 and HTR 2 for the heaters. During fabrication of an HDD 102 , the bond pads are electrically connected to the electrical connections (e.g., traces) along the suspension 110 . Typically, a conventional gold ball soldering operation is used to make the electrical connections from the bond pads of the slider 102 to the electrical connections of the suspension 110 . It should be noted that more or less bond pads may be used as appropriate to a specific application, e.g., the need for a dedicated bond pad, additional bond pads to accommodate additional readers, writers, heaters or sensors, additional bond pads to accommodate a HAMR laser, etc.
[0026] The embodiments presented herein below involve modifications to the wafer layout to enable surface potential setting/surface charge control of the slider 102 . FIGS. 3A-6 show the various end bond pad 200 configurations through which voltage may be applied to set the surface potential of the slider 102 . FIG. 3A illustrates an embodiment wherein the end bond pads 200 and circuitry of a DETCR temperature sensor, which is modified by utilizing a common mode voltage that is bled to ground, are used to establish the surface potential of the slider 102 body. The DETCR circuit uses a differential voltage across two end bond pads 200 , DETCR+ and DETCR−, to sense thermal fluctuations at a resistive element, R 1 . Modifying the circuit and adding a common mode voltage to both end bond pads 200 , DETCR+ and DETCR−, through use of resistors R 2 and R 3 , allows this common mode voltage to appear on the slider 102 body; the common mode voltage is bled to ground 200 , GND, through resistor R 4 . In addition to the common mode voltage, a differential voltage can be applied across the DETCR end bond pads 200 , DETCR+ and DETCR−, enabling the primary function of the DETCR, e.g., sensing thermal fluctuations. FIG. 3B illustrates an alternative embodiment of the DETCR end bond pad 200 configuration of FIG. 3A wherein the common mode voltage is isolated from ground 200 , GND, i.e., resistor R 4 has been eliminated and the DETCR circuit is not connected to ground, GND; however, the common mode voltage, through use of resistors R 2 and R 3 , may still be used to set a voltage on the slider 102 body.
[0027] FIGS. 4A-4C illustrate additional embodiments for setting/controlling surface potential of the slider 102 body through use of end bond pads 200 . In FIG. 4A , surface potential is set by the voltage applied to a dedicated end bond pad 200 , SCC (surface charge control). In FIG. 4B , a resistor R 1 is fabricated between the dedicated end bond pad 200 , SCC, and the slider 102 body wherein the voltage applied through the resistor R 1 to the dedicated end bond pad 200 , SCC, establishes the slider 102 surface potential. In FIG. 4C , a resistor R 2 is included between the slider 102 and ground 200 , GND, such that a fraction of the voltage applied to the dedicated end bond pad 200 , SCC, is bled to ground 200 , GND, and the remaining voltage establishes the slider 102 surface potential.
[0028] FIG. 5 illustrates another embodiment where the surface potential of a slider 102 is established through use of end bond pads 200 . In this instance, the slider 102 comprises an element of a HAMR disk drive where an energy source, e.g., a laser, is mounted within or upon the slider 102 to provide heating to an underlying magnetic recording medium prior to or during a write operation. The use of a laser requires modification of the end bond pads 200 to include laser power monitor end bond pads 200 , LPM 1 and LPM 2 . The laser power monitor element, LPM, may be: (1) a thermal coefficient of resistance temperature sensor, e.g., a DETCR; (2) a thermocouple temperature sensor; or (3) a photodiode. Each of these elements work based on a differential voltage, thus a common mode voltage applied to both end bond pad 200 terminals, LPM 1 and LPM 2 , through resistors R 1 and R 2 , does not interfere with the laser power monitor, LPM, primary function of monitoring laser power.
[0029] FIGS. 6A-6B illustrate embodiments wherein the DC voltage of an AC signal is used to establish the surface potential of the slider 102 . In this configuration, an AC heater signal is injected into the circuit via the heater end bond pad 200 , HTR. An inductor L 1 allows the passage of the DC voltage of the AC signal to charge/establish the slider potential of the slider 102 . The combination of a resistor and capacitor, e.g., R 1 -C 1 ( FIG. 6A ) or C 1 -R 1 ( FIG. 6B ), connects the heater circuit to ground 200 , GND. The capacitor C 1 allows passage of the AC signal required to power the heater. The heater is located in the circuit at a position beyond where the DC signal and AC signal diverge to ensure the heater is exclusively drive by the AC signal as the heater can respond to both an AC signal and a DC signal.
[0030] As noted above, it may be desirable to bias the slider 102 body through use of end bond pads 200 with an AC voltage. Applying a common mode voltage to a differential sensor such as the DETCR or laser power monitor can lead to noise in the differential sensor signal if the bleed resistors on the circuit are imbalanced. In the case of imbalanced bleed resistors, the electrical impedance is different between the sensor ends and ground. Because of this difference, a common mode voltage applied to both ends of the sensor will result in a differential voltage between the ends of the sensor. This differential voltage is interpreted as a sensor signal, reducing the signal-to-noise ratio of the sensor. Various schemes to improve the bleed resistor balancing enable AC biasing of the slider body. Two possible schemes are illustrated in FIGS. 7 and 8 , which are further described below.
[0031] FIG. 7 illustrates a design for enhanced bleed resistor balancing. Large low resistance contacts are shown as items 702 and 704 . As an example, a DETCR sensor, which is a resistive sensor, includes sensor resistance primarily in the region identified as item 706 . The circuit is bled from the center of the DETCR resistive sensor, along region 708 , which is made of a material with higher electrical resistivity than the sensor region 706 . The bleeder feature is placed in the center of the sensor region 706 so that the resistance between either contact ( 702 , 704 ) and ground 200 , GND, are equal.
[0032] A second scheme for enhancing bleed resistor balancing is disclosed with reference to FIG. 8 . Again, the DETCR sensor is used as an example. This application is not limited to DETCR, but can also be applied to a magnetic read sensor, laser power monitor, or any other sensor in the head. In FIG. 8 , resistor R 1 is the sensor region of the circuit. A differential voltage across resister R 1 is used as a sensor signal. The bleed resistance path includes resistors R 2 , R 3 and R 4 . In this embodiment, bleed resistor R 4 is common to both ends of the sensor circuit. This enhances bleed resistor balancing because this single feature contributes the same electrical resistance to both ends of the sensor. Resistors R 2 and R 3 should be built to be as equal as possible in terms of resistance. The sum of resistances R 2 and R 3 is balanced against the sensor resistance R 1 . The resistance of R 2 plus R 3 should be large enough to prevent signal degradation due to decreased current flow across resistor R 1 .
[0033] The surface potential of metal features on the air bearing surface can be controlled along with the control of the slider body surface potential. In FIG. 9 , the recording media is shown as 901 . The slider body 902 flies above the recording media 901 and is supported by an air bearing. The techniques described earlier provide ways for setting the potential on the conductive portion 903 of the slider body 902 . Material 904 within the slider body 902 is non-conductive but contains within it conductive structures 905 and 906 . In this example, item 905 corresponds to the metallic reader shields while item 906 corresponds to the metallic writer shields. However, this concept is applicable to any conducting structure on the surface of the slider facing the recording media 901 . Metallic reader shields 905 and metallic writer shields 906 may be electrically connected to the conductive portion 903 of the slider body 902 to match the potential applied to the conductive portion 903 of the slider body 902 . Alternatively, metallic reader shields 905 and metallic writer shields 906 may be electrically connected to the ground and maintain a potential different from the conductive portion 903 of the slider body 902 .
[0034] Systems, devices or methods disclosed herein may include one or more of the features structures, methods, or combination thereof described herein. For example, a device or method may be implemented to include one or more of the features and/or processes above. It is intended that such device or method need not include all of the features and/or processes described herein, but may be implemented to include selected features and/or processes that provide useful structures and/or functionality.
[0035] Various modifications and additions can be made to the disclosed embodiments discussed above. Accordingly, the scope of the present disclosure should not be limited by the particular embodiments described above, but should be defined only by the claims set forth below and equivalents thereof. | An apparatus includes a slider body of a disk drive. The slider body is electrically coupled to a plurality of end bond pads. A voltage applied to one more of the end bond pads sets a surface potential of the slider body. | 6 |
RELATED APPLICATION
This patent application claims benefit of U.S. Provisional patent application 60/415,582 filed Oct. 2, 2002.
TECHNICAL FIELD
This invention relates generally to a power operated sliding door closure system for opening and closing a sliding door on a vehicle and more particularly to a cable drive assembly for such a system.
BACKGROUND OF THE INVENTION
Van type vehicles for passengers and for cargo are frequently equipped with sliding side doors. Many vans include a single sliding door on the passenger side of the van. However, the van may be equipped with sliding doors on both sides. Drivers and passengers can open or close sliding doors of this type manually from inside or outside of the vehicle. However, the sliding door is usually heavy and often inconvenient and/or difficult to move manually, particularly from inside the vehicle.
For convenience, power operated sliding door closure systems have been developed to allow drivers and passengers to open and close a sliding door virtually effortlessly. Moreover the sliding door usually can be opened or closed from the driver's seat and/or one or more other locations remote from the sliding door.
One type of power operated sliding door closure system, known as a “closed loop” system, is disclosed in U.S. Pat. No. 5,396,158 which issued Mar. 7, 1995 to Joseph D. Long et al. The Long et al. '158 patent discloses a power operated sliding door closure system in which a sliding door is mounted on a van by travelers that are slidably supported in upper, center and lower tracks. An opening and closing module is mounted inside the van adjacent the center track. A front cable is attached to a front cable drive pulley or drum and extends from the front drum to the traveler through a front cable roller guide assembly. A rear cable is attached to a rear cable drive pulley or drum and extends from the rear drum to the traveler through a rear cable roller guide assembly. The front and rear cable drive drums each have a large diameter helical cable groove.
A motor drive unit rotates the front and rear cable drive drums to move the sliding door. The motor drive unit, as best shown in FIG. 3 of the Long et al. '158 patent, comprises an electric motor that drives a drive gear that is coaxially aligned with the front and rear cable drive drums. A coil spring is seated in an annular opening in the cable drive drums. An upper spring end is anchored on the rear cable drive drum and a lower spring end is anchored on the front cable drive drum. The coil spring is a tension retaining spring that urges the front cable drive drum in the counterclockwise winding direction and the rear cable drive spool in the opposite clockwise winding direction so that the front and rear cables are maintained in tension at all times.
While the “closed loop” type of system disclosed in the Long et al. '158 patent is satisfactory for its intended purpose, assembly of the system may be difficult because of the tension retaining spring that takes up slack and insures that the front and rear cables are maintained in tension at all times. Considerable slack is often desired to facilitate assembly of the closed loop system because the traveler (roller hinge assembly shown at 26 in the Long et al. '158 patent) must be inserted into the track (usually the center track shown at 18 in the Long et al. '158 patent) after the ends of the front and rear cables are attached to the traveler. However, the coil spring in the system noted above, must be tensioned or wound up to provide any slack at all and even then the slack may not be enough to facilitate insertion of the traveler into one end of the track. Furthermore even with sufficient slack, the cables may not position the traveler correctly for insertion into the one end of the track.
Another way to take up slack in a “closed loop” system is disclosed in the U.S. Pat. Nos. 5,319,880 and 5,319,881 granted to Howard W. Kuhlman Jun. 14, 1994. These patents disclose a mechanical take-up device comprising a small cable slack take-up pulley 174 and a cooperating tooth rack 172 mounted on the cable pulley. One end of one of the cables is attached to the small cable slack take-up pulley. After both cables are attached to the traveler and the traveler is inserted into the track, the cable slack is taken up by rotating the small cable slack take-up pulley with a special tool. See also pending patent application Ser. No. 09/970,167 filed Oct. 3, 2001. The mechanical take up device facilitates assembly by allowing sufficient slack in the cables. However, the cables still may not position the traveler correctly. Moreover, the take-up device is complicated and expensive and requires a special tool for operation.
SUMMARY OF THE INVENTION
According to the invention, a cable drive assembly for a power operated sliding door closure system on a vehicle is provided that facilitates insertion of a traveler into a track and takes up slack in the cables attached to the traveler in an efficient and unique manner.
The drive assembly includes front and rear drums with helical front and rear cable grooves respectively that are supported for rotation about a longitudinal axis. A front cable extends from the front cable groove to a traveler attached to a vehicle sliding door in a position to be wound into and unwound from the front cable groove in response to front drum rotation in respective opposing directions about the longitudinal axis. A rear cable extends from the rear cable groove to the traveler for the sliding door in a position to be unwound from and wound onto the rear cable groove in response to rear drum rotation in respective opposing directions about the longitudinal axis. The cable drive unit also includes a spring that biases the front drum and the rear drum in opposite directions to maintain the front and rear cables in tension.
The front and rear drums are configured to provide a catch that holds the front and rear drums in a cocked condition where the spring is tensioned so that the cable purposely has slack to facilitate inserting the traveler into a track during assembly. The cocked drums are rotatable in a drum housing which has a catch release. The cocked drums are manually rotated in the drum housing in one direction, preferably by pulling on one of the cables, to move the traveler and position the traveler for insertion into one end of the track. After the traveler has been inserted into the track, the cocked drums are manually rotated in the drum housing in the opposite direction, preferably by pulling on the other cable. This operates the catch release in the drum housing which releases the catch holding the drums in the cocked condition. When released, the spring rotates the drums relative to each other and takes up the slack in the cables.
BRIEF DESCRIPTION OF THE DRAWINGS
These and other features and advantages of the invention will become apparent to those skilled in the art in connection with the following detailed description and drawings, in which:
FIG. 1 is a schematic perspective view of a power operated sliding door closure system having a cable drive assembly constructed according to the invention.
FIG. 2 is an exploded perspective view of a cable drive assembly constructed according to the invention;
FIG. 3 is an opposite end view of one of the cable drums shown in FIG. 2 ;
FIG. 4 is a section of the cable drive assembly showing the cable drums, in a cocked position;
FIG. 5 is a section similar to FIG. 4 showing the cocked cable drums being rotated in the cable drum housing in a first direction to position a traveler for insertion into the end of a guide track;
FIG. 6 is a section similar to FIG. 4 showing the cocked cable drums being rotated in the cable drum housing in an opposite direction to release the cocked cable drums so that the cable tensioning spring takes up the slack in the cables;
FIG. 7 is a section taken substantially along the line 7 — 7 of FIG. 5 looking in the direction of the arrows.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
A closed loop power operated sliding of a door closure system for opening and closing a sliding door on a vehicle is generally shown at 20 in FIG. 1 . In FIG. 1 the system 20 is shown configured to be installed in a van that includes a sliding door supported on a plurality of tracks mounted on a vehicle frame, typically a top track, a bottom track and a center track. The system 20 includes a traveler, shown at 22 in FIG. 1 , that connects the closure system 20 to the sliding door (not shown). The door closure system moves the sliding door and traveler 22 along one of the tracks, usually the center track shown at 21 in FIG. 1 , between a closed position and an open position. The closed loop cable closure system 20 is mounted on the vehicle frame and includes a cable drive assembly 24 .
The cable drive assembly 24 constructed according to the invention may be used in a closed loop cable closure system 20 such as that described in U.S. Pat. No. 5,396,158 which is described above and incorporated herein by reference.
Referring now to FIG. 2 , the cable drive assembly 24 comprises a motor sub-assembly 26 that is attached to the exterior of a housing 28 . Motor sub-assembly 26 includes a reversible electric motor 30 that drives a reduction gear unit 32 that has an output shaft 34 . Output shaft 34 extends into housing 28 on a longitudinal axis 36 to drive an electromagnetic clutch indicated generally at 38 . Electromagnetic clutch 38 is disposed inside housing 28 along with an interrupter 40 , a front drum 42 , a tension spring 44 , and a rear drum 46 . Housing 28 is closed by a cover 48 .
Interrupter 40 comprises a plate having an integral annular sleeve 41 that is journalled on shaft 34 for concentric rotation about shaft 34 and longitudinal axis 36 . Sleeve 41 extends through respective bores of front and rear drums 42 , 46 and supports the front and rear drums 42 , 46 rotationally on axis 36 . The free end of sleeve 41 attaches to a friction output plate of electromagnetic clutch 38 . The plate of the interrupter 40 has a plurality of circumferentially spaced windows that cooperate with an optical sensor (not shown) to determine the speed and location of the van door (not shown) in the opening and closing operations. The output shaft 34 of the motor sub-assembly 26 extends through annular sleeve 41 of the interrupter 40 and drives the input member of the electromagnetic clutch 38 . Electromagnetic clutch 38 operates in a conventional manner to drive the friction plate of the electromagnetic clutch 38 when energized while allowing free rotation of the friction plate when deenergized. This facilitates manual operation of the van door by eliminating the necessity to back drive electric motor 30 .
Front drum 42 is cup shaped having an end wall with a large diameter rim 50 that includes a helical front cable groove 52 and a cable anchor slot 54 in rim 50 that communicates with the front cable groove 52 as best shown in FIG. 2 . Front drum 42 has an integral pin shaped lug 55 that extends from rim 50 in an axial direction. Lug 55 serves as a spring anchor and as well as a catch lug as explained below.
Rear drum 46 is also cup shaped having a large diameter outer rim 56 that includes a helical rear cable groove 58 and a reduced diameter hub 60 . A radial wall 62 and radial ribs 64 connect rim 56 to hub 60 . The radial ribs 64 are on one side of wall 62 . The space between rim 56 and hub 60 on the other side of wall 62 provides an annular spring chamber 66 of about 350° as best shown in FIG. 3 . Chamber 66 has a pin shaped spring anchor lug 68 at one end and a fixed stop 70 at the other end. Stop 70 is part of a trapezoidal lug 72 of about 10° that fills the space between rim 56 and hub 60 . Lug 72 also provides a cable anchor slot 74 .
Rear drum 46 includes a spring catch 76 comprising an accurately shaped, flexible cantilever arm 78 attached to an end of radial wall 62 . Catch 76 includes a moveable stop face 80 near the free end of flexible arm 78 and a ramp 82 leading up to stop face 80 from a point closer to the fixed end of the flexible arm 78 . Catch 76 also has a cam follower 84 . Cam follower 84 is bidirectional having inner and outer cam follower surfaces 86 and 88 that are ramped at opposite ends resulting in a diamond or parallelogram like shape for the follower 84 . The cam follower 84 is attached to the free end of the flexible arm 78 at one side so that the entire peripheral surface of the cam follower 84 that provides the cam follower surfaces 86 and 88 is engageable by a cam as explained below.
Rear drum 46 is partially nested in front drum 42 with its rim 50 juxtaposed rim 56 as best shown in FIG. 4 . Tension spring 44 is disposed in spring chamber 66 with one end attached to spring anchor lug 55 and the other end attached to spring anchor lug 68 . When in tension, tension spring 44 biases front drum 42 counterclockwise and rear drum 46 clockwise as viewed in FIG. 2 .
Tension spring 44 is pre-tensioned by rotating front drum 42 clockwise with respect to rear drum 46 until spring anchor lug 55 engages ramp 82 as shown in phantom in FIG. 4 and then continues along the ramp 82 until it snaps behind stop face 80 of spring catch 76 as shown in solid line in FIG. 4 . Drums 42 and 46 are now in a cocked condition. Stop 70 of lug 72 limits further clockwise rotation. Cocked drums 42 and 46 are disposed inside housing 28 which has a catch release 90 attached to cover 48 .
Catch release 90 comprises a flexible strip 92 of cover 48 which supports a cam 94 . Cam 94 is bidirectional having inner and outer cam surfaces 96 and 98 that are ramped at opposite ends resulting in a diamond or parallelogram like shape for the cam 94 . Cam 94 is attached to the flexible strip 92 at one side so that the entire peripheral surface of cam 94 that provides cam surfaces 96 and 98 is engageable by cam follower 84 as shown in FIG. 7 and further explained below.
Front and rear cables 100 and 102 shown in FIG. 1 , are anchored in drums 42 and 46 respectively and wound in opposite circumferential directions around the respective drums 42 and 46 . Cables 100 and 102 extend from the respective drums 42 and 46 in the opposite tangential directions and out respective exits of housing 28 . In operation, front cable 100 wraps onto front drum 42 while rear cable 102 unwraps from rear drum 46 and vice-versa.
The front cable 100 extends from the front cable groove of drum 42 to the sliding door traveler 22 in a position to be wound onto the drum 42 and into the front cable groove in response to front drum 42 and front cable groove rotation about the longitudinal axis 36 in a forward direction (counterclockwise as shown in FIG. 1 ) which closes the sliding door of the van (not shown). When the drum 42 and front cable groove rotate in a reverse or clockwise direction, opposite the forward direction to open the sliding door, the front cable 100 winds off of the drum 42 and out of the front cable groove.
Similarly, the rear cable 102 extends from the rear cable groove to the sliding door traveler 22 in a position to be wound off of the drum 46 from the rear cable groove in response to drum 46 and rear cable groove rotation about the longitudinal axis 36 in the forward or counterclockwise direction which closes the sliding door. When the drum 46 and rear cable groove rotate in the reverse or clockwise direction to open the sliding door, the rear cable 102 winds onto the drum 46 into the rear cable groove.
The cable drive assembly 24 with cables 100 and 102 is manufactured at one location and then delivered to an assembly plant where it is attached to a vehicle so as to become a part of the power operated sliding door closure system shown in FIG. 1 .
In initial steps of the assembly process, cable drive assembly 24 is attached to a vehicle and cables 100 and 102 are attached to the traveler 22 . Traveler 22 must then be inserted into the guide track 21 which has already been attached to the vehicle as part of the body build.
When attached to the vehicle, cable drive assembly 24 is in the cocked condition which provides slack in cables 100 and 102 to facilitate insertion of traveler 22 into guide track 21 . However, traveler 22 may not be positioned correctly for insertion into the end of the guide track 21 . For instance, the traveler 22 should be positioned at 23 as shown in FIG. 1 whereas traveler may be positioned a few feet away from this ideal location.
Traveler 22 can be moved to the ideal location at 23 easily because of the bidirectional nature of cam 94 and cam follower 84 . The cocked drums 42 and 46 are simply rotated relative to the housing 28 in the proper direction as shown in FIG. 5 . When the cocked drums 42 and 46 are rotated in this direction, catch 76 is not released. When catch 76 approaches catch release 90 from the right as shown in FIG. 5 , inner cam surface 96 of cam 94 engages outer cam follower surface 88 of cam follower 84 . This simply raises cam 94 and/or pushes catch 76 deeper into spring chamber 66 . In either event, catch lug 55 is held in the cocked position of FIG. 4 by spring catch 76 .
Traveler 22 is moved to the ideal location, preferably by pulling cable 102 to rotate the cocked drums 42 and 46 in the proper direction. Traveler 22 is then inserted into guide track 21 . The cables 100 and 102 are then properly located on any guide pulleys, such as guide pulleys 25 and 27 shown in FIG. 1 .
Once the system is assembled, slack in cables 100 and 102 is taken-up by releasing spring catch 76 . Spring catch 76 is released simply by rotating the cocked drums 42 and 46 in the opposite direction. When the cocked drums 42 and 46 are rotated in the opposite direction, spring catch 76 is released. When catch 76 approaches catch release 90 from the right as shown in FIG. 6 , outer cam surface 98 of cam 94 engages inner cam follower surface 86 of cam follower 84 . This lifts catch 76 away from catch lug 55 and tension spring 44 contracts, rotating drum 42 with respect to drum 46 to take up slack in cables 100 and 102 .
Cable drive assembly 24 now operates in the following manner.
As shown in FIG. 2 , electric motor 30 is drivingly connected to the input member of electromagnetic clutch 38 . For closure, electric motor 30 is energized to drive output shaft 34 and the input member connected to it in the forward direction, i.e. clockwise. At the same time electromagnetic clutch 38 is energized so that the input member drives the friction plate which in turn rotates drum 42 and its cable groove 50 in the forward or clockwise direction. Clockwise rotation about the longitudinal axis 36 winds front cable 100 onto drum 42 to close the sliding door (not shown). As drum 42 is driven clockwise, drum 46 is pulled clockwise via tension spring 44 , winding rear cable 102 off of drum 46 ; with drum 46 being biased counterclockwise by tension spring 44 to maintain tension in cables 100 and 102 .
When the sliding door of the van door is closed, electric motor 30 and electromagnetic clutch 38 are deenergized through a suitable control (not shown).
To open the sliding door (not shown), electric motor 30 and electromagnetic clutch 38 are energized to drive output shaft 34 and the friction plate in the rearward direction, i.e. counterclockwise. The friction plate in turn rotates the rear drum 46 and its cable groove in the rearward or counterclockwise direction. Counterclockwise rotation about the longitudinal axis 36 winds rear cable 102 onto drum 46 to open the sliding door (not shown). As drum 46 is driven counterclockwise, tension spring 44 pulls front drum 42 counterclockwise winding front cable 100 out of cable groove and off of drum 42 ; with drum 42 being biased clockwise by tension spring 44 to maintain tension in cables 100 and 102 .
The above description is intended to illustrate a preferred embodiment of the invention rather than to limit the invention. Therefore, it uses descriptive rather than limiting words. Obviously, it's possible to modify this invention from what the description teaches. Within the scope of the claims, one may practice the invention other than as described. | A cable drive assembly for opening and closing a sliding vehicle door has first and second drums that are drivingly connected to each other via a tension spring that biases the drums in opposite directions. The drums include a catch that holds the first and second drums in a cocked condition where the spring is tensioned to provide slack in a closed loop cable to facilitate inserting a traveler attached to the cable into a track. The cocked drums are manually rotated in a drum housing in one direction to move the traveler and insert it into the track. After the traveler is inserted, the cocked drums are manually rotated in the opposite direction. This releases the catch so that the tensioned spring takes up the slack in the closed loop cable. | 4 |
This is the U.S. National Stage Application of PCT/E598/00017 filed Jan. 23, 1998.
INTRODUCTION
The present invention describes the preparation of α-alkyl cinnamaldehydes and preferably, the preparation of α-n-amylcinnamaldehyde (Jasmine aldehyde), through aldolic condensation catalyzed by zeolite type solid acids.
α-n-amylcinnamadehyde is a substance with a violent scent and it is commonly used in perfumery. The production of α-n-amylcinnamaldehyde can be carried out through aldolic condensation between heptanal and benzaldehyde using alkaline catalysts.
A difficulty with aldol condensation is that both reagents can undergo side reactions giving rise to by-products that reduce the yield of alkyl cinnamaldehyde and that furthermore they can provide an unpleasant scent, thus reducing the quality of the perfume. One of these undesired reactions is self-condensation of n-alkyl aldehyde, which can be inhibited to a great extent, by keeping the concentration of this reagent relative to that of the benzaldehyde in the reaction mixture very low. Therefore, this methodology requires long addition times of heptanal, leading to the use of batch reactions with long reaction times and renders impractical the use of plug-flow continuous reactors.
Further by-products that are formed in these conditions are those resulting from the limited stability of benzaldehyde which tends to disproportionate via the Cannizzaro reaction to yield Benzes alcohol and benzoic acid, which in turn reacts with the alkaline catalyst, and therefore, causing the neutralization of the catalyst.
BACKGROUND OF THE INVENTION
A. Weissenborn in East German patent 11,191 (1956) describes a produce for the preparation of Jasmine aldehyde wherein the catalysts are Ni, Co or Fe salts of carboxylic acids. The reaction is carried out at the temperature range of 180-190° C., in the presence of toluene in order to facilitate azeotropic distillation of the water and the heptanal is added slowly to the reaction mixture. Yields around 80% of Jasmine aldehyde are obtained.
R. Mahrwald and H. Schick in East German patent DD 287,712 (1991) describe a procedure wherein the aldolic condensation between heptanal and benzaldehyde is accomplished in the presence of Titanium compounds (tetraisopropiltitanium) and toluene as the azeotropic agent. Yields around 56% of Jasmine aldehyde are obtained.
L. S. Payne in European patent 392,579 (1990) describes a procedure for the selective preparation of α-cinnamaldehydes by aldolic condensation in two phases, using glycols (especially ethylene glycol) as solvents and sodium or potassium hydroxides as catalysts. Yields around 90% of α-cinnamaldehyde are obtained.
P. Mastagli et al. in Bull. Soc. Chim. France, 1955, p. 268, describe the preparation of Jasmine aldehyde using anionic exchange resins (IR-4B) as catalysts. The yields obtained varied between 2 and 12%.
The same author describes in Compt. Rend. 1957 vol. 244, p. 207, a process starting from n-alkyl aldehyde and benzaldehyde acetals using as a catalyst a mixture of an acid catalyst (cationic exchange resin) and a basic catalyst (anionic exchange resin) in order to produce the hydrolysis and aldolic condensation respectively. The yields obtained varied between 5 and 28%.
A. Sakar et al. in Ind. J. Chem., 1986, vol. 25,p. 656 accomplish aldolic condensation using potassium carbonate and a phase transfer catalyst such as benzyltriethylammonium chloride. On the other hand, D. Abenhaim et al in Synthetic Comm., 1994, vol. 24, p. 1199 carry out condensation using the same type of catalysts but under microwave effect. In both cases yields around 80% of Jasmine aldehyde are obtained.
BRIEF DESCRIPTION OF THE INVENTION
This invention describes the selective obtainment of α-alkyl cinnamaldehydes and specifically, Jasmine aldehyde, by direct reaction between the acetal of n-alkyl aldehyde (heptanal) and benzaldehyde where zeolites and zeotypes with medium and large pore diameters with 10 and preferably 12 member rings, as well as mesoporous molecular sieves are used as acid catalysts.
The process involves a first acetalization step which is carried out directly with an alcohol or through transacetalization using trialkyl orthoformate (TOF) in the presence of the above-mentioned catalysts. The second step involves the elimination of the remaining alcohol or TOF by distillation and addition of benzaldehyde.
These acid catalysts subsequently cause slow hydrolysis of the acetal and mixed aldolic condensation, maintaining at all times a low concentration of the n-alkylaldhyde with respect to the benzaldehyde, thus obtaining the α-alkyl cinnamaldehydes with high yields and selectivities.
DETAILED DESCRIPTION OF THE INVENTION
The present invention relates the use of acid zeolites and mesoporous molecular sieves, that in a certain way could be assimilated to zeotype materials, as selective catalysts in the aldolic condensation between acetalizated n-alkyl aldehydes and benzaldehyde and in order to obtain α-alkyl cinnamaldehydes with yields higher than 80%.
The first stage of the process involves the acetalization of the aldehyde which takes place according to conventional procedures in a continuous or discontinuous batch reactor or in a continuous fixed or fluidized bed reactor filled with the catalyst. The reaction temperature ranges from 25 to 280° C. When the transacetalization method is used, the aldehyde and the corresponding trialkyl orthoformate molar ratio are between 1:1 and 1:10 preferably between 1:2 and 1:5.
Short chain saturated primary alcohols and glycols are the preferred alcohols. Methanol, ethanol, propanol and ethylene glycol are non-restrictive examples.
The second step of the reaction, and after distillation of the remaining alcohol or TOF, involves the addition of benzaldehyde to the reaction mixture. The heptanal/benzaldehyde molar ratio are between 1:1 and 1:10 m preferably between 1:2 and 1:5.
The reaction can be accomplished under inert atmosphere, such as nitrogen, and at a temperature ranging from 25 to 200° C., preferably between 50 and 150° C.
The amount of catalyst used is between 2 and 30% based on the weight of the n-alkyl aldehyde.
When the reaction is carried out in a batch reactor, at the end of the reaction the zeolite is filtered, washed with dichloromethane and the solvent is evaporated.
The catalysts used in the present invention are zeolites and zeotypes specifically of medium and large pore, preferably with 12 membered rings and mesoporous molecular sieves since the geometric constraints, due to the poor size, make it possible to obtain products with high selectivities from mixed aldolic condensation.
The zeolite catalysts that meet the previous specifications are, among others, the following (the initials between brackets being accepted by the International Zeolite Associations (see W. M. Meier and D. H. Olson in Atlas of Zeolites Structure Types, 1992)
Mordenite (MOR), Ofretite (OFF), Omega (MAZ), Beta (BEA), Y (FAU), SSZ-24 (AFI), ZSM-12 (AFI) and SSZ-42
New zeolites which combine channels of 10 MR with 12 MR (MCM-22), SSZ-26, SSZ-36, CIT-1 and zeotypes with extra large pore sizes (20-100 Å) such as M41S (such as MCM-41, (Beck et al. JACS, 114, 10834, (1992)), and amorphous mesoporous silica-alumina (SAM), with pore size in a narrow pore range (Bellussi et al.) Stud. Surf. Sci. 84, 93 (1994)) are also applicable.
The catalysts, prior to be used, have to be prepared in their acid form.
Preparation of the Acid Form
The preparation of the acid form is accomplished directly by exchange with an acid mineral when this is allowed by the zeolite stability, or if this is not possible, by an indirect method which consists in an exchange of its alkaline and alkaline earth cations by NH 4 + through a treatment with aqueous solution of ammonium chloride followed by calcination, following conventional methods. It can also be prepared by exchange with di- or trivalent ions, followed by thermal treatment at temperatures between 100 and 600° C. for time intervals between 30 minutes and 6 hours.
On the other hand, the number of acid sites, the distribution of acid strength and the hydrophilic-hydrophobic characteristics of the catalyst can be controlled by varying its Si/Al ratio of the crystalline framework. The Al content of a zeolite can be modified directly during synthesis and this is not possible post-synthesis dealuminations are carried out. They mainly consist of the extraction of aluminum from the framework by acid treatment or using a complexing agent such as EDTA. Furthermore, if desired, it is possible to introduce silicon at the same time by chemical treatment with reagents such as (NH 4 )2F 6 Si or SiCl 4 .
EXAMPLES
Example 1
Acetalization of heptanal and subsequent condensation with benzaldehyde in the presence of zeolitic catalysts with a different structure.
Immediately before its use, the catalyst, in an amount equivalent to 10% (1.1 g) of the weight of the heptanal, is activated by heating at 100° C., under pressure of (1 mm Hg) for 2 h. After this time, the system is allowed to cool at room temperature and 11.5 g (0.1 mol) of heptanal dissolved in 150 ml. of methanol are added. The solution is heated at the reflux temperature of methanol during the time necessary to achieve an acetal (1,1-dimethoxyheptane) yield of around 90%. Thereafter, the methanol is evaporated and 10.6 g (0.1 mol) of benzaldehyde) are added. The condensation reaction is carried out under magnetic agitation at 125° C., under a nitrogen atmosphere for a reaction time between 4 and 16 h. After this time the catalyst is filtered and washed repeatedly with dichloromethane. The crude of the reaction is analyzed by gas chromatography-mass spectrometry. The Jasmine aldehyde yield in molar %, for the different catalysts, is:
______________________________________Catalyst Jasmine Aldehyde Yield (%)______________________________________MCM-41 87 SAM 83 HY 75______________________________________
Example 2
Acetalization and condensation between benzaldehyde and 1,1-dimethoxyheptane in the presence of MCM-41 catalyst with different benzaldehyde/heptanal molar ratios.
In the same conditions as in Example 1, the reaction is carried out in the presence of MCM-41 catalyst with a Si/Al ratio of 14, and using different benzaldehyde/heptanal molar ratios (1:1, 1:3 and 1:5). The results show that the variation of the ratio of reagents has little influence on the selectivity to jasmine aldehyde, obtaining final yields in the neighborhood of 85%.
Example 3
Influence of the temperature on the condensation reaction in the presence of MCM-41.
In the same conditions as in Examples 1 and 2, the reaction is carried out in the presence of MCM-41 catalyst with a Si/Al ratio of 14 at different reaction temperatures. The Jasmine aldehyde yield obtained after one hour reaction time is shown on the table:
______________________________________Temperature (° C.) Jasmine Aldehyde Yield (%)______________________________________100 10 125 60 140 70______________________________________ | The selective obtainment of α-alkyl cinnamaldehydes, such as Jasmine aldehyde is carried out by a process that involves two consecutive reactions: acetalization of an n-alkyl aldehyde by direct reaction with an alcohol or by transacetalization followed by the reaction between said acetal and aromatic aldehyde such as benzaldehyde using molecular sieves with regular pore distribution in the range of micro and mesopores and between 6 and 100 Å as acid catalysts. | 2 |
FIELD
The present embodiments generally relate to method for drilling using a power swivel that rotates a pipe string suspended from the traveling block of a drilling rig.
BACKGROUND
The present embodiments relate to methods for drilling new wells and servicing old wells beneath the earth's surface.
A need exists for methods useful on a drilling rig that allows drilling that can be accomplished quickly, efficiently, and economically.
A further need exists for a method for drilling using a power swivel assembly suspended from a lifting means, such as a traveling block, forming a remote control tiltable power swivel assembly that allows remote control tilting to align the power swivel axis with pipe located in the opening in a derrick for passage of equipment, also referred to as a V-door.
The present embodiments meet these needs.
BRIEF DESCRIPTION OF THE DRAWINGS
The detailed description will be better understood in conjunction with the accompanying drawings as follows:
FIG. 1A depicts the remote controlled tilting power swivel assembly usable with the method.
FIG. 1B depicts a side view of the power swivel with a tilt plate.
FIG. 1C depicts a detail view of the tilt plate.
FIG. 2 depicts a side view of the power swivel tilted away from a substantially vertical position.
FIG. 3 depicts an embodiment of the tilt cylinder assembly.
FIG. 4 depicts a power swivel installed on a drilling rig.
FIG. 5 depicts a detail of an embodiment of an axle of the hydraulic hose reel assembly.
FIGS. 6A and 6B depict a hydraulic hose reel assembly.
FIG. 7 depicts the steps of the method for using a power swivel with tilt.
The present embodiments are detailed below with reference to the listed Figures.
DETAILED DESCRIPTION OF THE EMBODIMENTS
Before explaining the present method in detail, it is to be understood that the method is not limited to the particular embodiments and that it can be practiced or carried out in various ways.
Specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a basis of the claims and as a representative basis for teaching persons having ordinary skill in the art to variously employ the present invention.
Power swivel is an industry term known to persons having ordinary skill in the art to describe a drilling machine used with tubulars or drill pipes in oil well operations. A typical power swivel performs at least the following basic functions: providing torque for pipe rotation, supporting the weight of a rotating pipe, housing a sealing arrangement to allow for the pumping of high pressure drilling fluids.
The present invention provides a method of using a power swivel assembly accommodating the needs listed above for use with a drilling rig mast or derrick. The present invention allows for a method of utilizing a tilt function of the power swivel allowing greater safety, as well as cost and time savings in the manipulation of tubulars or drill pipes.
A benefit of various embodiments is that the invention provides a method for accommodating drill pipe at an angle, by tilting a power swivel attached to a lifting means, such as a traveling block, through mechanical actuation with a hydraulic cylinder, and can be remotely operable.
The invention relates to a method for drilling using a remote controlled tilting power swivel assembly attached to a lifting means of a drilling rig for rotating tubulars to drill into a wellbore.
In embodiments, the remote controlled tilting power swivel assembly usable to employ the method can have a tilt cylinder assembly attached between a power swivel housing and a connecting means for engaging a lifting means of the drilling rig.
The power swivel assembly incorporates a power swivel and a tilt cylinder assembly.
In embodiments of the method, the tilt cylinder assembly is powered in part by hydraulic fluid from the power swivel, and powered in part from a separate hydraulic fluid line connected to the tilt cylinder assembly. This novel arrangement allows for the operation of the tilt function with the addition of only one hydraulic hose to existing equipment, resulting in cost savings and allowing all required hoses to be rolled up on a single hose reel.
As used herein, the term “hose” can refer to any fluid conduit used for supplying hydraulic fluids or other fluids.
In embodiments of the method, a separate hydraulic fluid line can pass through a hydraulic hose reel assembly. A commonly used hydraulic hose reel assembly for a power swivel has three hoses including two hydraulic supply hoses and a drain hose.
The present invention is a method of use for using the added tilt function of the power swivel with the addition of a fourth hose, which can be accomplished with minimal modification to the hydraulic hose reel assembly and the power swivel.
In embodiments of the method, the separate hydraulic fluid line can be controlled by a tilt valve connected to a hydraulic pump, or any commonly used means of supplying or flowing hydraulic fluid.
In embodiments of the method, the tilt valve is fluidly controlled by a hydraulic remote control that can be operated to “tilt” or “retract” the power swivel as the power swivel is connected to the connecting means engaging the lifting means of the drilling rig.
As used herein, the term “tilt” refers to angling or orientation of the power swivel away from a substantially vertical position and “retract” refers to angling or orientation of the power swivel toward a substantially vertical position. The “substantially vertical position” refers to when the power swivel is positioned directly above the wellbore.
The hydraulic remote control can cause the power swivel to rotate toward or away from a substantially vertical position, up to an orientation of 90 degrees in relation to the substantially vertical position.
The tiltable remote controlled power swivel enables picking up and inserting tubulars or drill pipes into the wellbore in a manner that is safer than non-tilting power swivels. For example, tubulars or drill pipes can be staged at an angle on a pipe rack and engaged by the power swivel when tilted.
The method enables this manipulation and engagement of a tubular that is not vertical, and further facilitates alignment and placement of the tubular with minimal involvement from the operators. This, in turn, allows for safer operation at a well site with less chance for operator injury, equipment damage, and other undesirable outcomes.
The method uses an inventive power swivel assembly which comprises a connecting means that attaches to a lifting means of a derrick for drilling oil or water wells, natural gas wells, and the like.
The method uses an inventive power swivel that can have a power swivel housing for containing the power swivel components.
The power swivel can include a rotating drive shaft also referred to as a stem, which is rotatable on an axis.
The power swivel can receive hydraulic fluid to operate. In embodiments, this hydraulic fluid is supplied by two main hoses from the hydraulic hose reel assembly. The rotating drive shaft can rotate at various rotational speeds as desired.
Within the field of drilling, in general, power swivels can simultaneously suspend the weight of a drill string and provide for the rotation of the drill string beneath it. A power swivel includes a stationary part that is coupled with a power source and, in embodiments, can be in communication with hydraulic motors and a rotating part that is coupled with a drill string. A power swivel can further provide a sealed pathway for high-volume flow of drilling mud or air from the stationary part to the rotating part.
For example, in oilfield applications, hydraulic motors can cause a drive shaft of the power swivel to rotate which can also be connected to a drill string. By rotating the drill string a drill bit rotates and cuts through the strata.
Typical size bore holes can range from about 1.25 inches in diameter to about 12.75 inches in diameter; although larger scale equipment can be used to produce larger holes.
The power swivel comprises all required working components, including, but not limited to a motor, a shaft, a brake assembly, a thrust bearing assembly and a connecting means for engaging a lifting means.
The method can make use of various embodiments of the power swivel. The power swivel described herein relates to fluid drilling. The present invention can utilize water or mud drilling techniques as well. Similarly, air drilling, mist drilling, foam drilling and other drilling techniques can be usable with the method.
Turning now to the Figures, FIG. 1A depicts a remote controlled tilting power swivel assembly usable with the method.
The remote controlled tilting power swivel assembly 2 can include a power swivel 10 .
The power swivel 10 can be attached to lifting means of a drilling rig. The power swivel can be a remote controlled tilting power swivel.
In an embodiment, the lifting means can be a lifting block, such as a traveling block connected to the hoist system of a derrick or tower, or another form of lifting device, such as a links connected to the hoist system of a derrick.
The remote controlled tilting power swivel assembly 2 can be attached to a connecting means 18 , which is depicted as an elevator bail. The connecting means can comprise a first side 19 a extending over one side of a power swivel 10 and a second side 19 b extending over an opposite side of the power swivel 10 .
In embodiments, the connecting means 18 can be secured to the power swivel with a means of connecting 24 a and 24 b , such as a pair of bail pins that extend into a power swivel housing 11 of the power swivel 10 .
One of the bail pins 24 a can secure the power swivel 10 to the first side 19 a of the connecting means and through the power swivel housing 11 , and the other bail pin 24 b can secure through the power swivel housing 11 attaching the power swivel 10 to the second side 19 b of the connecting means.
A tilt plate 26 can be mounted to the power swivel housing 11 and around the bail pin 24 b.
A tilt valve 57 can be in fluid communication between a hydraulic remote control 55 and a tilt cylinder assembly 32 . The fluid in this embodiment is hydraulic fluid. While one embodiment of remote control is shown here, various arrangements of valves and types of control can be used.
The tilt valve 57 can provide fluid to an extend port 46 . In embodiments, a lever 56 on the hydraulic remote control 55 can actuate the tilt valve 57 to tilt the power swivel, allowing fluid to flow into the extend port 46 .
The hydraulic remote control 55 can retract the power swivel by causing hydraulic fluid to flow from the power swivel into a retract port 48 of the tilt cylinder assembly 32 .
In embodiments, the tilt valve causes hydraulic fluid to enter the extend port on the tilt cylinder assembly 32 , extending the cylinder, thus tilting the power swivel at an angle away from a substantially vertical position until rotation of the power swivel is stopped.
A means of retracting the power swivel can be housed within the valve manifold block 304 on the cylinder.
Embodiments of the power swivel can include a stem 300 for connecting to a tubular 301 extending from the power swivel housing 11 for pushing into the wellbore.
The power swivel can include a brake 302 swivel and a valve manifold block 304 adjacent the brake.
A first power swivel port 306 and a second power swivel port 308 , in embodiments, can allow for the flowing of hydraulic fluid into the power swivel 10 . A thrust bearing 314 can be in the power swivel housing and connect to the stem. A hydraulic motor 316 can rotate the stem supported by the thrust bearing.
In embodiments, the means of retracting can include one or more check valves and a valve for reducing and relieving pressure. In embodiments, the means of retracting can be connected to a retract hose 61 for flowing hydraulic fluid to the retract cylinder.
In embodiments, the hydraulic fluid can be moved through the tilt valve 57 with a hydraulic pump 111 .
In embodiments, the remote controlled tilting power swivel assembly 2 can include a hydraulic hose reel assembly 60 fluidly connected between the tilt valve 57 and the extend port 46 .
A port 112 for flowing hydraulic fluid from the hydraulic source 49 is also shown.
FIG. 1B depicts a side view of the power swivel with a tilt plate. FIG. 1C depicts a detail view of the tilt plate.
Referring to FIGS. 1B and 1C , the power swivel 10 can include a tilt plate 26 . The tilt plate 26 , in embodiments, can have a thru hole 30 , wherein a bail pin can penetrate through the tilt plate 26 into the power swivel housing.
One or more valves within the valve manifold block can flow hydraulic fluid into the retract port 48 , retracting the power swivel until limited by an adjustable stop.
The means of retracting can be used to move the power swivel from its tilted angle back toward a substantially vertical position. The exact orientation of the power swivel can be adjustable using the adjustable stop 27 . The adjustable stop is adjustable for different angles around a center point 31 of the thru hole 30 .
The adjustable stop 27 can be mounted to the tilt plate 26 . In embodiments, the adjustable stop can engage a tilt plate clevis 50 which can be connected to the cylinder of the tilt cylinder assembly.
In embodiments, the adjustable stop 27 can be fixed in position using a lock nut 18 . The adjustable stop 27 can limit the rotation of the power swivel at a substantially vertical position.
The stem of the power swivel can be rotatable on an axis 93 .
The connecting means 18 with the second side 19 b and the extend port 46 are also shown.
FIG. 2 depicts a side view of the power swivel tilted away from a substantially vertical position.
When the tilt cylinder assembly 32 extends the cylinder 40 , the power swivel 10 can tilt away from a substantially vertical position and can be tilted up to a full extension of the cylinder. When the cylinder retracts, the power swivel can be rotated in an opposite direction to be repositioned at a desired angle within the range of rotation. The tilt cylinder assembly 32 can control tilting of the power swivel 10 about the center point 31 to a tilt angle 91 . The full extension of the cylinder can be adjusted to control the tilt angle 91 . The tilt angle can be a preset tilt angle.
In embodiments, the plate 26 can comprise a tilt plate clevis 50 .
FIG. 3 depicts an embodiment of the tilt cylinder assembly.
In this embodiment, one manner in which the full extension of the cylinder can be adjusted is shown. The present detail is shown in an extended orientation, when the power swivel has been angled with respect to the wellbore.
The tilt cylinder assembly 32 can have a cylinder 40 which can be hydraulic. Inserted into the cylinder 40 on one end can be a hollow piston rod 43 .
In embodiments, the extension of the tilt cylinder assembly can be adjusted by using a threaded rod 42 which can be threaded inside of the hollow piston rod 43 which can be extended and retracted by the cylinder 40 . The full rotational range can be adjusted by manipulating the extended length of the threaded rod 42 .
In embodiments, the threaded rod can adjustably extend from the cylinder, in that the threaded rod can be threaded into or out of the cylinder, and so long as the threads engage the hollow piston rod, the tilt cylinder assembly can operate to tilt the power swivel.
In embodiments, the tilt cylinder assembly 32 can engage the connecting means on a side opposite the tilt plate.
The threaded rod can adjust from 0.5 inches to 15 inches in embodiments into and away from the hollow piston rod.
In embodiments, a piston 45 in the cylinder 40 can be connected to the hollow piston rod 43 . The piston can be used to extend or retract the hollow piston rod.
In embodiments, a cylinder attachment 44 , such as a bail attachment clevis, can connect the cylinder 40 to the connecting means.
In embodiments, the cylinder can have an extend port 46 for receiving hydraulic fluid into the body of the cylinder, allowing the hydraulic fluid to extend the hollow piston rod 43 .
The cylinder can also have a retract port 48 for receiving hydraulic fluid into the body of the cylinder, allowing the hydraulic fluid to push on the piston and the hollow piston rod and retract into the body of the cylinder, in part.
The tilt cylinder assembly 32 can include a tilt plate clevis 50 secured to the threaded rod 42 , opposite the cylinder. The tilt plate clevis 50 can secure the tilt cylinder assembly 32 to the tilt plate.
A pin 51 a can secure a tilt plate clevis 50 moveably to the tilt plate.
In embodiments, the hydraulic remote control can contain other meters and gauges for operating the power swivel on the rig. However, the hydraulic remote control controls power swivel tilting while keeping the operator a safe distance from the power swivel's moving components.
FIG. 4 depicts a power swivel 10 installed on a drilling rig 14 over a wellbore 8 . Also shown is the lifting means 158 of the derrick.
FIG. 5 depicts a detail of an embodiment of an axle of the hydraulic hose reel assembly.
While embodiments with a fixed axle are easily implemented, FIG. 5 depicts a rotating axle for use with a hydraulic hose reel assembly.
Swivel joint assemblies 134 a and 134 b can be disposed proximate each end of the axle 116 . The fluid pathway to ports 120 and 128 can be maintained even while the axle is rotating.
Embodiments of the axle of a hydraulic hose reel assembly can have a plurality of ports 118 , 120 , 122 , 124 , 126 , 128 , 130 and 132 for flowing hydraulic fluid. In embodiments, the ports can function as inlet ports, outlet ports, or combinations thereof. Ports 120 and 128 can function as an axle tilt port and an axle drain port. The hydraulic fluid can flow bidirectionally through any of the plurality of ports as needed.
Ports 122 and 132 can be disposed on either end of a fluid conduit through the axle. Similarly, ports 126 and 130 , ports 124 and 128 , and ports 118 and 120 can all define separate fluid conduits.
The ports and the associated fluid conduits can be in communication with a rotational mechanism of the power swivel, a tilt mechanism of the power swivel, or for draining fluid from the power swivel. Various hoses can be attached to accomplish this purpose.
In embodiments, the hydraulic hose reel can flow hydraulic fluid to power the rotational mechanism of the power swivel, conduct drain fluid, or power the tilt mechanism. Various hoses can be attached to accomplish this purpose.
For example, an embodiment can use two hoses with the hydraulic hose reel in fluid communication with ports 130 and 132 and the power swivel to supply hydraulic fluid to power the rotational mechanism of the power swivel. A third hose can be in fluid communication with port 120 and to a drain of the power swivel, and a fourth hose can be in fluid communication with port 128 and the tilt cylinder assembly.
FIGS. 6A and 6B depict a hydraulic hose reel assembly.
In embodiments, the hydraulic hose reel assembly 60 can have a first wheel 102 , a second wheel 104 , a drum 106 mounted between the wheels, a ring gear 108 secured to the drum 106 , a pinion gear 109 connected to the ring gear, and a drive motor 110 connected to the pinion gear. Ports 112 , 114 and 128 for flowing hydraulic fluid are shown.
In embodiments, a drive motor 110 can connect to a pinion gear rotating the pinion engaging with the ring gear thereby rotating the wheels and drum.
In embodiments, the hydraulic hose reel assembly can have four separate fluid flow pathways.
The hydraulic hose reel assembly 60 can have a plurality of hoses for hydraulic fluid. The first hose 160 and second hose 162 can be in fluid communication with a rotational mechanism of the power swivel. The third hose 164 can be in fluid communication with a drain of the rotational mechanism of the power swivel. The fourth hose 166 can be in fluid communication with the power swivel, for supplying the hydraulic fluid to tilt the power swivel.
FIG. 7 depicts the steps of the method for using a power swivel with tilt.
The method can include connecting a remote controlled tilting power swivel assembly to a lifting means, as shown in step 702 . The lifting means can be connected to a drilling rig for drilling a wellbore.
The method can include setting a desired substantially vertical position by manipulating the adjustable stop, as shown in step 704 .
The method can include setting a maximum tilt angle of the power swivel by manipulating the adjustable extension, as shown in step 706 . In embodiments, setting the maximum tilt angle can comprise rotating the threaded rod clockwise or counter-clockwise to modify the full extension of the cylinder.
The method can include rotating the power swivel, as shown in step 708 . The power swivel can be rotated by either causing hydraulic fluid to flow into the extend port to tilt the power swivel to a desired orientation up to the maximum tilt angle, or causing hydraulic fluid to flow into the retract port to retract the power swivel.
In embodiments, the method can also include connecting a hydraulic hose reel assembly fluidly connected between the tilt valve and the extend port, as shown in step 710 .
While these embodiments have been described with emphasis on the embodiments, it should be understood that within the scope of the appended claims, the embodiments might be practiced other than as specifically described herein. | A method for using a power swivel with tilt capable of being tilted to any angle up to an adjustable maximum tilt angle. The method allows adjusting the tilting power swivel's angle of tilt to line up with pipe staged at various angles as required by different rigs. The method allows for adjusting the maximum extension of the tilt cylinder, and further allows the power swivel to be repeatedly positioned at a desired angle for the duration of a job. The method requires the addition of only one hydraulic fluid supply hose, thereby allowing a simple live hose reel with four hoses. The method for using a power swivel with tilt promotes safety, efficiency, and saves time by eliminating the need for a stabbing man hanging in the derrick. | 4 |
BACKGROUND OF THE INVENTION
The present invention relates to a cooling rack for cooling electronic devices and, more particularly, to a cooling rack having both fluid connectors and electrical connectors so that, as the cooling rack is attached to a chassis, the fluid connectors and electrical connectors of the rack will mate generally in unison with corresponding electrical connectors and fluid connectors on the chassis.
Electronic integrated circuits are used in a wide variety of data processing applications. These integrated circuits usually generate small amounts of power on the order of 1-5 watts and generally operate at temperatures less than 80° C. In some applications, power devices such as insulated gate bipolar transistors are used in conjunction with integrated circuit packages. These power devices can consume power on the order of several hundred watts and can generate temperatures well in excess of those generated by integrated circuit packages. Cooling arrangements must be provided to insure that the high temperatures generated by the power devices do not damage the integrated circuit packages.
Prior cooling arrangements did not lend themselves to high-density electronic arrangements because the fluid connections and manifolds for circulating the cooling fluid to the various integrated circuits and/or power devices consumed large amounts of space. Space is often at a premium in many applications such as those on aircraft. Avionics packages must be compact in size in order to maximize passenger space within an aircraft and must be light weight so that more passenger weight can be carried by the aircraft.
The typical avionics electronic instrumentality comprises a chassis or housing having a mother board and a series of printed circuit boards arranged to plug into the mother board in or on the chassis. The printed circuit boards typically carry integrated circuit packages and, in some cases, power electronic devices. A cooling mechanism must be provided for the integrated circuit packages and any power devices which may be used in conjunction with the integrated circuit packages. The cooling mechanism must be compact in order to minimize the required space and must allow for easy installation and removal of the printed circuit boards in or on the chassis.
SUMMARY OF THE INVENTION
Accordingly, a cooling rack is provided for cooperating with a chassis, the chassis having both electrical and fluid connectors, the fluid connectors being interconnected by a manifold for distributing cooling fluid to and from the rack, the rack having a cooling support including at least one electrical component cooling pad, a rack manifold for circulating cooling fluid to the cooling pad, a rack electrical connector, a rack inlet fluid connector in fluid communication with the rack manifold for receiving cooling fluid from the chassis to be circulated through the rack manifold for cooling the cooling pad, and a rack outlet fluid connector in fluid communication with the rack manifold for returning cooling fluid from the rack manifold to the chassis so that the cooling fluid can be recooled, wherein the rack electrical connectors, the rack inlet fluid connector, and the rack outlet fluid connector are arranged so that, when the cooling rack is attached to the chassis, the rack electrical connector, the rack inlet fluid connector, and the rack outlet fluid connector will mate generally in unison with the respective chassis electrical connector and chassis fluid connectors.
The cooling rack can be configured to provide electrical component cooling pads on two opposing sides thereof. The cooling rack can be further refined to carry printed circuit boards on board supports which board supports are mounted to the cooling support of the rack. The printed circuit board and the board support can have openings corresponding with the electrical component cooling pads such that as the board support is suitably affixed to the cooling support of the rack, the electrical components can also be suitably attached directly to the electrical component cooling pads and then electrically connected to the rack electrical connectors.
BRIEF DESCRIPTION OF THE DRAWINGS
These and other features and advantages will become more apparent from a detailed consideration of the invention when taken in conjunction with the drawings in which:
FIG. 1 is a perspective of a cooling rack having printed circuit boards and electrical components mounted thereto;
FIG. 2 is one of the electrical components for mounting through a suitable opening in the printed circuit board to a cooling pad on the rack;
FIG. 3 is a perspective view of a chassis for receiving a plurality of cooling racks such as the one shown in FIG. 1;
FIG. 4 is a side view of the chassis of FIG. 3 showing fluid and electrical inlet and outlet connectors thereon;
FIGS. 5A-5H show the rack fluid manifold and cooling pads in more detail;
FIG. 6 shows a board support for mounting to the rack cooling support and cooling pads shown in FIG. 5;
FIG. 7 shows a printed circuit board which may be mounted to the board support shown in FIG. 6;
FIG. 8 shows a bus bar support which may be used in conjunction with the board support shown in FIG. 6;
FIGS. 9 and 10 show two forms of bus bars which can be used on the board support in FIG. 6 and which cooperate with the electrical components such as the one shown in FIG. 2; and,
FIG. 11 shows the cooperation between the cooling rack and the chassis.
DETAILED DESCRIPTION
As shown in FIG. 1, rack 10 comprises cooling support 11 which will be shown in more detail in connection with FIGS. 5A-5H. Rack 10 has a pair of fluid connector manifolds 12 and 13 for supporting rack fluid inlet connector 14 and rack fluid outlet connector 15 (FIG. 11) respectively. A gasket (not shown) may be included between cooling support 11 and each of the connector manifolds 12 and 13 for sealing cooling fluid therein. Connector manifolds 12 and 13 may be suitably attached to cooling support 11 by way of fastening devices 16.
Mounted on each side of cooling support 11 are board supports 18 and 19. Printed circuit boards 20 can be mounted to each of the board supports 18 and 19 by suitable fastening means 17. The printed circuit board may have circuit paths deposited thereon for interconnecting various integrated circuit packages and electrical components. The circuits paths are connected to an electrical connector 21 which will engage a corresponding electrical connector in the chassis or housing. Board supports 18 and 19, and printed circuit boards 20, have corresponding openings 22 for receiving electronic components or power devices such as insulated gate bipolar transistors 23 in each of the openings for direct mounting to cooling support 11. Cooling pads are provided on the cooling support 11 in order to cool electrical components 23. Power bus bars 24 are supported by board supports 18 and 19 for carrying high-level power to and from power devices 23. Power devices 23 can be connected such as at 25 to the circuit paths carried by printed circuit boards 20 connectable to electrical connector 21. Power connectors 26 are suitably attached to the power bus bars and have corresponding connectors on the chassis.
As explained in more detail hereinafter, fluid inlet 14 is connected through connector manifold 12 to the rack manifold of cooling support 11 which receives cooling fluid from the chassis and circulates the cooling fluid to the various electrical component cooling pads which support electrical components such as power devices 23. The rack manifold returns fluid through connector manifold 13 to outlet connector 15 which returns fluid to the chassis.
The power device 23 as shown in FIG. 2 has pin connectors 31 which are bent in order to engage suitable holes on printed circuit boards 20 from the underneath side and so that power device 23 can then be pivoted about pin connectors 31 to mount flush against its corresponding electrical component cooling pad on cooling support 11. As power device 23 is pivoted, power tabs 32 engage corresponding bus bars 24.
Chassis 40 for receiving cooling rack 10 is shown in FIGS. 3 and 4. Chassis 40 includes housing 41 having mother board 42 supported by a backface thereof and further includes inlet manifold 42 and outlet manifold 43 within the respective top and bottom of housing 41. Inlet manifold 42 is in fluid communication with a plurality of connectors 44 for delivering cooling fluid to respective rack fluid inlet connectors 14 of the cooling racks. Manifold 43 is connected to a plurality of fluid connectors 45 for receiving back cooling fluid from connectors 15 of cooling racks 11. Manifold 42 is connected to fluid inlet 46 on side 47 of housing 41 as shown in FIG. 4. Manifold 43 is connected to fluid outlet 48 on side 47. Side 47 of housing 41 also carries low amp connector 51 and high amp connector 52 which are suitably connected to chassis low amp connector 53 and high amp connectors 54 mounted to mother board 42.
Accordingly, as rack 10 is attached to or inserted in chassis 40, rack fluid connector 14 will engage, in fluid communication, chassis fluid connector 44, rack fluid connector 15 will engage, in fluid communication, chassis fluid connector 45, rack low amp connector 21 will electrically engage low amp connector 53, and power connectors 26 of rack 10 will electrically engage power connectors 54. All of these connections are made generally in unison as rack 10 is connected to chassis 40 for ease of rack 10 insertion and removal. These connections are in the nature of quick connections.
Cooling fluid then flows from a cooling source through connector 46 and is distributed to the various chassis fluid connectors 44 by manifold 42 for delivery to corresponding racks 10. The cooling fluid then circulates through the racks for cooling the electrical component cooling pads and are returned through connectors 15 to chassis connectors 45. The cooling fluid then is delivered back by way of manifold 43 to fluid outlet 48 for return to the cooling mechanism which will then recool the cooling fluid and redeliver the cooling fluid to inlet 46. Chassis 40 may be provided with a plurality of receptacles 61 for receiving suitable fastening means for fastening racks 11 to chassis 40 by way of corresponding holes 62 on connector manifolds 12 and 13.
Cooling support 11 is shown in more detail in FIGS. 5A-5H. Cooling support 11 is assembled using a plurality of plates, such as aluminum plates, suitably formed, as by etching or stamping, to provide the rack manifold which receives fluid from connector manifold 12 for delivery of cooling fluid to electrical component cooling pads for cooling power devices 23 as shown in FIG. 1. Cooling rack 11 comprises eight such plates which are sandwiched together between connector manifolds 12 and 13 and board supports 18 and 19, all of which are secured by fastening devices 16 and 17.
Cooling rack 11 has plate 71, FIG. 5H, which provides first surface 72 having electrical component cooling pad 73A formed therein. Cooling pad 73A is formed by a depression in plate 71 and does not extend all the way through plate 71. Cooling pad 73A forms a thin cooling pad. An electrical component such as power device 23 may be mounted on the underside of pad 73A, as viewed in FIG. 5H, to be cooled thereby. Plate 71 has six such pads, although any suitable number can be provided. Pad 73A has mesas 74A for insuring that fluid is thoroughly swirled through pad 73A and for providing extra support for the electrical components mounted thereto. Plate 71 has similar pad areas B, C, D, E and F.
Plate 75, FIG. 5G, is next in the stack, is mounted on top of plate 71 and has fluid path 76A and fluid path 76B extending along opposite edges of plate 75. Fluid paths 76A and 76B may extend entirely through plate 75 with plate 71 acting as a seal for preventing leakage of cooling fluid flowing within channels 76A and 76B. Plate 75 also has a plurality of slots 78A separated by spacers 79A. Slots 78A are formed to be in fluid engagement with pad 73A of plate 71. Slots 78A need not extend entirely through plate 75 but may be depressions having a plurality of holes to allow fluid to flow through plate 75 from plate 82 to pad 73A. In fact, any of the plates may be so formed if extra rigidity is needed. Spacers 79A of plate 75 overlie mesas 74A in pad 73A. Channel 80A extends all of the way through plate 75 and fluidly engages pad 73A. Channel 80A acts as a return path for fluid which has been supplied to pad 73A. Channel 81A extends through plate 75 for allowing better distribution of cooling fluid through pad 73A. Plate 75 has similar areas B, C, D, E and F.
Next in the stack is plate 82, FIG. 5F, which has channels 83A and 83B extending therethrough for cooperation with channels 76A and 76B respectively in plate 75. Plate 82 also has a plurality of slots 84A for cooperating with slots 78A of plate 75. Slots 84A, extending all of the way through plate 82, are separated by spacers 85A which cooperate with spacers 79A of plate 75. Finally, plate 82 has channel 86A extending therethrough for cooperating with channel 80A of plate 75. Plate 82 has similar areas B, C, D, E and F.
Next plate 87, FIG. 5E, has channels 88A and 88B extending therethrough for fluid communication with respective channels 83A and 83B of plate 82. In addition, plate 87 has a pad 89A formed in, but not all of the way through, plate 87. On pad 89A are mesas 90A separating finger like depressions 91A, all of which are in fluid communication with each other and with channel 88A. Within depressions 91A of pad 89A are holes extending the rest of the way through plate 87 so that fluid entering pad 89A can flow into depressions 91A and then down through plate 87, through slots 84A in plate 82, slots 78A in plate 75, and to cooling pad 73A before it is returned up through slot 80A in plate 75, slot 86A in plate 82, and slot 92A in plate 87. Slot 92A communicates with channel 93 which then communicates with pad 89B having depressions 91B separated by mesas 90B. There are holes extending the rest of the way through plate 87 so that fluid being returned up through slot 92A can flow through channel 93 into pad 89B and then down through the holes within depressions 91B to the corresponding B areas of plates 82, 75, and 71 and then up through slots 80B of plate 75, slot 86B of plate 82, and into slot 92B of plate 87. Slot 92B is in fluid communication with channel 88B. Plate 86 has similar areas C, D, E and F.
Plate 101, FIG. 5D, is the next plate in the stack and is the mirror image of plate 87. Thus, channel 102A extending through plate 101 cooperates with channel 88A extending through plate 87. Channel 102A communicates with pad 103A, shown in phantom because it is beneath the surface of plate 101 shown in FIG. 5D, having depressions 104A separated by mesas 105A. As illustrated, depressions 104A do not extend all of the way through plate 101 except for holes extending the rest of the way through the plate 101. Thus, fluid entering pad 103A flows into depressions 104A and then up to corresponding slots 113A in plate 111A (FIG. 5C). Fluid returning to plate 101 enters slot 106A extending therethrough which communicates with channel 107. Channel 107 communicates with pad 103B having depressions 104B separated by mesas 105B. Holes in the depressions 104B extend the rest of the way through plate 101 so that fluid can flow from channel 107 into pad 104B and then up through plates 111 and 121 to cooling pad 132B on plate 131 and then returns through a series of slots to slot 106B which is in communication with channel 102B extending through plate 101. Four additional such areas C, D, E, and F are provided in plate 101.
Next plate 111, FIG. 5C, has channel 112A in communication with channel 102A of plate 101, and slots 113A which cooperate with the holes through depressions 104A of plate 101. Slots 113A are separated by spacers 114A which overlie mesas 105A of plate 101. Channel 115A is in communication with channel 106A of plate 101. Plate 111 has similar areas B, C, D, E and F.
Plate 121, FIG. 5B, the next plate in the stack, has channel 122A in fluid communication with channel 112A of plate 111, and has slots 123A in fluid communication with slots 113A of plate 111. Furthermore, return slot 124A in plate 121 is in communication with slot 115A of plate 111. Plate 121 also has a further slot 125A which cooperates with electrical component cooling pad 132A in final plate 131. Plate 121 has similar areas B, C, D, E, and F.
As illustrated, pad 132A is a depression in the underside surface of plate 131 and does not extend all of the way therethrough. Mesas 133A are provided with pad 132A to help the circulation of fluid and to provide additional support for the electrical component cooling pad provided on the surface of plate 131 away from plate 121, i.e. the top surface as shown in FIG. 5A. Slot 125A of plate 121 cooperates with pad 132A of plate 131 to help fluid circulating therein. Plate 131 has similar cooling pads B, C, D, E and F.
As indicated above, these plates can be etched or stamped for providing the various regions A-F as shown. They may be stacked together in the order illustrated and then braised for providing a substantially unitary structure sealed from fluid leakage. Supports 141 may be provided in the various channels of the plates to aid in the assembly process. Supports 141 are thin enough that they will evaporate during the braising process. Each of the plates is also provided with flanges 139 and 142. Flanges 139 and 142 of some of the plates have corresponding channels 143 and 144 such that channels 143 communicate with channels 76A, 83A, 88A, 102A, 112A, and 122A, whereas channels 144 communicate with channels 76B, 83B, 88B, 102B, 112B, and 122B.
Channels 143 communicate with tube connector 14 through its associated manifold 12 and channels 144 communicate with connector 15 through connector manifold 13.
Accordingly, fluid entering connector 14 for circulation through cooling rack 10 flows through manifold 12, through channels 143 and through channels 76A, 83A, 88A, 102A, 112A, and 122A to areas A, C, and E in the plate stack. Using area A as an example, fluid flowing into the area established by pads 89A and 103A will split, part of the fluid going to plates 71, 75, and 82, and part going to plates 111, 121, 131. The cooling fluid cools pads 73A and 132A and returns through slots 80A, 86A, 92A, 124A, 115A, and 106A to the channel formed by channels 93 and 107. Fluid from channels 93 and 107 then enters the area formed by pads 89B and 103B where it again divides, part of it flowing to electrical component cooling pad 73B on plate 72 and part of it flowing to electrical component cooling pad 132B on plate 131. Fluid flows back from pad 73B through slots 80B, 86B, and 92B and from pad 132B through slots 124B, 115B, and 106B where it is collected. The fluid then flows through the channel formed by channels 76B, 83B, 88B, 102B, 112B, and 122B. Fluid will exit the rack through channels 144, through manifold 13 and out through connector 15.
In this manner, the various electrical component cooling pad areas A-F on plates 71 and 131 will be cooled by the cooling fluid circulating through cooling support 11.
FIG. 6 shows a board support 141 which can be used as one of the board supports 18 and 19. Board support 141 has openings 142 extending therethrough. These openings in board 141 cooperate with the electrical component cooling pads on plates 71 and 131 of FIG. 5. Board 141 has a plurality of bus receiving grooves 146, 147, 148 and 149 for receiving power bus bars such as bus bars 161 and 162 shown in FIGS. 9 and 10. These bus bars both have an end with a hole extending therethrough. When the bus bars shown in FIGS. 9 and 10 are mounted to board support 141, the ends of bus bars 161 and 162 can be bent up so that power connectors 26, as shown in FIG. 1, can be attached thereto.
Circuit board 151 can be used for one of the circuit boards 20, the other of which may be identical. Circuit board 151 is shown in FIG. 7 and has openings 152 which cooperates with openings 142 on support board 141 such that the electrical components, such as the ones shown in FIG. 2, can be mounted through openings 142 and 152 directly to the appropriate electrical component cooling pads on plates 71 and 131. Printed circuit board 151 also carries electrical connector 21 connected to the various circuit paths which are placed on the surface of printed circuit board 151.
FIG. 8 shows a further bus bar carrier which cooperates with board support 141.
Accordingly, devices 23 are bolted or otherwise fastened through appropriate holes which extend through the plates shown in FIG. 5 which make up cooling support 11. There are a set of these holes for each of the cooling pad areas on plates 71 and 131. The electrical devices are then plugged into and soldered to circuit boards 20. The tabs of the electrical components make contact with appropriate power bus bars running along circuit board supports 18 and 19 and are soldered thereto. Thus, first board support 18 carrying first printed circuit board 20 is attached to one of the plates 71, 131, using suitable fasteners 17 and second board support 19 supporting a second printed circuit board is attached to the other of the two plates 71, 131 by the fastening means 17. Once the board supports carrying printed circuit boards are fastened to plate stack 11, electronic devices 23 can then be electrically connected to the printed circuit board and to the power bus bars. The cooling rack can then be inserted into chassis 40.
FIG. 11 shows the insertion process in more detail. As rack 10 is inserted into chassis 40, rack fluid connector 14 is inserted into chassis fluid connector 44 and rack fluid connector 15 is inserted into a chassis fluid connector 45. "O" rings 171 and 172 are provided within respective chassis connectors 44 and 45 in order to provide a fluid-tight seal between connectors 44 and 45 and their respective rack connectors 14 and 15. The electrical connectors carried by rack 10 engage their corresponding electrical connectors on mother board 42 of chassis 40 generally in unison with the engagement of rack connectors 14 and 15 to chassis fluid connectors 44 and 45. As shown in FIG. 11, pin connector 26 on rack 10 is inserted into receptacle connector 54 on mother board 42 as rack 10 is inserted into chassis 40.
A plurality of chassis fluid connectors 44 and 45 are provided in the chassis so that the chassis can receive a plurality of racks 10 and provide cooling fluid thereto. If fewer racks 10 are inserted into chassis 40 than there are connectors 44 and 45, plugs can be inserted into the unused connectors 44 and 45 to prevent leakage therefrom. Alternatively, each connector 44 and 45 can be provided with a valve which is opened if the specific connector 44, 45 receives a rack 10 and is left closed if they do not receive a rack 10. In another alternative, valve gates can be provided within connectors 44 and 45 which are automatically opened by rack connectors 14 and 15 if a rack 10 is inserted into corresponding chassis fluid connectors 44 and 45. If a specific set of connectors 44, 45 do not receive a rack 10, the gates act as a check valve for preventing fluid from exiting manifolds 42 and 43 through the unused chassis connectors 44, 45.
When rack 10 is inserted into chassis 40, fluid can then flow from chassis inlet 46 through manifold 42 to chassis fluid connector 44. Cooling fluid then flows into the corresponding rack connector 14 and then through the channels established as previously described with respect to FIGS. 5A-5H to the various cooling pads and then back out through the appropriate rack channels in the plate stack to rack fluid outlet 15. Fluid then flow into chassis connector 45, through manifold 43, and back to chassis outlet 48. | A cooling rack is provided for cooperating with a chassis, the chassis having both electrical and fluid connectors, the fluid connectors being interconnected by a manifold for distributing cooling fluid to and from the rack, the rack having a cooling support including at least one electrical component cooling pad, a rack manifold for circulating cooling fluid to the cooling pad, a rack electrical connector, a rack inlet fluid connector in fluid communication with the rack manifold for receiving cooling fluid from the chassis to be circulated through the rack manifold for cooling the cooling pad, and a rack outlet fluid connector in fluid communication with the rack manifold for returning cooling fluid from the rack manifold to the chassis so that the cooling fluid can be recooled, wherein the rack electrical connectors, the rack inlet fluid connector, and the rack outlet fluid connector are arranged so that, when the cooling rack is attached to the chassis, the rack electrical connector, the rack inlet fluid connector, and the rack outlet fluid connector will mate generally in unison with the respective chassis electrical connector and chassis fluid connectors. | 7 |
BACKGROUND OF THE INVENTION
The present invention relates to means for reducing or eliminating the internal bypassing of gas streams around the heating elements in rotary regenerative heat exchangers and particularly relates to the internal bypassing of air and flue gas streams around the heating elements in an air preheater.
In a rotary regenerative air preheater, the rotor is divided up into pie-shaped sectors, which are in turn subdivided into rotor compartments. Each rotor compartment is designed to accommodate one or more assemblies of heating elements comprising basket-like containers and heat transfer surfaces therein. Because of fabrication tolerances and/or the distortion of the rotor structure associated with extended operation under varying thermal conditions, it is usually necessary to design the heating elements to allow a clearance around each basket so as to avoid interference at installation.
When fabrication tolerances, rotor distortion and/or design clearances result in excessive gaps ("bypass gaps") between the sides of the basket and the corresponding side wall of the rotor compartment or adjacent basket, a portion of the air and gas streams will flow through the gaps thereby bypassing the heat transfer surfaces and thereby resulting in a loss in heat transfer efficiency.
Bypass gaps have been addressed in the past by a practice known as "tabbing" which entailed the welding of bypass strips over gaps deemed large enough to close, or with resilient sealing devices installed in gap areas large enough to accept them. Both of these approaches are costly in field labor expense and/or material. Generally, every layer of heating elements needs to be tabbed or sealed individually.
SUMMARY OF THE INVENTION
The present invention provides a unique means to reduce or eliminate air and gas flow bypass around the heat transfer surfaces in rotary regenerative heat exchangers. The invention involves the use of floating seals placed in the rotor compartments adjacent the ends of the heating elements and around the periphery of the heating elements ends. The floating seals are sized to fit each compartment with minimal clearance whereby the seals bridge the gaps between the heating elements and the sides of the compartments. The seals may be adjustable to accommodate various sized compartments. A modification includes deformable edge seals attached to two or more sides of the floating seals whereby the edge seals are deformed to conform to the walls when the floating seals are pressed into position.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a generalized perspective view of a typical rotary regenerative air preheater showing the rotor sectors and compartments.
FIG. 2 is a cross section elevation through one sector of a portion of a rotor illustrating conventional heating elements stacked vertically in one of the compartments and showing the bypass gap.
FIG. 3 is a plan view of a rotor compartment of the prior art containing a heating element and illustrating the bypass gaps.
FIG. 4 is a perspective view of one of the floating seals of the present invention.
FIG. 5 is a partial elevation cross section of a rotor similar to FIG. 2 but illustrating a compartment with the floating seal of the present invention in position between the heating elements.
FIG. 6 is a partial plan view of a rotor illustrating a compartment containing a heating element and a floating seal.
FIG. 7 shows an adjustable modification of the floating seal.
FIG. 8 is a side view of a modified floating seal with deformable edge seals.
FIG. 9 is a side view illustrating the modified floating seal of FIG. 8 in a compartment with the edge seals deformed.
FIGS. 10, 11 and 12 show three types of heating elements.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
In the description of the present invention, rotary regenerative air preheaters which are used for transferring heat from flue gas to combustion air will be used as the example. However, it is to be understood that the invention is applicable to any rotary or stationary regenerative heat exchangers. FIG. 1 of the drawing illustrates a partially cut-away perspective view of such a conventional air preheater showing a housing 12 in which a rotor 14 is mounted on drive shaft or post 16 for rotation as indicated by the arrow 18. The rotor has an outer shell 20 and a plurality of radially extending diaphragms 22 dividing the rotor into the pie-shaped sectors 24. The tangential plates 26 divide each sector 24 into the generally trapezoidally-shaped compartments 28. The outermost compartments usually have a curved outer end defined by the rotor shell 20. Although not shown in this FIG. 1, each compartment contains a plurality of stacked heating elements. The housing of the air preheater is divided by the plate 30 into a flue gas side and an air side. A corresponding center section is located on the bottom of the unit. The hot flue gases enter the air preheater through the inlet duct 32, flow axially through the rotor where heat is transferred to the heat transfer surface and then exit through the gas outlet duct 34. The countercurrent flowing air enters through the air inlet duct 36, flows through the rotor 14 and picks up heat and then exits through the air outlet duct 38.
FIG. 2 is an elevation cross section of a portion of the rotor of FIG. 1 basically showing one sector with the radial diaphragm 22 extending between the rotor post 16 and the rotor shell 20. The tangentially extending plates 26 together with the diaphragms 22 form the compartments 28. This FIG. 2 illustrates two heating elements 40 stacked in one of the compartments 28. However, it will be understood that there will be heating elements in each of the compartments and that there may be more or less than two heating elements stacked in each compartment. This FIG. 2 illustrates the tangential gaps 42 between the elements and the tangential plates 26.
In order to further illustrate the problem with prior designs, FIG. 3 is a plan view showing a heating element 40 in a compartment 28 bounded by the diaphragms 22 and the tangential plates 26. As can be seen, there are radial gaps 44 between the sides of the heating element 40 and the diaphragms 22 and the tangential gaps 42 between the inner and outer ends of the heating element 40 and the tangential plates 26 as also shown in FIG. 2.
There are basically two types of conventional heating elements 40. One type is commonly referred to as a picture frame style basket 140 having only a frame 142 around each of its four vertical faces as shown in FIG. 10. The heat transfer surface consisting of a large number of individual plates 144 parallel to the inner and outer ends is installed in the basket. With this type of basket, the air and gas can escape through the sides of the heating element into the bypass gap either above or below any tabbing which may be installed. The other general type of heating element is typically referred to as a full wrapper basket 240 with each of the four vertical faces being closed by a continuous plate 242 wrapped around the basket as shown in FIG. 11. Since the sides and ends are all closed, there can be no escape of air or gas from the inside to the outside of each individual heating element. Another type of closed heating element 340 is a hybrid of the picture frame type and the full wrapper type. It has a picture frame basket 342 but the four vertical faces have plates 344 attached to the frame to close off the sides as shown in FIG. 12. With any of these types of heating elements, the bypass gap is a problem. With respect to the present invention, baskets of any style will work, however, use of the present invention with baskets of the closed type such as the full wrapper basket of FIG. 11 or the picture frame type with side plates of FIG. 12 will produce preferential results.
FIG. 4 shows a floating bypass seal 46 in accordance with the present invention. This seal 46 is generally a trapezoidal shaped frame sized to fit a given rotor compartment 28 with minimal clearance. There are various sized seals to fit the various sized compartments. Also, the seals for the outermost compartments may have a curved outer end to conform to the curved rotor shell 20. The sizes of the floating bypass seals are selected for the various sized compartments such that they are capable of being inserted into the compartments with any clearance being minimized taking into consideration the tolerances on the compartment sizes and any expected distortion. The width of the sides 48 of the seals 46 is selected such that there will be continuous engagement with the upper or lower perimeter of any given heating element 40. The thickness of the seals 46 is selected to be substantial enough for handling, for installation into the compartments and for withstanding any loading induced by the adjacent heating elements.
FIG. 5 is an elevation cross section of a portion of a rotor illustrating the floating bypass seal 46 of the present invention located in position in a compartment between the heating elements 40. As can be seen, the floating bypass seal essentially extends out to the tangential plates 26 to close off the gap 42. FIG. 6 is another showing of the floating bypass seal 46 in position overlying a heating element 40. The periphery of the heating element 40 is shown in dotted line below the seal 40. It can be seen that the seal extends out to the sides of the compartment with minimal clearance and that the seal overlaps the heating element 40 to form a flow restriction and essentially close the gap. As can be seen in the FIG. 5, the floating bypass seal 46 is sandwiched between the two heating elements 40. Therefore, the seal, which is typically free floating, cannot be blown out of position such as when soot blowing pressures are applied. During installation of the seal, it may be advantageous to at least temporarily fasten the seal in position in the compartment. This can be done by welding such as tack welding along at least one side. This may facilitate the assembly even though the tack welds may later break due to the forces created such as by thermal expansion.
Since some air preheaters may have corresponding compartments 28 in various sectors 24 which vary in size, either due to manufacturing tolerance or thermal deformations, FIG. 7 shows a modified floating bypass seal 50 which is adjustable. This floating bypass seal is subdivided into segments identified as 52 which are connected to each other by the sliding coupling means 54. The coupling means 54 which are illustrated are merely heavy sheet metal bent around the joints between the segments to hold the segments together while permitting the segments to slide within the coupling means. However, other forms of coupling means could also be used in the present invention. For example, the ends of the segments could have openings into which a coupling bar is slidably inserted thereby bridging the joints. After assembly of the four segments 52 with the coupling means 54, the floating bypass seal 50 is installed in a compartment 28 and then adjusted outward so that the segments engage the radial and tangential plates or, in the case of the outermost compartment, engage the rotor shell. This assures that the clearances between the floating bypass seals and the walls of the compartments are always minimal.
Another embodiment of the invention is shown in FIGS. 8 and 9. In this embodiment, the floating bypass seal, now identified as 56, consists of a base frame 58 which is sized to fit a rotor compartment with a slightly increased but still small clearance. Attached to the base frame 58 is a deformable edge seal 60 which may be on all four sides as shown in FIG. 8 or may only be on fewer than four sides. This deformable edge seal may be attached by any suitable means such as welding and may be formed from any light gauge metal strip which is capable of being deformed to conform to the shape of the compartment walls. For installation, this modified floating bypass seal 56 is positioned in the intended compartment, usually at an angle, and then pressed down into position in engagement with the top of a heating element. In the process of pressing the seal into position, the edge seal 60 is deformed to essentially form a continuous engagement between the seal and the compartment wall as shown in FIG. 9. | The gas flow bypass around the heating elements in a regenerative air preheater is reduced by the use of floating bypass seals which are placed in the rotor compartments between stacked heating elements. The seals comprise a frame with an open center with the peripheral frame portion bridging the gaps between the heating elements and the sides of the compartments. The seals may be adjustable and may include a deformable edge seal to actually contact and seal against the sides. | 8 |
CROSS REFERENCE TO RELATED APPLICATION
[0001] This application claims the priority benefit of U.S. Provisional Patent Application Ser. No. 61/753,656, “Vehicle Tire Deflation Device,” filed Jan. 17, 2013, which is hereby expressly incorporated by reference herein in its entirety.
TECHNICAL FIELD
[0002] The present disclosure generally relates to vehicle tire deflation devices, particularly to such devices employed by law enforcement to deflate the tires of a vehicle.
BACKGROUND
[0003] Conventional tire deflation devices are used by law enforcement to prevent or end vehicle chases. Once deployed on road surfaces, a device which comes into contact with a vehicle's tires can deploy spikes, thereby deflating the tires. However, it has been observed that such conventional devices may fail to properly deploy such spikes due to insufficient collapse of the device or movement of device when contacted by the targeted vehicle. Accordingly, it is desirable to provide improved vehicle tire deflation devices.
SUMMARY
[0004] In accordance with one example, a vehicle tire deflation device includes a housing structure, a core structure, a plurality of spikes, a first end cap and a second end cap. The housing structure includes a first end and a second end. The core structure resides within the housing structure. The plurality of spikes is maintained by the core structure and positioned in a predetermined orientation. The predetermined orientation positions the spikes to penetrate a tire when a vehicle travels over the vehicle tire deflation device. Each end cap selectively attaches to the respective ends of the housing structure. Each end cap defines an opening and comprises an outer wall. Each of the openings communicates with the interior of the device so as to permit air to pass from the interior to the exterior of the device. The outer wall of each end cap comprises a plurality of grip members.
[0005] In accordance with one example, a vehicle tire deflation device includes a housing structure, a core structure, a plurality of spikes, a first end cap and a second end cap. The housing structure includes a first end and a second end. The core structure resides within the housing structure. The plurality of spikes is maintained by the core structure and positioned in a predetermined orientation. The predetermined orientation positions the spikes to penetrate a tire when a vehicle travels over the vehicle tire deflation device. Each end cap selectively attaches to the respective ends of the housing structure. Each end cap defines an opening and comprises an outer wall. Each of the openings communicates with the interior of the device so as to permit air to pass from the interior to the exterior of the device. Each of the housing structure, core structure, and end caps is formed from a collapsible material. The collapsible material is sufficiently malleable such that each of the housing structure, core structure and end caps are configured to collapse as a vehicle travels over the vehicle tire deflation device.
[0006] In accordance with one example, a method of using a vehicle tire deflation device is provided. The method includes deploying the vehicle tire deflation device onto a road, contacting a tire of a desired vehicle with the vehicle tire deflation device, puncturing the tire of the desired vehicle, and stopping the desired vehicle. The vehicle tire deflation device includes a housing structure, a core structure, a plurality of spikes, a first end cap and a second end cap. The housing structure includes a first end and a second end. The core structure resides within the housing structure. The plurality of spikes is maintained by the core structure and positioned in a predetermined orientation. The predetermined orientation positions the spikes to penetrate a tire when a vehicle travels over the vehicle tire deflation device. Each end cap selectively attaches to the respective ends of the housing structure. Each end cap defines an opening and comprises an outer wall. Each of the openings communicates with the interior of the device so as to permit air to pass from the interior to the exterior of the device. Each of the housing structure, core structure, and end caps is formed from a collapsible material. The collapsible material is sufficiently malleable such that each of the housing structure, core structure and end caps are configured to collapse as a vehicle travels over the vehicle tire deflation device.
[0007] While the specification concludes with claims particularly pointing out and distinctly claiming the subject matter that is regarded as the present invention, it is believed that the invention will be more fully understood from the following description.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] FIG. 1 is a partially cut-away elevational view of an example of a vehicle tire deflation device.
[0009] FIG. 2 is a side elevational view of the tire deflation device of FIG. 1 , with the end cap removed.
[0010] FIG. 3 is a prospective view of a vehicle tire deflation device having an end cap.
[0011] FIG. 4 is an enlarged view of the end cap shown in FIG. 3 .
[0012] FIG. 5 is a perspective view of an example of a vehicle tire deflation device.
[0013] FIG. 6 is a partial exploded view of FIG. 5 illustrating partial removal of a housing.
[0014] FIG. 7 is a partial exploded view of FIG. 6 illustrating removal of a housing to depict a core structure.
[0015] FIG. 8 is an exploded view of the core structure of FIG. 7 , further illustrating spike subassemblies.
DETAILED DESCRIPTION
[0016] Tire deflation devices are being placed in greater use by the law enforcement community. Such conventional devices typically include a base and a plurality of tire deflating spikes or quills removably secured to the base. When a tire of a vehicle pursued by law enforcement rolls over such a device, spikes or quills can be embedded in the tire and pulled free from the base. Such spikes or quills cause the tire to deflate, thus immobilizing the vehicle and the fleeing suspect. The quills may be hollow to accelerate deflation of the tires. Such tire deflation devices are disclosed in U.S. Pat. Nos. 5,330,285, 5,452,962, 5,820,293, and 6,155,745, each of which is hereby incorporated by reference herein as if fully set forth in their entirety.
[0017] One disadvantage of tire deflation devices of the type described above is construction of the end caps. Such end caps can prevent deployment of the deflation device during use. It would therefore be desirable to provide a more effective vehicle tire deflation device having improved end caps.
[0018] Referring now to the drawings, FIG. 1 illustrates one representative example of a vehicle tire deflation device 100 in a partially cut-away view so that details regarding the positioning of spikes 133 can be easily discerned. In one example, the vehicle tire deflation device 100 can have a triangular cross-sectional shape and can have a desired length (e.g., about three feet long). The desired length can be sufficient to cover a significant portion of a road surface, and will also allow the tire deflation device 100 to easily fit inside the trunk space of a standard vehicle (e.g., police car). For example, multiple such tire deflation devices 100 could easily be stored in the trunk of a police vehicle to be available to an officer when needed. These devices could be placed across a road surface (e.g., along a common axis) so as to cover a majority of a particular lane when deployed. It will be appreciated that a substantial portion of a road would need to be traversed to increase the likelihood that a fleeing vehicle makes contact with the vehicle tire deflation device 100 .
[0019] In one example, the tire deflation device 100 can have a triangular shape which can be symmetrical, both in its outer dimensions, and its inner components, such that a three-piece spike subassembly 132 , described herein and shown in FIGS. 1-2 , can be positioned parallel to each of panels 102 , 104 , and 106 which can form the outer surfaces of a housing of the tire deflation device 100 . Since the vehicle tire deflation device 100 shown in FIGS. 1 and 2 can be symmetrical (e.g., triangular shape), it can be placed upon a road surface in any of the six possible orientations (i.e., on any one of its panels 102 , 104 , or 106 , and in either direction) and can be equally effective in puncturing the tires of a vehicle passing thereover from either direction. Panels ( 102 , 104 , and 106 ) can form a collapsible housing. Such panels can be formed of a variety of suitable materials, including for example, polypropylene, polyethylene, laminated paper board, butyrate plastic, or any other suitable material which will be sufficiently malleable and collapse when subjected to the weight of a vehicle when run over. The first panel, generally designated by the numeral 102 , can be positioned at an angle of about 60 ° from the second panel (designated by the numeral 104 ), which in turn can be positioned at about 60 ° from the third panel (designated by the numeral 106 ). In certain examples, panels can have a thickness of about 0.01 inch to about 0.05 inch; in certain examples of about 0.02 inch to about 0.03 inch; and in certain examples a thickness of about 0.025 inch. The panels ( 102 , 104 , and 106 ) can be attached to each other using a variety of suitable fastening techniques. For example, in one example, each of the panels 102 , 104 , 106 can be held in place with respect to one another by an adhesive material (e.g., tape). These strips of adhesive material (not shown) can each run parallel to the longitudinal axis of the tire deflation device 100 , and run the entire length of the device 100 . Such that in one example, a weather seal can be formed by the combination of the adhesive materials and the material (e.g., laminated film) used to form each of the panels 102 , 104 , and 106 . In another example, panels to form the housing can be formed as a unitary structure such that each respective panel is integrally attached to the other panels. Such a unitary structure can be formed by forming a mold of the housing with each of the respective panels.
[0020] In certain examples once the housing is formed, a core structure 120 (as generally shown in FIG. 2 ) can be placed inside the housing of the tire deflation device 100 , and can be used to maintain the three-piece spike subassemblies 132 in a proper and predetermined orientation, for example, as generally shown in FIG. 1 . The core structure 120 can be formed from any suitable collapsible materials, including for example, Styrofoam®. In one example, each of the spike subassemblies 132 can be positioned apart from one another by a distance of about one-half (½) inch along the longitudinal axis of the vehicle tire deflation device 100 . As FIG. 1 depicts, the spike subassemblies 132 can include in spikes 133 in groups of three, one spike 133 pointing in each of the three possible directions for each group. Each of these groups of spikes 133 can be separated along the core structure 120 at desired intervals, each interval having a distance of approximately three inches. Such an arrangement provides a sufficient number of spike subassemblies to be available to puncture a tire crossing a tire deflation device without having to place spike subassemblies at each of the designated intervals, thereby reducing the amount of spike subassemblies needed and thus reducing the cost of a tire deflation device.
[0021] As illustrated in FIGS. 1 and 2 , each spike 133 of a spike subassembly 132 can include a first spike tip 134 , a spike quill 136 , and a second spike tip 138 (which can be substantially identical to the first spike tip 134 ). In one example, spike subassemblies 132 can be designed to; first, penetrate the surface of a tire by use of one spike tip 134 or 138 , after which time the spike quill 136 becomes embedded in the tread, casing and/or belts of the tire. As the tire passes over spike subassembly 132 , the bottom tip of the other spike tip 134 or 138 can fall free from the tire because it can easily slide out from the spike quill 136 . Once the remaining portions of spike subassembly 132 are rotated to the top of the tire (by the inherent rotation of the tire as it passes over the tire deflation device 100 ), the upper spike tip 134 or 138 can similarly fall free from the spike quill 136 , thereby falling into the interior spaces of the tire. Since spike quill 136 can be hollow, now that it is embedded in the tread, casing and/or belts of the tire, it can allow the air inside the tire to leak outside due to the pressurization of the interior chamber of the tire. The depressurization of the tire is controlled to the extent that the tire does not blow out, thereby allowing the driver of the vehicle to fairly easily control the direction of the vehicle while the tire is losing air. The spike tips 134 and 138 and spike quill 136 can be made of steel, or any other suitable material that can be used to penetrate a tire. It will be appreciated that other spike assemblies (having different configurations) could be utilized in a tire device as described herein.
[0022] It will be appreciated that various subassemblies can be utilized in forming a tire deflation device. Other suitable designs are described in U.S. Pat. No. 5,452,962, and hereby incorporated by reference herein as if fully set forth in its entirety.
[0023] The vehicle tire deflation device 100 can also include a pair of collapsible end caps 140 . The end caps 140 , as shown in FIG. 1 , can be collapsible to prevent a vehicle tire from “ramping over” an otherwise rigid cap and thereby avoiding the spikes 133 . In one example, the end caps 140 can be removably secured to each opposed end of the tire deflation device 100 . However, it will be appreciated that the end caps 140 can be selectively attached to a tire deflation device using a variety of techniques. In one example, outer surfaces of the end cap 140 can be laminated so as to protect the end cap 140 from weather conditions. The end cap 140 can be formed a variety of materials, including for example, polypropylene, polyethylene, paper board, butyrate plastic, or any other suitable material that permits sufficient collapse when the end cap is subjected to the weight of a vehicle.
[0024] FIGS. 3 and 4 illustrate another example of an end cap 240 . End cap 240 can have a generally triangular shape and include a rear flange 250 configured to removably secure the end cap 240 to one end of a housing 201 of a tire deflation device 200 . An outer wall 252 of the end cap 240 can include outwardly projecting serrated grips 254 . Such grips 254 can provide increased interaction (e.g., increased traction) with a road surface during deployment of the tire deflation device 200 , thereby substantially preventing the tire deflation device 200 from moving or shifting once deployed and placed in contact with a tire of a desired vehicle. The end cap 240 can be formed of a variety of materials, including polyethylene (e.g., low density polyethylene) or polypropylene. In certain examples, the materials forming the end cap 240 can be sufficiently malleable providing greater ease in securing the end cap 240 to a housing 201 of a tire deflation device 200 .
[0025] In one example, as shown in FIG. 4 , an opening (e.g., “SS” designation 256 ) in the end cap 240 can assist in facilitating the expulsion of air upon use of the vehicle tire deflation device 200 . Once crushed, any air residing within an interior of the housing 201 of the tire deflation device 200 can escape through the opening improving the collapsibility of the vehicle tire deflation device 200 , thus improving the overall operation and deployment of the tire deflation device 200 . Without such a mechanism to release air residing within the tire deflation device, the housing 201 may not sufficiently collapse to permit quills (not shown) to properly extend and provide the means by which to deflate the tires on a desired vehicle. It will be appreciated that such openings can be design to have a variety of suitable shapes and configurations.
[0026] FIGS. 5-8 illustrate another example of a tire deflation device 300 . The tire deflation device 300 can include a label 360 on at least one portion of the device 300 , such as a housing 301 (as shown in FIG. 6 ). This label 360 can include certain indicia that can include warnings, advertisements or other suitable indicia (e.g., “Stop Stick”). As further shown in FIG. 6 , the housing 301 can include an inner portion 370 and an outer portion 380 . Inner and outer portions 370 , 380 can be formed of a variety of suitable materials, including for example, polypropylene, polyethylene, laminated paper board, butyrate plastic, or any other suitable material which will be sufficiently malleable and collapse when subjected to the weight of a vehicle when run over.
[0027] The outer portion 380 can include a unitary structure that is configured to pass over and substantially cover the inner portion 370 . End caps 340 can be attached to the housing 301 via an intermediary device 346 . As illustrated in FIG. 7 , the inner portion 370 can include panels 302 , 304 and 306 which can be in contact with a core structure 320 . Each of the panels 302 , 304 , 306 can be held in place with respect to one another by an adhesive material (e.g., tape). These strips of adhesive material (e.g., 345 ) can each run parallel to the longitudinal axis of the tire deflation device 300 , and run the entire length of the tire deflation device 300 . Such that in one example, a weather seal can be formed by the combination of the adhesive materials and the laminated film of each of the panels 302 , 304 , and 306 . The panels ( 302 , 304 , 306 ) can further be held in place with the attachment of intermediary device 346 . Finally, as depicted in FIG. 8 , the core structure 320 can be used to hold a three-piece spike subassembly 332 in a proper orientation, similar to that as shown in FIG. 1 . The core structure 320 can be formed from any suitable collapsible materials, including for example, Styrofoam®. Each spike 333 of a spike subassembly 332 can include a first spike tip 334 , a spike quill 336 , and a second spike tip 338 (which can be substantially identical to the first spike tip 334 ). The spike subassembly 332 can be loaded into and maintained in the core structure 320 and operate in a similar manner as previously described herein.
[0028] Those skilled in the art will readily recognize numerous adaptations and modifications which can be made to the present disclosure which will result in an improved vehicle tire deflation device, yet all of which will fall within the spirit and scope of the present disclosure as set forth in the following claims. For example, a tire deflation device can be utilized to deflate the tires of a fleeing vehicle, as well as placed behind the tires of a stationary vehicle to prevent the stationary vehicle from being employed as an escape vehicle during, for example, the serving of a felony arrest warrant or drug raid. For use in deflating the tires of fleeing vehicles, in certain examples a vehicle tire deflation device can be configured to include cartridges which include only 1 quill each, and 7-10 cartridges per base. For use in placing behind the tires of a stationary vehicle, a tire deflation device can be configured with cartridges which include two quills each, and 1 cartridge per base.
[0029] The dimensions and values disclosed herein are not to be understood as being strictly limited to the exact numerical values recited. Instead, unless otherwise specified, each such dimension is intended to mean both the recited value and a functionally equivalent range surrounding that value. For example, a dimension disclosed as “40 mm” is intended to mean “about 40 mm.”
[0030] Every document cited herein, including any cross-referenced or related patent or application, is hereby incorporated herein by reference in its entirety unless expressly excluded or otherwise limited. The citation of any document is not an admission that it is prior art with respect to any invention disclosed or claimed herein or that it alone, or in any combination with any other reference or references, teaches, suggests, or discloses any such invention. Further, to the extent that any meaning or definition of a term in this document conflicts with any meaning or definition of the same term in a document incorporated by reference, the meaning or definition assigned to that term in the document shall govern.
[0031] The foregoing description of examples has been presented for purposes of illustration and description. It is not intended to be exhaustive or limiting to the forms described. Numerous modifications are possible in light of the above teachings. Some of those modifications have been discussed and others will be understood by those skilled in the art. The examples were chosen and described for illustration of various examples. The scope is, of course, not limited to the examples set forth herein, but can be employed in any number of applications and equivalent devices by those of ordinary skill in the art. Rather it is hereby intended the scope be defined by the claims appended hereto. | A vehicle tire deflation device includes a housing structure, a core structure, a plurality of spikes, a first end cap and a second end cap. The housing structure includes a first end and a second end. The core structure resides within the housing structure. The plurality of spikes is maintained by the core structure and positioned in a predetermined orientation. The predetermined orientation positions the spikes to penetrate a tire when a vehicle travels over the vehicle tire deflation device. Each end cap selectively attaches to the respective ends of the housing structure. Each end cap defines an opening and comprises an outer wall. Each of the openings communicates with the interior of the device so as to permit air to pass from the interior to the exterior of the device. Methods of using a vehicle tire deflation device are also described. | 4 |
CROSS-REFERENCES TO RELATED APPLICATIONS
This application claims the benefit of the German patent application No. 110 2010 043 433.7 filed on Nov. 4, 2010 and the German patent application No. 10 2010 043 836.7 filed on Nov. 12, 2010, the entire disclosures of which are incorporated herein by way of reference.
BACKGROUND OF THE INVENTION
The instant invention relates to a filter for a fluid medium, in particular oil, water, fuel or air filter for an internal combustion engine, comprising a filter housing and a cover, which is releasably connectable to the latter, comprising a replaceable filter insert, which consists of a hollow-cylindrical filter cloth body and two end discs, enclosing the latter frontally, the one end disc of which encompasses a central through hole, wherein, leading with the open end disc, the filter insert can be plugged onto a central stand pipe, which forms part of the filter housing, wherein a locking ring is guided in an axially displaceable manner on the stand pipe, wherein the locking ring is preloaded by a force acting in a pushed-out direction pointing towards the free end of the stand pipe, wherein, in a pushed-out position, the locking ring is locked by a locking device against being pushed in, wherein provision is made for unlocking means, which are guided by the filter insert and which, when the filter insert is pushed onto the stand pipe, actuate the locking device in the unlocking direction and enable the locking ring and the filter insert to be pushed in, and wherein, when the filter insert is fitted into the filter housing, a seal provided on the end disc or on the locking ring interacts with a sealing surface of the filter housing to separate an untreated medium side from a clean medium side of the filter. The invention furthermore relates to a filter insert for use in the above-mentioned filter.
Increasingly higher demands are made on filters, in particular oil, water, fuel or air filters for an internal combustion engine, in particular in view of the filter refinement and the service life of the replaceable filter inserts. These high demands can only be fulfilled, when suitable high-quality filter inserts are fitted into the filters.
A filter, by means of which the installation of an unsuitable third-party filter insert within the context of a filter maintenance with a filter insert replacement is interrupted, is known from EP 1 235 624 B 1. This document describes a filter comprising the above-mentioned features. The locking ring, which is guided on the stand pipe, is also a valve sleeve, which can be displaced axially on the stand pipe and which is preloaded with a force, which acts in valve closing direction. In the closed position of the valve, the locking ring latches with the stand pipe by means of locking lugs, which face radially inward, on locking tabs. By attaching a filter insert by means of suitable unlocking means, the latching of the locking ring or of the valve sleeve, respectively, with the stand pipe, is released, in that the locking tabs are pivoted radially outwardly. The locking ring is then displaced by means of the filter insert into valve open position and is held therein. An unsuitable third-party filter insert does not disengage the latching of the locking ring on the stand pipe and the filter insert cannot be attached completely onto the stand pipe. An operation of the filter is thus not possible, due to the valve body, which is in closed position; the same applies when a filter insert is missing. The locking ring is sealed against the stand pipe by means of a sealing ring. The end disc of the filter insert, which interacts with the locking ring, is sealed against the locking ring via a further sealing ring on the end disc.
Even though this known filter fulfills the demands of preventing the installation of an unsuitable third-party filter insert, a filter insert comprising an end disc comprising unlocking means, which are designed so as to be relatively extensive, is necessary for this purpose and two sealing locations, in each case comprising a sealing ring, are present, which is associated with an increased parts and assembly effort in a disadvantageous manner.
SUMMARY OF THE INVENTION
The instant invention thus has the object of creating a filter of the above-mentioned type, which makes it impossible to use unsuitable filter inserts and to operate the filter without a filter insert and which thereby encompasses a simple design comprising a small number of individual components and still comprising a high functional reliability.
According to the invention, the solution of the part of this object relating to the filter is possible by means of a filter of the above-mentioned type, which is characterized in that, in the case of a locking ring, which is in pushed-out direction and in the case of a filter insert, which is in axial contact with the locking ring, the seal is held at a distance from the corresponding sealing surface of the filter housing.
An advantageously simple design is attained by means of the invention, because only one seal is required in the filter between the filter insert and the filter housing; further seals are not required. The desired function, namely to prevent the operation of the filter with an unsuitable third-party filter insert, which does not encompass the required unlocking means, is also attained by means of only the single seal. This is attained in a particularly simple manner in that, when using a filter insert, which does not encompass the required unlocking means, the seal provided between said filter insert and the filter housing does not reach a sealing position at all; according to the invention, the seal is in this case instead held at a distance from the corresponding seal seat. At the same time, the filter insert cannot be brought into its fitted position, which prevents a closing of the filter housing by means of the corresponding housing cover. The desired function is thus reached in a highly reliable manner and with cost-efficient production and assembly costs by means of technically simple means.
In a further embodiment, provision is preferably made for the filter housing to have a bottom comprising a central, hollow-cylindrical bottom part and for the sealing surface on the filter housing side to be arranged on an inner peripheral surface or outer peripheral surface or end surface of the hollow-cylindrical bottom part. In the case of this embodiment, a seal comprising a relatively small diameter is sufficient in an advantageous manner, which contributes to cost-efficient production costs. The seal can be embodied so as to seal radially or so as to seal axially, wherein a radially sealing seal is preferred, because a compensation of dimensional tolerances is simpler by means of it.
In terms of a compact design, it is proposed for the hollow-cylindrical bottom part and a lower part of the stand pipe to define an annular gap, which accommodates the locking ring in the pushed-in position thereof at least across a part of its height.
Provision is furthermore made in an advantageous manner for the end disc of the filter insert, which encompasses the through hole, to encompass a central annular appendage, which surrounds the through hole, on its side, which faces away from the filter cloth body, and which supports the seal. Due to the fact that the seal is assigned to the filter insert, the seal is renewed with each filter insert replacement during maintenance of the filter, which contributes to a reliable function.
A further development concerning this matter proposes for the appendage to engage with the annular gap by means of the seal when the filter housing is fitted in the filter housing. An advantageous arrangement and accommodation of the seal is possible in this embodiment.
In the case of the filter according to the invention, the unlocking means can be arranged or integrally molded on the filter insert or on a separate unlocking means body, which can be plugged onto the stand pipe before the filter insert. In the first alternative, a particularly small amount of component parts are required. In the case of the second alternative, one extra component is present due to the separate unlocking means body, but this provides for a larger freedom when connecting filter inserts, because the latter then do not need to encompass the unlocking means, but only guide and position the unlocking means body in response to the installation of the filter insert into the filter housing.
However, provision is preferably made for the unlocking means to be arranged or integrally molded on the end disc of the filter insert, which encompasses the through hole, or on a support body, which forms part of the filter insert and which is arranged in the interior of the filter cloth body between the end discs. Parts of the filter insert, which are present in any event, are thereby used for arranging the unlocking means, which is advantageous from a technical point of view. The support body can be a hollow-cylindrical support grid, for example.
The above-mentioned locking device of the filter can be designed in different ways. A first embodiment to this effect provides for the locking device to be formed by means of locking guides, which are embodied so as to be integrally molded with or fixedly connected to the stand pipe, being movable in radial direction, in each case comprising a locking surface, which is oriented in axial direction, for the locking guides to be prestressed with a force, which acts in locking direction and, in each case lock the locking ring in its pushed-out position against an axial insertion relative to the stand pipe by means of its locking surface and for the locking guides to be directly movable in radial direction into the unlocked position thereof by means of the unlocking means when the filter insert is plugged onto the stand pipe. Due to the fact that the locking guides, which form the locking device, are embodied so as to be integrally molded with or fixedly connected to the locking ring, these parts form a unit, which can be connected as a whole to the stand pipe. An unlocking of the locking ring can take place here in an advantageous manner only when the unlocking means, which are required for unlocking the locking guides in response to the installation of the filter insert, are brought into unlocking engagement with the locking guides in the suitable design and arrangement. A particularly reliable function is attained due to the direct impact of the unlocking means onto the locking guides.
The locking guides thereby preferably run in axial direction. The locking guides can thus be embodied with a sufficiently large length, which provides for the required radial movability without special articulations without any problems. At least the locking guides consist of a flexible material for this purpose.
In a further preferred manner, provision is made for the locking guides to consist of a resilient material. In this embodiment, the force, which prestresses the locking guides in locking direction, can simply be created by means of the material itself, which eliminates separate springs or similar parts.
A further embodiment proposes for the locking ring to be hollow-cylindrical and to be attached to the stand pipe on the outside and for the locking guides to be provided on the stand pipe and in each case to encompass a locking nose, which is oriented radially outwardly, wherein the locking noses can be engaged with and disengaged from an end side of the locking ring. A simple and good guide of the locking ring on the stand pipe is attained in this embodiment. The locking ring simultaneously protects the locking guides from harmful external influences, which benefits a permanently reliable function.
In terms of a simple design having a high functional reliability, provision is preferably made for the locking guides to encompass a cam in each case, which radially protrudes in locking direction and for the unlocking means to engage with the cams when the filter insert is plugged onto the stand pipe and for the locking guides to pivot radially in unlocking direction.
To prevent that the locking guides are bent in locking direction or even broken off accidentally or due to intentional manipulation, it is proposed for a stop, which defines the movement thereof in locking direction, to be assigned to each locking guide.
So as to attain a design, which is as simple as possible and reliable in view of the unlocking means, the unlocking means are preferably formed by ribs, which protrude radially in unlocking direction of the locking guides. When the filter insert is inserted into the filter housing, these ribs ensure a pivoting of the locking guides, so as to enable the locking ring to be pushed in on the stand pipe and so as to be able to completely insert the filter insert into the filter housing and so as to be able to engage the corresponding sealing surface with one another.
An alternative embodiment of the filter according to the invention in view of the locking device proposes for the locking device to be formed by means of guide means, which are arranged on the outer periphery of the stand pipe and on the inner periphery of the locking ring, which together form a locking stage and an axial or transverse guide, which is offset thereto in peripheral direction, for the guide means to lock the locking ring in its pushed-out position against an axial insertion relative to the stand pipe by means of the locking stage and for the locking pin to be twistable into an unlocked position in peripheral direction by means of the unlocking means when the filter insert is plugged onto the stand pipe and then to be capable of being inserted along the axial or transverse guide. In this embodiment of the locking device, the elements thereof are also embodied integrally with the stand pipe and the locking ring, so that separate component parts are also not required here for this purpose. An unlocking of the locking ring can also take place here in the desired manner only when the unlocking means, which are required for unlocking the locking device, are present in the suitable embodiment and arrangement when the filter insert is fitted.
In a concrete further development, provision is preferably made for one or a plurality of interacting inclined planes to be in each case arranged on the inner periphery of the filter insert and on the outer periphery of the locking ring such that the locking ring is set into a limited rotation in response to an axial displacement of the filter insert. The interacting inclined planes, which are provided here, are a simple and reliable means for creating the desired limited rotation of the locking ring for the purpose of unlocking.
To attain an arrangement comprising an advantageous design, the inclined planes on the filter insert side are preferably arranged on the inner periphery of the central through hole of the end disc.
To also attain an arrangement, which is simple and simultaneously advantageous from a functional point of view, in view of the interacting guide means on the stand pipe and on the locking ring, it is proposed for the guide means, which are arranged on the outer periphery of the stand pipe, to be formed by at least one protruding web, which forms a guide contour, and for the guide means, which are arranged on the inner periphery of the locking ring, to be formed by means of at least one guide nose, which protrudes into the guide contour. The guide nose can thus move within the guide contour, but cannot be moved beyond the guide contour, which is formed by means of the protruding web. Advantageously, the guide contour, which is formed by means of the protruding web, as well as the guide nose, can be embodied so as to be integrally molded with the respective assigned component.
To ensure that the locking ring assumes its locked position reliably when the filter insert is removed from the filter housing, it is proposed for the guide means, which are arranged on the outer periphery of the stand pipe, to encompass a guide bevel, which positively guides the locking ring into its locked position in response to its push-out movement.
For all of the above-described embodiments of the filter, provision is preferably made on the outer periphery of the stand pipe for position guide means, which interact with the unlocking means or with guide means, which are additionally arranged on the inner periphery of the filter insert and which positively guide the unlocking means in peripheral direction into a position, which is suitable for engagement for the locking guides of the stand pipe or for the inclined planes of the locking ring when the filter insert is plugged on, and which then lock the filter insert against being twisted in peripheral direction. The correct installation position of the mentioned parts relatively to one another is effected through this even without particular attention by operating personnel and without the necessity of an accurate manual positioning of filter insert and locking ring relative to one another. When embodying the filter with an unlocking device, which must carry out a limited twisting of the locking ring, the operating personnel must thus also not ensure that the filter insert does not carry out a rotation in peripheral direction when it is inserted into the filter housing.
A further contribution to a cost-efficient production of the filter is that the force, which prestresses the locking ring in pushed-out direction, is preferably created by means of at least one pressure spring, which is arranged on the outside of the stand pipe and which is supported on the stand pipe or on the filter housing on the one hand and on the locking ring on the other hand. In the simplest case, the pressure spring can be a helical spring, which surrounds the stand pipe.
The invention also creates the possibility of providing locking devices, which are designed differently, and for unlocking means, which are designed differently, for forming a coded lock-key system, wherein a certain embodiment of the locking device can only be unlocked by means of a certain, matching embodiment of the unlocking means. This can contribute to preventing the installation of unsuitable filter inserts into the filter housing.
In the case of many filters, provision is made for a filter bypass valve, which allows for a fluid flow directly from the untreated medium side to the clean medium side of the filter by bypassing the filter cloth body, when the filter cloth body is clogged by dirt particles. A particularly advantageous integration of such a filter bypass valve into the filter according to the invention is attained, when, as is proposed in a further development according to the invention, an end disc of the filter insert encompasses a valve seat for a valve body on the filter housing side, which is prestressed with a force acting in valve closing direction, for forming a filter bypass valve. Advantageously, no additional valve seat component is required hereby for realizing the filter bypass valve, because the valve seat is provided on the end disc of the filter insert.
In the case of filters, it is desirable in many cases to provide for an emptying of the filter housing in the context of a filter maintenance, before the filter insert is removed from the filter housing. For this purpose, provision is made in the case of the filter insert according to the invention for the filter housing to encompass an eccentrically arranged discharge channel in its bottom, for the filter insert to encompass an axially protruding, eccentric locking bolt for the discharge channel on the side of the end disc facing the bottom, which faces away from the filter cloth body, and for provision to be made for position guide means, which interact on the inner periphery of the filter insert and on the outer periphery of the stand pipe and which positively guide the filter insert in peripheral direction into a position of the locking bolt, which is suitable for engagement for the discharge channel, when the filter insert is plugged onto the stand pipe. In this embodiment of the filter, the discharge channel, which is arranged in the bottom of the filter housing, is closed reliable on the one hand when the filter insert is inserted, because it is ensured that the locking bolt is positioned so as to match the discharge channel. The position guide means mentioned herein for the locking bolt can thereby be separate means or also, which is preferable, simultaneously be position guide means, which are already provided for the engagement-suitable positioning of the unlocking means relative to the locking device. When the cover of the filter housing is removed in the context of a maintenance operation and when the filter insert is moved to the extent, which is sufficient for removing the locking bolt from the discharge channel, the liquid located in the filter housing and in the filter insert drains through the discharge channel. A filter insert, which is largely free of liquid, can thus be removed from the filter housing. As is known per see, the filter insert can thereby by latched to the cover, so as to transfer an axial traction force onto the filter insert, which moves the filter insert together with the cover in removal direction, when the cover is removed from the filter housing.
The above-described filter can be a standing filter, in the case of which the filter insert can be removed towards the top, as well as a hanging filter, in the case of which the filter insert can be removed towards the bottom.
In addition to the above-described locking ring as well as the corresponding locking device and the corresponding unlocking means, the filter according to the invention can also encompass a further locking device so as to increase the safeguarding against the use of unsuitable third-party filter inserts, wherein the further locking device encompasses an end piece, which is guided on the stand pipe so as to be capable of being displaced, and locking guides, which form a part of the stand pipe or of the end piece and which can be moved in radial direction, in each case comprising a locking surface, which faces in axial direction, wherein the locking guides are prestressed by means of a force, which acts in locking direction and in each case lock the end piece in its pushed-out position against an axial insertion relative to the stand pipe by means of its locking surface, and wherein the locking guides can be moved directly in radial direction into their unlocked position by means of the unlocking means. A double safeguard is attained in this manner, when particularly high demands are made in view of a safeguarding against the installation of unsuitable filter inserts into the filter housing.
The invention finally also relates to a filter insert for being used in a filter wherein the filter insert consists of a hollow-cylindrical filter cloth body and two end discs, which surround it on the end side, the one end disc of which encompasses a central through hole, wherein the filter insert can be plugged onto a central stand pipe, which forms part of the filter housing, with the open end disc first, and wherein provision is made for unlocking means, which are guided with the filter insert and which actuate a locking device in unlocking direction when the filter insert is plugged onto the stand pipe, and which enable the filter insert to be plugged on completely. The filter insert is characterized in that the unlocking means are arranged or integrally molded on the filter insert. It is attained through this that only a certain filter insert can be fitted into a certain filter, wherein separate unlocking means are not required.
BRIEF DESCRIPTION OF THE DRAWINGS
Exemplary embodiments of the invention will be defined below by means of a drawing.
FIG. 1 shows a filter in a first embodiment comprising an open filter housing and without filter insert, in longitudinal section,
FIG. 2 shows the filter from FIG. 1 , comprising a partially inserted filter insert and comprising a cover, in longitudinal section,
FIG. 3 shows the filter from FIGS. 1 and 2 , comprising the further inserted filter insert, in longitudinal section,
FIG. 4 shows the filter from FIGS. 1-3 , comprising a completely inserted filter insert and attached cover, in longitudinal section,
FIG. 5 shows a stand pipe of the filter according to FIGS. 1 to 4 as component part, in top view,
FIG. 6 shows a locking ring of the filter according to FIGS. 1 to 4 as component part, in top view,
FIG. 7 shows a filter insert of the filter according to FIGS. 1 to 4 as component part, in top view,
FIG. 8 shows a filter in a second embodiment in a longitudinal section through the lower area of the filter, without filter insert,
FIG. 9 shows the filter from FIG. 8 , comprising an fitted filter insert, in a first longitudinal section,
FIG. 10 shows the filter from FIG. 9 in a second longitudinal section,
FIG. 11 shows the filter from FIGS. 8 to 10 , comprising an unsuitable third-party filter insert, in longitudinal section,
FIG. 12 shows the lower part of a stand pipe of the filter from FIGS. 8 to 11 , as component part in top view,
FIG. 13 shows a locking ring, which can be displaceably connected to the stand pipe from FIG. 12 , as component part in top view,
FIG. 14 shows the lower part of a filter insert, comprising integrated unlocking means, in top view,
FIG. 15 shows the filter in a third embodiment in a longitudinal section through the lower area of the filter, comprising a partially inserted filter insert, in longitudinal section,
FIG. 16 shows the filter from FIG. 15 , comprising a further inserted filter insert in longitudinal section,
FIG. 17 shows the filter from FIGS. 15 and 16 , comprising an even further inserted filter insert, in longitudinal section,
FIG. 18 shows the filter from FIGS. 15 to 17 , comprising a once again even further inserted filter insert, in longitudinal section,
FIG. 19 shows the filter from FIGS. 15 to 18 , comprising a once again even further inserted filter insert, in longitudinal section,
FIG. 20 shows the filter from FIGS. 15 to 19 , comprising a completely inserted filter insert, in a first longitudinal section,
FIG. 21 shows the filter from FIG. 20 in a second longitudinal section,
FIG. 22 shows the filter from FIGS. 20 and 21 in a third longitudinal section,
FIG. 23 shows the filter from FIGS. 15 to 22 , comprising an unsuitable third-party filter insert, in longitudinal section, and
FIG. 24 shows a filter insert, which matches the filter according to FIGS. 15 to 22 , in top view, transversely from the bottom.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 shows a filter 1 in a first embodiment, comprising an open filter housing 2 and without filter insert, in longitudinal section. The filter housing 2 is cup-shaped with a bottom 25 , in the center of which a hollow-cylindrical bottom part 25 ′, which continues downwards, is located. The inner periphery of this bottom part 25 ′ forms a sealing surface 26 for a seal 36 of a filter insert 3 , which is not yet fitted here. On its upper end, the housing 2 has a thread 22 for being screwed to a cover 21 , which is removed here. A stand pipe 4 , the lower end of which is connected to the filter housing 2 and which extends upwards from that location until approximately half of the height of the filter housing 2 , is arranged centrally in the interior of the filter housing 2 .
A locking ring 5 is displaceably guided on the stand pipe 4 so as to be defined in axial direction. In its pushed-out direction, which faces upwards, the locking ring 5 is prestressed by the force of a spring 44 , the lower end of which is supported on a spring support 44 ′ in the hollow-cylindrical bottom part 24 ′ and the upper end of which is supported on a spring support 54 on the locking ring 5 . In FIG. 1 , the locking ring 5 is thus in its pushed-out position due to the effect of the spring 44 . In this pushed-out position, an upper edge 51 of the locking ring 5 rests against a stop, here in the form of cams 43 , which is embodied on the stand pipe 4 .
The stand pipe 4 encompasses a locking device 40 , by means of which the locking ring 5 can be locked in its pushed-out position. Here, the locking device 40 comprises two resilient locking guides 41 , which run in axial direction and which are embodied so as to be integrally molded with the stand pipe 4 . In each case close to the lower end of each locking guide 41 , the latter, on its outer side, in each case encompasses a locking surface 41 ′, which points upwards in axial direction and which is located directly below a lower edge 51 ′ of the locking ring 5 . The locking ring 5 is thus prevented from being inserted downwardly.
FIG. 2 shows the filter 1 from FIG. 1 , comprising a partially inserted filter insert 3 and comprising a cover 21 in longitudinal section. The filter insert 3 consist of a hollow-cylindrical filter cloth body 30 , for example of a filter paper, which is folded in a zigzag-shaped manner and which is surrounded on the end side by a lower end disc 31 and an upper end disc 32 . A hollow-cylindrical support grid 30 ′ is arranged in the interior of the filter cloth body 30 for supporting the latter from collapsing during operation. The lower end disc 31 is embodied so as to be open in its center and is plugged onto the stand pipe 4 . On the bottom side, an annular appendage 35 , on the lower end of which a seal 36 , here a radial sealing ring, is attached, extends downwards from the lower end disc 31 . To be able to install the filter insert 3 , the latter has an unlocking means, which is not visible here, by means of which the locking device 40 can be unlocked. To bring the unlocking means into an engagement-suitable position for the locking guides 41 , interacting position guide means 48 and 38 are arranged on the outer periphery of the stand pipe 4 and on the inner periphery of the lower end disc 31 . In peripheral direction, said position guide means guide the filter insert 3 into a position, in which the unlocking means are located so as to match the locking guides 41 . The unlocking means then interact with the cams 43 on the locking guides 41 , so as to pivot the locking guides 41 inwards in radial direction and to thus unlock the locking device 40 .
The cover 21 of the filter housing 2 , which also encompasses a thread 22 on its lower edge for being screwed to the filter housing 2 , can also be seen on the top in FIG. 2 . The filter housing 2 and the cover 21 are then sealed against one another so as to be liquid-tight by means of a seal 23 .
FIG. 3 shows the filter 1 from FIGS. 1 and 2 , comprising the further inserted filter insert 3 , again in longitudinal section. The rib-shaped unlocking means 33 , which, in the state according to FIG. 3 , interact in particular in an unlocking manner with the cams 43 of the locking guides 41 , can now be seen radially inwardly on the lower end disc 31 of the filter insert 3 . The locking guides 41 are now in their released position, which is pivoted radially inside, in which the locking surfaces 41 ′ are located radially inward of the lower edge 51 ′ of the locking ring 5 . A downward displacement of the locking ring 5 against the force of the spring 44 is thus enabled.
FIG. 4 shows the filter 1 from FIGS. 1 to 3 , comprising a completely inserted filter insert 3 and attached cover 21 , again in longitudinal section. The unlocking means 33 are now displaced downwards beyond the locking guides 41 , whereby the resilient locking guides 41 are returned into their initial position. The lower end disc 31 of the filter insert 3 is now located at a small distance above the bottom 25 of the filter housing 2 . The hollow-cylindrical bottom part 25 ′ and the lower part of the stand pipe 4 form an annular gap 28 , into which the locking ring 5 is now displaced and which also accommodates the spring 44 below the locking ring 5 . The annular appendage 35 , which starts at the bottom side of the lower end disc 31 and which supports the seal 36 , furthermore protrudes into the annular gap 28 above the locking ring 5 , whereby the seal 36 now comes to a tight rest against the sealing surface 26 . An untreated medium side 10 of the filter 1 is thus separated from a clean medium side 11 in a liquid-tight manner and the filter is ready for operation. During operation, a liquid, which is to be filtered, flows via a non-illustrated inlet to the untreated medium side 10 of the filter 1 , flows through the filter cloth body 30 in radial direction from outside to inside and then leaves the filter 1 through a liquid discharge channel 42 , which is embodied in the hollow interior of the stand pipe 4 . The support grid 30 ′ thereby protects the filter cloth body 30 from collapsing inwardly in radial direction.
It can be seen on the very top of FIG. 4 that, on the upper side of its upper end disc 32 , the filter insert 3 encompasses snap-in pins 34 , which protrude upwards and which are in locking engagement with suitably arranged snap-in pins 24 on the bottom side of the cover 21 . The cover 21 can exert an axial traction force on the filter insert 3 via this locking engagement, when the cover 21 is unscrewed from the filter housing 2 . The cover 21 takes along the filter insert 3 through this.
FIG. 5 of the drawing shows a stand pipe 4 of the filter 1 according to FIGS. 1 to 4 as component part in top view. The stand pipe 4 has a hollow-cylindrical basic shape. With its lower end 46 , the stand pipe 4 can be connected to the filter housing 2 , for example by means of screwing or latching. In its upper part, opposite one another, the stand pipe 4 has the two locking guides 41 with its respective locking surface 41 ′ for forming the locking device 40 .
Guide contours 45 , which serve the purpose of bringing the unlocking means 33 provided on the filter insert 3 into a twist position, which is engagement-suitable for the locking guides 41 and the cams 43 thereof, are furthermore integrally molded on the outer periphery of the stand pipe 4 . At the same time, the lower part of the guide contours 45 serves to safeguard the locking ring 5 from twisting. The liquid discharge channel 42 runs through the interior of the stand pipe 4 . Finally, a spring support 44 ′ for the spring 44 is visible on the very bottom of the stand pipe 4 .
FIG. 6 shows the locking ring 5 of the filter 1 according to FIGS. 1 to 4 as component part in top view. The locking ring 5 has a circumferential upper edge 51 and a circumferential lower edge 51 ′ as well as a plurality of guide noses 55 radially on the inside, which interact with the above-mentioned guide contour 45 on the stand pipe 4 , when the locking ring 5 is attached to the stand pipe 4 .
FIG. 7 shows a filter insert 3 of the filter 1 according to FIGS. 1 to 4 as component part in top view. The two end discs 31 and 32 , between which the filter cloth body 30 is arranged, can be seen on the bottom and on the top. In the center, the lower end disc 31 has the through hole 31 ′, by means of which it can be plugged onto the stand pipe 4 . The annular appendage 35 , which surrounds the through hole 31 ′ and which, on its lower end, supports the seal 36 , which faces readily outwardly, extends downwards from the lower end disc 31 . The unlocking means 33 , which serve to release the locking device 40 , concretely for pivoting the locking guides 41 radially inwardly in release direction, when the filter insert 3 is plugged onto the stand pipe 4 , are visible on the inner periphery of the annular appendage 35 .
In the case of the above-described exemplary embodiment, the locking device 40 comprises a plurality of resilient locking guides 41 . Exemplary embodiments, in the case of which the locking device 40 is embodied differently, will be described below.
FIG. 8 shows a filter 1 in a second embodiment in a longitudinal section through the lower area of the filter 1 , here still without filter insert. On the outside, a part of the filter housing 2 comprising the bottom 25 can be seen. The hollow-cylindrical bottom part 25 ′, the inner periphery of which forms the sealing surface 26 , is located in the center of the bottom 25 .
The stand pipe 4 is arranged in the center of the housing 2 . The locking ring 5 is arranged so as to be displaceable in axial direction on the stand pipe 4 . Here, the locking ring 5 can additionally also be twisted to a limited extent in peripheral direction relative to the stand pipe 4 . The locking ring 5 is also prestressed here with a force, which acts in the pushed-out direction thereof, that is, upwards according to FIG. 8 , and which is also created here by means of a helical spring 44 . Due to the fact that a filter insert has not yet been inserted into the housing 2 in FIG. 8 , the spring 44 ensures that the locking ring 5 assumes its pushed-out position. In this pushed-out position of the locking ring 5 , the latter is furthermore locked from being inserted in axial direction, that is, downwards according to FIG. 8 . This is attained by means of a guide contour 45 , which forms part of the locking device 40 , on the outer periphery of the stand pipe 4 . The guide contour 45 encompasses a locking stage 45 ′, which is oriented upwards, and which, in the state according to FIG. 8 is located in axial direction, exactly below a guide nose 55 on the inner periphery of the locking ring 5 . When a force, which acts from the top to the bottom only in axial direction, is exerted onto the locking ring 5 , the guide nose 55 thereof reaches the locked stage 45 ′, whereby a further axial displacement is prevented.
To release the locking device 40 , the locking ring 5 must also carry out a rotary motion in addition to its downwards axial movement, so that the guide nose 55 can be moved past the locked stage 45 ′. For this purpose, a plurality of inclined planes 59 , one of which can be seen in FIG. 8 , are integrally molded on the outer periphery of the locking ring 5 . The inclined planes 59 interact with inclined planes 39 on the filter insert 3 (see FIG. 14 ), when the filter insert 3 is attached to the stand pipe 4 and ensure that the axial movement of the filter insert 3 creates a limited rotary motion of the locking ring 5 in unlocking direction. Within the guide contour 45 , the guide nose 55 thus reaches a position, in which it is offset in peripheral direction against the locked stage 45 ′, whereupon a further movement of the locking ring 5 in downwards axial direction is then free.
FIG. 9 shows the filter 1 from FIG. 8 comprising a completely fitted filter insert 3 in a first longitudinal section, which is located upstream of the center axis of the filter housing 2 . The locking ring 5 is now displaced into its inserted position and the guide nose 55 of the locking ring 5 is now in a position axially below the locked stage 45 ′ as well as offset in peripheral direction to the locked stage 45 ′. The spring 44 is now compressed and is held in this state via the locking ring 5 by means of the filter insert 3 . A displacement of the filter insert 3 back to the top is prevented by means of a cover 21 , which is not illustrated here, which is attached to the housing 2 .
The annular appendage 35 on the bottom side of the lower end disc 31 now protrudes into the hollow-cylindrical bottom part 25 ′ of the bottom 25 of the filter housing 2 , together with the seal 36 , which is supported by it, and the seal 36 now rests tightly against the sealing surface 26 .
FIG. 10 shows the filter from FIG. 9 in a second longitudinal section, which runs through the center axis of the filter housing 2 . It can also be seen here that the locking ring 5 and, below it, the spring 44 are located in the annular gap 28 between the hollow-cylindrical bottom part 24 ′ and the lower part of the stand pipe 4 . It can again be seen that the annular appendage 35 of the lower end disc 31 engages into the annular gap 28 by means of the seal 36 , whereby the seal 36 rests tightly against the sealing surface 26 .
Radially inside the locking ring 5 , the guide noses 55 thereof are visible, which are guided in the guide contour 45 on the outer periphery of the stand pipe 4 .
FIG. 11 shows the filter 1 from FIGS. 8 to 10 , comprising an unsuitable third-party filter insert 3 ′ in longitudinal section. The third-party filter insert 3 ′ differs from the filter insert 3 in that it does not encompass the unlocking means 33 , which are required for releasing the locking device 40 . As a result, the lower end disc 31 can only move the locking ring 5 downwards purely axially until the guide nose 55 of the locking ring 5 impacts the locked stage 45 ′ of the guide contour 45 on the outer periphery of the stand pipe 4 when the filter insert 3 ′ is inserted into the filter housing 2 . A further insertion of the filter insert 3 ′ into the filter housing 2 is now no longer possible. A liquid-tight separation into an untreated medium side and clean medium side of the filter housing 2 is not attained. It is also impossible to attach the cover 21 to the filter housing 2 , because the filter insert 3 ′ still protrudes too far from the filter housing 2 on the top.
In an enlarged illustration, FIG. 12 shows the lower part of the stand pipe 4 of the filter 1 from FIGS. 8 to 11 as component part in top view. The liquid discharge channel 42 runs through the hollow interior of the stand pipe 4 . On the one hand, two guide contours 45 are arranged, here integrally molded, on the outer periphery of the stand pipe 4 , so as to be located opposite one another in pairs, and, on the other hand, the position guide means 48 are arranged in peripheral direction therebetween, also so as to be located opposite one another in pairs. As already explained above, the guide contour 45 comprises the locked stage 45 ′ as well as the guide bevel 45 ″, which serves the purpose of bringing the locking ring 5 back into the locked position, in which the guide nose 55 thereof is located exactly axially above the locked stage 45 ′, when returning it in pushed-out direction. The lower end 46 of the stand pipe 4 serves for connection to the filter housing 2 .
FIG. 13 shows a locking ring 5 , which can be displaceably connected to the stand pipe 4 from FIG. 12 , as component part in top view. The locking ring 5 has the basic shape of a low hollow cylinder and, radially on the outside, has the projecting spring support 54 , on the bottom side of which the spring 44 is supported in the assembled state of the filter 1 .
In FIG. 13 , the circumferential upper edge 51 of the locking ring 5 , into which a plurality, here a total of four, inclined planes 59 are integrally molded, faces the observer. These inclined planes 59 serve to interact with the above-mentioned inclined planes 39 on the filter insert 3 . The two guide noses 55 , which serve to interact with the guide contour 45 on the stand pipe 4 , are integrally molded so as to project radially inwardly on the inner periphery of the locking ring 5 , located opposite one another.
FIG. 14 shows the lower part of a filter insert 3 in a view, transversely from the bottom. The lower end disc 31 closes the filter cloth body 30 on its lower end side. The through hole 31 ′, which is surrounded by the annular appendage 35 , is located in the center of the end disc 31 . On its axially lower end, the appendage 35 supports the seal 36 , which faces radially outwardly.
On the one hand, the position guide means 38 , which serve to interact with the position guide means 48 on the stand pipe 4 , and, on the other hand, the inclined planes 39 , which serve to interact with the inclined planes 59 on the locking ring 5 , are located on the inner periphery of the appendage 35 .
FIGS. 15 to 24 show the filter 1 in a third embodiment, for which it is characteristic that the filter housing 2 additionally encompasses a discharge channel 27 , which is arranged in an eccentric position on the bottom 25 of the housing 2 . The discharge channel 27 serves the purpose of releasing a path for draining liquid from the filter housing 2 when the filter insert 3 is pulled out, so that a filter insert 3 , which is free from liquid as much as possible, can be removed from the filter housing 2 . It is necessary thereby that the discharge channel 27 is closed during the operation of the filter 1 .
FIG. 15 shows the filter 1 in the third embodiment in a longitudinal section through the lower area of the filter 1 , comprising an only partially inserted filter insert 3 in longitudinal section. The cup-shaped filter housing 2 with the bottom 25 and the hollow-cylindrical bottom part 25 ′ thereof again forms the outer limitation of the filter insert 1 . A stand pipe 4 , which is connected on its lower end 46 to the filter housing 2 , is again arranged centrally in the filter housing 2 .
The locking ring 5 , which, just as the corresponding locking device 40 , corresponds to the above-described exemplary embodiment, is again arranged on the lower part of the stand pipe 4 . The spring 44 , which is also embodied as a pressure spring here, is again located below the locking ring 5 .
In the upper part of FIG. 15 , the lower part of the filter insert 3 can be seen at the onset of its insertion into the filter housing 2 . Here, the filter insert 3 also has a filter cloth body 30 , the lower end side of which is covered by the end disc 31 . The annular appendage 35 with the seal 36 , which faces radially outwardly, extends concentrically from the end disc 31 .
On the outer periphery of the stand pipe 4 , the position guide means 48 runs in the form of a coil, which initially runs transversely, viewed from top to bottom, and which then merges into an axial course further below. The position guide means 38 , which is present on the filter insert 3 , interacts with the position guide means 48 , in that the position guide means 38 glides along the position guide means 48 . Due to the coil shape of the upper part of the position guide means 48 , the filter insert 3 is simultaneously twisted in peripheral direction in response to its downwards movement, which serves the purpose of bringing the filter insert 3 into a desired twist position relative to the filter housing 2 and to the discharge channel 27 , before the filter insert 3 reaches its final installation position.
FIG. 16 shows the filter 1 from FIG. 15 with a further inserted filter insert 3 in a further longitudinal section, which is twisted as compared to FIG. 15 . The section now runs such that the position guide means 48 , which are arranged on the outer periphery of the stand pipe 4 , face the observer. The position guide means 38 of the filter insert 3 is located between the position guide means 48 . The locking ring 5 is still in its pushed-out position, because the lower end disc 31 of the filter insert 3 is still spaced apart from the locking ring 5 . On the outer periphery of the locking ring 5 , one of its inclined planes 59 is visible, which interact with the inclines planes 39 , which are not visible here, on the inner periphery of the end disc 31 when the filter insert 3 is further displaced downwards.
FIG. 17 shows the filter 1 from FIGS. 15 and 16 , comprising an even further inserted filter insert 3 , again in longitudinal section, comprising a sectional plane, which is parallel to the sectional plane of FIG. 16 . With its lower end disc 31 , the filter insert 3 is now just about to be in contact with the locking ring 5 , which is still also in its pushed-out position. The position guide means 38 , which is present on the filter insert 3 , is located between the axially running sections of the position guide means 48 , the distance of which is reduced towards the bottom, so as to effect the final positioning of the filter insert 3 .
FIG. 18 once again illustrates the filter 1 from FIGS. 15 to 17 , comprising a once again even further inserted filter insert 3 , again illustrated in longitudinal section, wherein the section is now placed such that the guide contour 45 on the outer periphery of the stand pipe 4 faces the observer and that the section goes through the discharge channel 27 . The filter insert 3 is now displaced downwards on the stand pipe 4 to the extent the lower end disc 31 has come into engagement with the locking ring 5 . By means of the interacting inclined planes 39 and 59 , which are not visible in FIG. 18 , the locking device 40 is unlocked by a certain twisting of the locking ring 5 relative to the stand pipe 4 . In this unlocked state, the guide nose 55 of the locking ring 5 is located offset in peripheral direction to the locked stage 45 ′ of the guide contour 45 . The lock is thus released and filter insert 3 can be moved further downwards, together with the locking ring 5 , with which it is engaged, against the force of the spring 44 , wherein this downwards movement is also preferably carried out here by screwing a cover 21 onto the filter housing 2 .
On the bottom side of the end disc 31 , the locking bolt 37 , which is embodied integrally molded with the latter, and which has now reached its engagement-suitable position to the discharge channel 27 by means of the guiding by means of the position guide means 38 and 48 , is visible to the right in FIG. 18 . A twisting of the filter insert 3 by means of the locking bolt 37 relative to the discharge channel 27 is now no longer possible due to the guiding of the filter insert 3 by means of the position guide means 38 and 48 , which are not visible in FIG. 18 .
FIG. 19 shows the filter 1 from FIGS. 15 to 18 , comprising a once again even further inserted filter insert 3 , in a longitudinal section, which is placed such that the position guide means 48 on the outer periphery of the stand pipe 4 now again face the observer. By further axially displacing the filter insert 3 downwards, the position guide means 38 thereof has now reached into that area of the position guide means 48 , in which they run with a smaller distance in axial direction, viewed in peripheral direction. The distance between the position guide means 48 is thereby so small that the position guide means 38 of the filter insert 3 , which is guided therein, has just enough room to move. At the same time, the locking ring 5 is displaced further downwards against the force of the spring 4 by means of the filter insert 3 , which was moved further downwards, on the stand pipe 4 .
FIG. 20 now shows the filter 1 form FIGS. 15 to 19 , comprising a completely inserted filter insert 3 , in a further longitudinal section, which is located in the sectional plane of FIG. 19 . The locking ring 5 now engages with the hollow-cylindrical bottom part 24 ′, and the annular appendage 35 engages with the sealing ring 36 . The position guide means 38 of the filter insert 3 is now located on the lower end of the position guide means 48 . The filter 1 is thus now ready for operation after the cover 21 has been attached.
FIG. 21 shows the filter 1 from FIG. 20 in a second longitudinal section, rotated by 90°. Here, the view is again onto the area of the outer periphery of the stand pipe 4 comprising the locking device 40 and the corresponding guide contour 45 . The guide nose 55 of the locking ring 5 is now located offset in peripheral direction and in axial direction to the locking stage 45 ′, which is synonymous with the unlocked position of the locking device 40 . The locking bolt 37 now rests tightly in the upper en area of the discharge channel 27 , whereby liquid can no longer flow out of the interior of the filter housing 2 into the discharge channel 27 .
In FIG. 22 , the filter 1 from FIGS. 20 and 21 is illustrated in a third longitudinal section, which is offset parallel to the front relative to the previous longitudinal section, so that the sectional plane now in each case runs through one of the inclined planes 39 and 59 on the filter insert 3 and on the locking ring 5 . The inclined planes 39 and 59 are now completely engaged with one another, which means that the filter insert 3 , which is now inserted completely into the housing 2 , has twisted the locking ring 5 by a certain angle in peripheral direction, which is sufficient for unlocking the locking device 40 , by means of its axial movement. The discharge channel 27 comprising the locking bolt 37 , which rests tightly against it, is now located on the bottom right in FIG. 22 , behind the sectional plane.
FIG. 23 shows the filter 1 from FIGS. 15 to 22 , comprising an unsuitable third-party filter insert 3 ′ in a longitudinal section, which is located such that the outer periphery of the stand pipe 4 comprising the locking device 40 faces the observer. Here, the third-party filter insert 3 ′ presses the locking ring 5 beyond the upper edge 51 thereof I downwards in axial direction with its lower end disc 31 , but a further downwards movement is locked, because the guide nose 55 of the locking ring 5 impacts the locked stage 45 ′ of the guide contour 45 after a short movement path, because the third-party filter insert 3 ′ illustrated herein does not have the means, which are required for unlocking the locking device 40 , in particular not the necessary inclined planes 39 . A force, which is oriented in peripheral direction, thus does not act on the inclined planes 59 of the locking ring 5 here, which has the result that the locking ring 5 maintains its locked position, Due to the fact that the third-party filter insert 3 ′ cannot be inserted completely into the housing 2 , a separation between untreated medium side and clean medium side is also not attained and the cover of the housing 2 cannot be attached. Finally, the locking pin for the discharge channel 37 is also missing in the case of the third-party filter insert 3 ′, so that the filter 1 cannot be made ready for operation by means of said third-party filter insert 3 ′.
Finally, FIG. 24 shows a filter insert 3 , which matches the filter 1 according to FIGS. 15 to 22 , in top view transversely from the bottom, wherein only the lower part of the filter insert 3 is illustrated here. It can be seen that the filter cloth body 30 is covered on the bottom by the lower end disc 31 , which is moreover embodied so as to be identical to the end disc 31 according to FIG. 14 . In addition, the end disc 31 according to FIG. 24 has the eccentrically arranged locking bolt 37 , which is embodied here so as to be integrally molded to the end disc 31 . The sealing effect can be optimized by means of a separate sealing ring, consisting of an elastomer or rubber, which is attached to the locking bolt 37 .
As is apparent from the foregoing specification, the invention is susceptible of being embodied with various alterations and modifications which may differ particularly from those that have been described in the preceding specification and description. It should be understood that I wish to embody within the scope of the patent warranted hereon all such modifications as reasonably and properly come within the scope of my contribution to the art.
List of Reference Numerals:
Numeral
Description
1
filter
10
untreated medium side
11
clean medium side
2
filter housing
21
cover
22
thread
23
seal in 22
24
snap-in pins on 21
25
bottom of 2
25′
hollow-cylindrical bottom part
26
sealing surface in 25′
27
discharge channel
28
annular gap
3
filter insert
3′
third-party filter insert
30
filter cloth body
30
support grid in 30
31
first (lower) end disc
31′
through hole in 31
32
second (upper) end disc
33
unlocking means (ribs)
34
snap-in pins on 32
35
annular appendage on 31
36
seal on 35
37
locking bolt for 27
38
position guide means on 3
39
inclined planes on 31
4
stand pipe
40
locking device
41
locking guides
41′
locking surface
42
liquid discharge channel in 4
43
cams on 41
44
spring
44′
spring support
45
guide contour for 5
45′
locking stage
45″
guide bevel
46
lower end of 4
48
position guide means on 4
5
locking ring
51
upper edge
51′
lower edge
54
spring support
55
guide nose on 5
59
inclined planes on 5 | A fluid filter with a housing, a releasable cover, and a replaceable filter having a filter body and two end discs. The filter is plugged onto a housing pipe and a locking ring is guided on the pipe, preloaded in a push-out direction. The locking ring is locked in a pushed-out position by a locking device. An unlocking device guided by the filter unlocks the locking device when the filter is pushed onto the pipe and enables the locking ring and the filter to be pushed in. When the filter is fitted into the housing, a seal on the end disc or locking ring interacts with a housing sealing surface to separate an untreated filter side from a clean side. When the locking ring is in the pushed-out position and the filter bears against the locking ring, the seal is held away from the sealing surface of the housing. | 1 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This application claims priority of provisional application Ser. No. 60/580,161, filed Jun. 16, 2004, and provisional application Ser. No. 60/679,305 filed May 10, 2005.
TECHNICAL FIELD
This invention relates to a medical device and more particularly to a medical device for the introduction of a stent graft into a human or animal body.
BACKGROUND OF THE INVENTION
This invention will be generally discussed in relation to deployment of stent grafts into the aorta but it is not so limited and can be applied to other vasculature or other body lumens.
The introduction of endovascular techniques for the placement of stent grafts into the vascular of human or animal patient has revolutionized the treatment of vascular diseases. As treatment techniques have improved there is a requirement for deployment devices which can provide a physician with more flexibility and control in placement of stent grafts.
The object of this invention is to provide an introducer for a stent graft which will give a physician more control or at least provide the physician with a useful alternative.
Throughout this specification the term “distal” with respect to a portion of the aorta, a deployment device or a prosthesis is the end of the aorta, deployment device or prosthesis further away in the direction of blood flow away from the heart, and the term “proximal” means the portion of the aorta, deployment device or end of the prosthesis nearer to the heart. When applied to other vessels similar terms such as caudal and cranial should be understood.
Throughout this discussion the term “stent graft” is intended to mean a device which has a tubular body of biocompatible graft material and at least one stent fastened to the tubular body to define a lumen through the stent graft. The stent graft may be bifurcated and have fenestrations, side arms or the like. Other arrangements of stent grafts are also within the scope of the invention.
SUMMARY OF THE INVENTION
In one form, the invention is said to reside in a stent graft introducer for intraluminal deployment of a stent graft, the introducer comprising a stent graft retention and release mechanism to allow selective release of each end of the stent graft when carried on the introducer, an indwelling catheter extending from a distal end of the introducer to a proximal end of the introducer and passing through the stent graft when retained on the introducer, whereby control of the stent graft can be maintained while allowing access into the lumen of the stent graft by use of the indwelling catheter.
Preferably the release mechanism includes a fastening between the stent graft and introducer at both proximal and distal ends of a stent graft retained on the introducer.
The stent graft introducer may have a sheath surrounding the deployment catheter and preferably the sheath is a highly flexible sheath.
In a further form the invention is said to reside in a stent graft introducer for intraluminal deployment of a stent graft, an introducer having:
a guide wire catheter extending from a proximal to a distal end,
a nose cone dilator on the proximal end of the guide wire catheter, the nose cone dilator having a proximal end and a distal end and a longitudinal groove therein,
a deployment catheter on the guide wire catheter, the guide wire catheter passing through a lumen in the deployment catheter and the deployment catheter being able to move longitudinally and rotationally with respect to the guide wire catheter,
a first retention arrangement at the proximal end of the deployment catheter to retain the distal end of a stent graft thereon,
a second retention arrangement at the distal end of the nose cone dilator to retain the proximal end of a stent graft thereon,
a release arrangement associated with the handle to separately release the first retention arrangement and the second retention arrangement, and
an indwelling catheter extending from the handle to the groove in the nose cone dilator.
Preferably, each release arrangement includes a trigger wire extending from the retention arrangement to a respective trigger wire grip on the handle, and the trigger wire grips are arranged on the handle so that they can only be released in a selected order.
In a preferred form of the invention the stent graft has a distally extending exposed stent and the first retention arrangement for the distal end of the stent graft includes a capsule covering the exposed stent and acting as the first retention arrangement and a trigger wire associated with the capsule which prevents the exposed stent from being released from the capsule until the trigger wire has been removed as discussed earlier.
There can be further diameter reducing ties associated with the stent graft when retained on the introducer and the handle including a release arrangement for the diameter reducing ties. The diameter reducing ties comprise loops of suture or other thread material which extend around part of the periphery of the stent graft and are located by a trigger wire and are tightened to reduce the circumference of the stent graft. When released, the stent graft can expand to its full diameter.
In a preferred form the stent graft has at least one fenestration such that when the stent graft is deployed in the body lumen such as an aorta fluid communication can occur between the lumen of the stent graft and a branch artery of the lumen. For instance in the case of a stent graft deployed in the aorta of a patient then the fenestration may allow access to the renal, mesenteric or coeliac axis arteries. In the case of a stent graft deployed into the descending aorta the fenestration may be at or adjacent the distal end of the stent graft to allow access to a branch artery. The indwelling catheter would allow access from the thoracic arch such as by a brachial or carotid access. Such a fenestration may be in the form of a scallop at the distal end of the stent graft or may be an aperture in the body of the stent graft. The aperture may be reinforced with a resilient wire ring around its periphery. When the stent graft has been at least partially released the resilient wire ring will cause the fenestration to open to assist with access through the fenestration.
Preferably the introducer further comprises an indwelling catheter extending from a distal end of the introducer to a proximal end of the introducer and passing through the stent graft when retained on the introducer. Preferably the indwelling catheter extends through the deployment catheter to the nose cone dilator to be received in the groove therein. Preferably the indwelling catheter extends through the fenestration.
In a further form the invention is said to reside in a stent graft introducer for intraluminal deployment of a stent graft, an introducer having:
a guide wire catheter extending from a proximal to a distal end,
a nose cone dilator on the proximal end of the guide wire catheter, the nose cone dilator having a proximal end and a distal end,
a deployment catheter on the guide wire catheter, the guide wire catheter passing through a lumen in the deployment catheter and the deployment catheter being able to move longitudinally and rotationally with respect to the guide wire catheter,
a distal retention arrangement a the proximal end of the deployment catheter to retain the distal end of a stent graft thereon and an associated distal release arrangement,
a proximal retention arrangement at the distal end of the nose cone dilator to retain the proximal end of a stent graft thereon and an associated proximal release arrangement, the proximal retention arrangement including multiple fastenings between the stent graft and the release mechanism,
a first release arrangement associated with the handle to release the distal retention arrangements,
a second release arrangement associated with the handle to release the proximal fastenings,
each release arrangement including a trigger wire extending from the respective retention arrangement to a trigger wire grip on the handle,
the trigger wire grips being arranged on the handle so that they can only be released in a selected order.
There can be further diameter reducing ties associated with the stent graft when retained on the introducer and the handle including a release arrangement for diameter reducing ties on the stent graft.
In a preferred form of the invention the stent graft has a distally extending exposed stent and the distal retention arrangement includes a capsule to cover the exposed stent and the distal release arrangement includes means to withdraw the capsule from the exposed stent. There can be further included a capsule trigger wire associated with the capsule which engages with the exposed stent within the capsule and prevents the capsule from being removed from the exposed stent until the capsule trigger wire has been removed and there is a respective trigger wire grip on the handle.
In a preferred form the stent graft has at least one fenestration at a distal end thereof such that when the stent graft is deployed in the body lumen, such as an aorta, fluid communication can occur between the lumen of the stent graft and a branch artery of the lumen. For instance, in the case of a stent graft deployed in the aorta of a patient then the fenestration may allow access to the renal, mesenteric or coeliac axis arteries.
The fenestration may be an aperture through the wall of the stent graft or may be a cut out in an end of the stent graft.
The stent graft may comprise a tubular body of a biocompatible graft material and a plurality of stents to define in use a lumen through the stent graft.
In an alternative form the invention is said to reside in a stent graft introducer for intraluminal deployment of a stent graft, the introducer comprising a stent graft release mechanism to allow partial release of at least one end of the stent graft when carried on the introducer, whereby control of the stent graft can be maintained while allowing access into the lumen of the stent graft through the partially released at least one end of the stent graft.
Preferably the release mechanism includes a fastening between the stent graft and introducer at both proximal and distal ends of a stent graft retained on the introducer and the partial release releases at least part of the fastening at either the proximal or distal end.
Preferably the partial release is only a part of the total fastening at either the proximal or distal end and hence because there is still some retention at both the proximal and distal ends of the stent graft, control of the positioning of the stent graft within a body lumen is still possible.
In a preferred embodiment retention of either the proximal or distal ends of the stent graft includes at least three fastenings between the stent graft and a release mechanism with the fastening spaced around the periphery of the stent graft and the partial release releases at one of these at least three fastenings thereby releasing part of the end of the stent graft to allow the access as discussed above.
In a further form the invention is said to reside in a stent graft introducer for intraluminal deployment of a stent graft, the introducer having proximal and distal stent graft release mechanisms, the proximal release mechanism having at least two fastenings between the stent graft and at least two release mechanisms for the fastenings at the proximal end to allow partial release of part of the proximal end of the stent graft when carried on the introducer, whereby control of the stent graft can be maintained while allowing access into the lumen of the stent graft from the partially released proximal end of the stent graft.
In a further form the invention is said to reside in a stent graft introducer for intraluminal deployment of a stent graft, an introducer comprising:
a guide wire catheter extending from a proximal to a distal end,
a nose cone dilator on the proximal end of the guide wire catheter, the nose cone dilator having a proximal end and a distal end,
a deployment catheter on the guide wire catheter, the guide wire catheter passing through a lumen in the deployment catheter and the deployment catheter being able to move longitudinally and rotationally with respect to the guide wire catheter,
a first retention arrangement at the proximal end of the deployment catheter to retain the distal end of a stent graft thereon,
a second retention arrangement at the distal end of the nose cone dilator to retain the proximal end of a stent graft thereon,
a release arrangement associated with the handle to separately release the first retention arrangement and the second retention arrangement,
either the first or the second retention arrangement including multiple fastenings between the stent graft and the release mechanism and wherein one of the multiple fastenings can be released independently of the others of the multiple fastenings,
a stent graft retained on the introducer, the stent graft comprising at least one fenestration whereby when the stent graft is deployed in a body lumen fluid communication can occur between the lumen of the stent graft and a branch artery of the lumen through the fenestration,
an indwelling catheter extending from a distal end of the introducer through the deployment catheter to a proximal end of the stent graft when retained on the introducer,
and the indwelling catheter extending through the fenestration.
In one embodiment the fenestration comprises a scallop at the distal end of the stent graft. Alternatively the fenestration is an aperture in the body of the stent graft and being reinforced with a resilient wire ring around its periphery.
The graft material may be a woven or non-woven fabric such as Dacron or may be a polymeric material such as expandable PTFE. The graft material may alternatively be a naturally occurring biomaterial, such as collagen, particularly a specially derived collagen material known as an extracellular collagen matrix (ECM), such as small intestinal submucosa (SIS) that causes remodelling of host tissue coming into contact therewith. Besides SIS, examples of ECM's include pericardium, stomach submucosa, liver basement membrane, urinary bladder submucosa, tissue mucosa, and dura mater.
The plurality of stents may be self-expanding zig zag stents or may be balloon expandable stents or other forms of stent.
U.S. Pat. No. 5,387,235 entitled “Expandable Transluminal Graft Prosthesis For Repair Of Aneurysm” discloses apparatus and methods of retaining grafts onto deployment devices. These features and other features disclosed in U.S. Pat. No. 5,387,235 could be used with the present invention and the disclosure of U.S. Pat. No. 5,387,235 is herewith incorporated in its entirety into this specification.
U.S. Pat. No. 5,720,776 entitled “Barb and Expandable Transluminal Graft Prosthesis For Repair of Aneurysm” discloses improved barbs with various forms of mechanical attachment to a stent. These features and other features disclosed in U.S. Pat. No. 5,720,776 could be used with the present invention and the disclosure of U.S. Pat. No. 5,720,776 is herewith incorporated in its entirety into this specification.
PCT Patent Publication No. WO 98/53761 entitled “A Prosthesis And A Method And Means Of Deploying A Prosthesis” discloses an introducer for a prosthesis which retains the prosthesis so that each end can be moved independently. These features and other features disclosed in PCT Patent Publication No. WO 98/53761 could be used with the present invention and the disclosure of PCT Patent Publication No. WO 98/53761 is herewith incorporated in its entirety into this specification.
U.S. Pat. No. 6,524,335 and PCT Patent Publication No. WO 99/29262 entitled “Endoluminal Aortic Stents” disclose a fenestrated prosthesis for placement where there are intersecting arteries. This feature and other features disclosed in U.S. Pat. No. 6,524,335 and PCT Patent Publication No. WO 99/29262 could be used with the present invention and the disclosure of U.S. Pat. No. 6,524,335 and PCT Patent Publication No. WO 99/29262 is herewith incorporated in its entirety into this specification.
U.S. patent application Ser. No. 10/280,486, filed Oct. 25, 2002 and published on May 8, 2003 as U.S. Patent Application Publication No. US-2003-0088305-A1 and PCT Patent Publication No. WO 03/034948 entitled “Prostheses For Curved Lumens” discloses prostheses with arrangements for bending the prosthesis for placement into curved lumens. This feature and other features disclosed in U.S. patent application Ser. No. 10/280,486, and U.S. Patent Application Publication No. US-2003-0088305-A1 and PCT Patent Publication No. WO 03/034948 could be used with the present invention and the disclosure of U.S. patent application Ser. No. 10/280,486, and U.S. Patent Application Publication No. US-2003-0088305-A1 and PCT Patent Publication No. WO 03/034948 is herewith incorporated in its entirety into this specification.
U.S. Pat. No. 6,206,931 entitled “Graft Prosthesis Materials” discloses graft prosthesis materials and a method for implanting, transplanting replacing and repairing a part of a patient and particularly the manufacture and use of a purified, collagen based matrix structure removed from a submucosa tissue source. These features and other features disclosed in U.S. Pat. No. 6,206,931 could be used with the present invention and the disclosure of U.S. Pat. No. 6,206,931 is herewith incorporated in its entirety into this specification.
U.S. Provisional Patent Application Ser. No. 60/392,682, filed Jun. 28, 2002, U.S. patent application Ser. No. 10/447,406, filed May 29, 2003, and Published on Dec. 18, 2003, as U.S. Patent Application Publication No. US-2003-0233140-A1, and PCT Patent Publication No. WO 03/101518 entitled “Trigger Wires” disclose release wire systems for the release of stent grafts retained on introducer devices. This feature and other features disclosed in U.S. Provisional Patent Application Ser. No. 60/392,682, U.S. patent application Ser. No. 10/447,406, and U.S. Patent Application Publication No. US-2003-0233140-A1, and PCT Patent Publication No. WO 03/101518 could be used with the present invention and the disclosure of U.S. Provisional Patent Application Ser. No. 60/392,682, U.S. patent application Ser. No. 10/447,406, and U.S. Patent Application Publication No. US-2003-0233140-A1, and PCT Patent Publication No. WO 03/101518 is herewith incorporated in its entirety into this specification.
U.S. Provisional Patent Application Ser. No. 60/392,667, filed Jun. 28, 2002, and U.S. patent application Ser. No. 10/609,846, filed Jun. 30, 2003, and Published on May 20, 2004, as US Patent Application Publication No. US-2004-0098079-A1, and PCT Patent Publication No. WO 2004/028399 entitled “Thoracic Deployment Device” disclose introducer devices adapted for deployment of stent grafts particularly in the thoracic arch. This feature and other features disclosed in U.S. Provisional Patent Application Ser. No. 60/392,667, U.S. patent application Ser. No. 10/609,846, and US Patent Application Publication No. US-2004-0098079-A1, and PCT Patent Publication No. WO 2004/028399 could be used with the present invention and the disclosure of U.S. Provisional Patent Application Ser. No. 60/392,667, U.S. patent application Ser. No. 10/609,846, and US Patent Application Publication No. US-2004-0098079-A1, and PCT Patent Publication No. WO 2004/028399 is herewith incorporated in its entirety into this specification.
U.S. Provisional Patent Application Ser. No. 60/392,599, filed Jun. 28, 2002, and U.S. patent application Ser. No. 10/609,835, filed Jun. 30, 2003, entitled “Thoracic Aortic Aneurysm Stent Graft” disclose stent grafts that are useful in treating aortic aneurysms particularly in the thoracic arch. This feature and other features disclosed in U.S. Provisional Patent Application Ser. No. 60/392,599 and U.S. patent application Ser. No. 10/609,835, filed Jun. 30, 2003 could be used with the present invention, and the disclosure are herewith incorporated in their entirety into this specification.
U.S. Provisional Patent Application Ser. No. 60/392,599, filed Jun. 28, 2002, and U.S. patent application Ser. No. 10/609,835, filed Jun. 30, 2003, and published on Jun. 3, 2004, as U.S. Patent Application Publication No. US-2004-0106978-A1, and PCT Patent Publication No. WO 2004/002370 entitled “Thoracic Aortic Aneurysm Stent Graft” disclose stent grafts that are useful in treating aortic aneurysms particularly in the thoracic arch. This feature and other features disclosed in U.S. Provisional Patent Application Ser. No. 60/392,599, U.S. patent application Ser. No. 10/609,835, and U.S. Patent Application Publication No. US-2004-0106978-A1, and PCT Patent Publication No. WO 2004/002370 could be used with the present invention, and the disclosure of U.S. Provisional Patent Application Ser. No. 60/392,599, U.S. patent application Ser. No. 10/609,835, and U.S. Patent Application Publication No. US-2004-0106978-A1, and PCT Patent Publication No. WO 2004/002370 is herewith incorporated in its entirety into this specification.
U.S. Provisional Patent Application Ser. No. 60/405,367, filed Aug. 23, 2002, U.S. patent application Ser. No. 10/647,642, filed Aug. 25, 2003, and published on Apr. 15, 2004, as U.S. Patent Application Publication No. US-2004-0073289-A1, and PCT Patent Publication No. WO 2004/017868 entitled “Asymmetric Stent Graft Attachment” disclose retention arrangements for retaining onto and releasing prostheses from introducer devices. This feature and other features disclosed in U.S. Provisional Patent Application Ser. No. 60/405,367, filed Aug. 23, 2002, U.S. patent application Ser. No. 10/647,642, filed Aug. 25, 2003, and U.S. Patent Application Publication No. US-2004-0073289-A1, and PCT Patent Publication No. WO 2004/017868 could be used with the present invention and the disclosure of U.S. Provisional Patent Application Ser. No. 60/405,367, filed Aug. 23, 2002, U.S. patent application Ser. No. 10/647,642, filed Aug. 25, 2003, and U.S. Patent Application Publication No. US-2004-0073289-A1, and PCT Patent Publication No. WO 2004/017868 is herewith incorporated in its entirety into this specification.
U.S. patent application Ser. No. 10/322,862, filed Dec. 18, 2002 and published as U.S. Patent Application Publication No. U.S. 2003-0120332, and PCT Patent Publication No. WO 03/053287 entitled “Stent Graft With Improved Adhesion” disclose arrangements on stent grafts for enhancing the adhesion of such stent grafts into walls of vessels in which they are deployed. This feature and other features disclosed in U.S. patent application Ser. No. 10/322,862, filed Dec. 18, 2002 and published as U.S. Patent Application Publication No. U.S. 2003-0120332, and PCT Patent Publication No. WO 03/053287 could be used with the present invention and the disclosure of U.S. patent application Ser. No. 10/322,862, filed Dec. 18, 2002 and published as U.S. Patent Application Publication No. U.S. 2003-0120332, and PCT Patent Publication No. WO 03/053287 is herewith incorporated in its entirety into this specification.
U.S. Provisional Patent Application Ser. No. 60/405,769, filed Aug. 23, 2002, U.S. patent application Ser. No. 10/645,095, filed Aug. 23, 2003, and published on Apr. 29, 2004, as U.S. Patent Application Publication No. US-2004-0082990-A1, and PCT Patent Publication No. WO 2004/017867 entitled “Composite Prostheses” discloses prostheses or stent grafts suitable for endoluminal deployment. These prostheses and other features disclosed in U.S. Provisional Patent Application Ser. No. 60/405,769, U.S. patent application Ser. No. 10/645,095, and U.S. Patent Application Publication No. US-2004-0082990-A1, and PCT Patent Publication No. WO 2004/017867 could be used with the present invention and the disclosure of U.S. Provisional Patent Application Ser. No. 60/405,769, U.S. patent application Ser. No. 10/645,095, and U.S. Patent Application Publication No. US-2004-0082990-A1, and PCT Patent Publication No. WO 2004/017867 is herewith incorporated in its entirety into this specification.
BRIEF DESCRIPTION OF THE DRAWING
This then generally describes the invention but to assist with understanding reference will now be made to the accompanying drawings which show preferred embodiments of the invention.
In the drawings:
FIG. 1 shows a general view of a deployment device according to one embodiment of the invention;
FIG. 2 shows a longitudinal cut-away view of the embodiment shown in FIG. 1 but with the device rotated through 90 degrees on a longitudinal axis;
FIG. 3 shows part of the deployment device as shown in FIG. 1 after a first stage of deployment and with a fenestrated stent graft retained thereon;
FIG. 3A shows the same view as FIG. 3 except that it shows the other side of the stent graft and deployment device;
FIG. 4 shows part of the deployment device as shown in FIG. 1 with an alternative stent graft retained thereon with a scalloped fenestration and an apertured fenestration;
FIG. 5 shows a longitudinal cross sectional view showing detail of the sliding handle mechanism of the deployment device of FIG. 1 ;
FIG. 6 shows a similar view to that of FIG. 5 except that the handle has been retracted;
FIG. 7 shows a detailed view of one embodiment of proximal fastening arrangement for a stent graft onto the deployment device of FIG. 1 ;
FIG. 8 shows a cross sectional view along the line 8 - 8 ′ in FIG. 7 ;
FIG. 9 shows a detailed view of one embodiment of a distal retention arrangement for a stent graft onto the deployment device of FIG. 1 ;
FIG. 10 shows one embodiment of a stent graft suitable for use with a deployment device according to one embodiment of the invention;
FIG. 11 shows a longitudinal cross sectional view of the stent graft of FIG. 10 ;
FIG. 12 shows a detail view of the proximal end fastenings of a stent graft onto a deployment device according to one embodiment of the invention;
FIG. 13 a detail view of an alternative embodiment of proximal end fastenings of a stent graft onto a deployment device according to the invention;
FIG. 14 shows a detail of the proximal end of a stent graft fastened onto a deployment device according to one embodiment of the invention;
FIG. 15 shows a detail of the proximal end of a stent graft fastened onto a deployment device according to an alternative embodiment of the invention;
FIG. 16 shows the detailed fastening of FIG. 15 but with the stent graft partially released;
FIG. 17 shows an alternative embodiment of a stent graft with a scalloped fenestration suitable for use with a deployment device according to one embodiment of the invention;
FIG. 18 shows detail of an alternative embodiment of scalloped fenestration;
FIG. 19 shows an alternative embodiment of a stent graft with a scalloped fenestration and an apertured fenestration suitable for use with a deployment device according to the invention;
FIG. 20 shows a perspective view of one embodiment of stent graft mounted onto a deployment device according to the present invention;
FIG. 21 shows the other side of the stent graft mounted onto a deployment device shown in FIG. 18 ; and
FIG. 22 shows a general view of an alternative embodiment of deployment device according to the invention.
DETAILED DESCRIPTION
FIG. 1 shows a general view of a deployment device according to one embodiment of the invention and FIG. 2 shows a longitudinal cut-away view of the embodiment shown in FIG. 1 but rotated through 90 degrees on a longitudinal axis.
In FIGS. 1 and 2 , it will be seen that the deployment device 1 generally consists of a guide wire catheter 2 which extends the full length of the device from a Luer lock connector 3 for a syringe at the far distal end of the device to and through a nose cone dilator 4 at the proximal end. The nose cone dilator 4 is fixed to the guide wire catheter 1 and moves with it. To lock the guide wire catheter with respect to the deployment device in general a pin vice 5 is provided.
Trigger wire release mechanisms generally shown as 6 on a fixed handle 10 includes three trigger wire release mechanisms as will be discussed below. The trigger wire release mechanisms 6 slide on a portion of the fixed handle 10 and hence until such time as they are activated the trigger wire mechanisms 6 which are fixed by thumbscrews 11 remain fixed with respect to the fixed portion of the fixed handle 10 .
The trigger wire release mechanisms generally shown as 6 includes three trigger wire mechanisms 7 , 8 and 9 for three different stages of release of the stent graft from the deployment device. The three stages of release generally comprise:
(1) release of the distal end of the stent graft; (2) release of diameter reducing ties; and (3) release of the proximal retention arrangements.
The trigger wire release mechanism 9 has a trigger wire 48 (see FIG. 3A ) which extends to the capsule 21 and engages one of the loops of the exposed stent 29 . When the thumb screw 11 on the retention mechanism 9 is removed, the trigger wire mechanism 9 and trigger wire 48 can be removed and the capsule 21 can be removed from the exposed stent.
The trigger wire release mechanism 8 extends a trigger wire 45 (see FIG. 3A ) to diameter reducing ties 43 on the stent graft. When the thumb screw 11 on the trigger wire mechanism 8 is removed, the trigger wire mechanism 8 and trigger wire 45 can be completely removed from the deployment device which releases the diameter reducing ties 43 .
The trigger wire mechanism 7 has three trigger wires 76 (see FIG. 7 ) connected to it and when this trigger wire release mechanism 7 and trigger wires 76 are removed the proximal retention fastenings 90 , 91 and 92 (see FIG. 12 ) can be released to release the proximal end of the stent graft as is discussed in relation to FIGS. 7 , 8 and 12 to 14 .
Immediately proximal of the trigger wire release mechanisms 6 on the fixed handle 10 is a sliding handle mechanism generally shown as 15 . The sliding handle mechanism 15 generally includes a fixed handle extension 16 and a sliding portion 17 the sliding portion 17 slides over the fixed handle extension 16 . A thumbscrew 18 fixes the sliding portion with respect to the fixed portion. The fixed handle portion 16 is affixed to the trigger wire mechanism handle 10 by a screw threaded nut 24 . More detail of the sliding and fixed handle mechanisms is shown in FIGS. 5 and 6 .
The sliding portion of the handle 17 is fixed to the deployment catheter 19 by a mounting nut 20 . The deployment catheter 19 extends through to a capsule 21 at the proximal end of the deployment catheter 19 .
Over and around the deployment catheter 19 is a sheath manipulator 22 and a sheath 23 which slides with respect to the deployment catheter 19 and in the ready to deploy situation extends forward to the nose cone dilator 4 to cover the stent graft 26 . The sheath 23 is preferably a highly flexible sheath.
In the ready to deploy condition as shown in FIGS. 1 and 2 the sheath 23 assists in retaining the stent graft 26 , which includes self-expanding stents 26 , in a compressed condition. The proximal covered stent 27 is retained at proximal end 28 by a retention mechanism as will be discussed in detail with reference to FIGS. 7 , 8 and 12 to 16 and the distal exposed stent 29 on the stent graft 26 is retained within the capsule 21 on the deployment catheter 19 and by the distal retention mechanism as will be discussed in relation to FIG. 9 .
An indwelling catheter 50 extends from the distal end of the deployment device along a groove 51 in the fixed handle 10 and under the trigger wire release mechanisms 7 , 8 and 9 . As can be seen particularly in FIG. 2 the indwelling catheter 50 then extends through an aperture 55 into the lumen between the guide wire catheter 2 and the fixed handle 10 to extend through the sliding handle mechanism as discussed below and then extends through the lumen between the guide wire catheter 2 and the deployment catheter to a further aperture 57 just distal of the capsule 21 . The indwelling catheter 50 then exits the deployment catheter 19 , passes over the capsule 21 and enters the fenestration 59 in the stent graft 26 and extends proximally through the lumen of the stent graft 26 to exit at the proximal end 28 and extend along the nose cone dilator 4 in a longitudinal groove 61 in the nose cone dilator 4 .
The indwelling catheter 50 has a auxiliary guide wire 53 extending through it. This auxiliary guide wire 53 can be extended through the indwelling catheter to be snared to enable trans-brachial access for placement of branch stents through the fenestrations in the stent graft.
FIG. 3 shows a detailed view of a portion of the deployment device shown in FIGS. 1 and 2 after a first stage of deployment and with a fenestrated stent graft retained thereon and FIG. 3A shows the same view as FIG. 3 except that it shows the other side of the stent graft and deployment device. In FIGS. 3 and 3A the stents on the stent graft are not shown for clarity.
In FIGS. 3 and 3A the sheath 23 has been withdrawn distally to expose the stent graft 26 and the capsule 21 . The stent graft 26 is retained on the deployment device between the nose cone dilator 4 and the deployment catheter 19 . The proximal end 28 of the stent graft 26 is retained onto the deployment device distally of the nose cone dilator 4 by a retention arrangement as discussed below. The distal exposed stent 29 is retained in the capsule 21 and is locked in place using a trigger wire 48 as will be discussed below. The indwelling catheter 50 exits the deployment catheter 19 through aperture 57 , passes over the capsule 21 and enters the fenestration 59 in the stent graft 26 and extends proximally through the lumen of the stent graft 26 to exit at the proximal end 28 and extend along the nose cone dilator 4 in a longitudinal groove 61 .
The other side of the stent graft 26 as shown in FIG. 3A has a number of diameter reducing ties 43 retained by a release mechanism as will be discussed below.
FIG. 4 shows part of the deployment device as shown in FIG. 1 with an alternative stent graft retained thereon with a scalloped fenestration 66 and an apertured fenestration 67 . In FIG. 4 the stents on the stent graft are not shown for clarity. In FIG. 4 the sheath 23 has been withdrawn to expose the stent graft 26 and the capsule 21 . In this case there are two indwelling catheters 63 and 65 with the indwelling catheter 63 extending through scalloped fenestration 66 and the indwelling catheter 65 extending through the apertured fenestration 67 . The two indwelling catheters 63 and 65 extend forward to the nose cone dilator 4 and are received in grooves 68 and 69 respectively in the nose cone dilator 4 .
Now looking more closely at FIGS. 5 and 6 the detailed construction of a particular embodiment of a sliding handle mechanism according to this invention is shown. FIG. 5 shows the sliding handle mechanism in the ready to deploy condition and FIG. 6 shows the mechanism when the deployment catheter and hence the capsule has been withdrawn by moving the sliding handle with respect to the fixed handle. The retraction of the capsule releases the distally extending exposed stent 29 on the stent graft 26 (see FIG. 2 ).
The fixed handle extension 16 is joined to the trigger wire mechanism handle 10 by screw threaded nut 24 .
The sliding handle 17 is fixed to the deployment catheter 19 by screw threaded fixing nut 20 so that the deployment catheter moves along with the sliding handle 17 . The sliding handle 17 fits over the fixed handle extension 16 and in the ready to deploy situation is fixed in relation to the fixed handle by locking thumbscrew 18 which engages into a recess 30 in the fixed handle extension 16 . On the opposite side of the fixed handle extension 16 is a longitudinal track 31 into which a plunger pin 32 spring loaded by means of spring 33 is engaged. At the distal end of the track 31 is a recess 34 .
A guide tube 35 is fixed into the proximal end of the sliding handle 17 at 36 and extends back to engage into a central lumen in the fixed handle extension 16 but able to move in the central lumen. An O ring 37 seals between the fixed handle extension 16 and guide tube 35 . This provides a hemostatic seal for the sliding handle mechanism. The trigger wire 38 which is fixed to the trigger wire releasing mechanism 8 by means of screw 39 passes through the annular recess 42 between the fixed handle extension 16 and the guide wire catheter 2 and then more proximally in the annular recess 44 between the guide wire catheter 2 and the guide tube 35 and forward to extend through the annular recess 46 between the guide wire catheter 2 and the deployment catheter 19 and continues forward to the proximal retaining arrangement. Similarly the distal trigger wire (not shown in FIGS. 5 and 6 ) extends to the distal retaining arrangement and the diameter reducing release wire (not shown in FIGS. 5 and 6 ) extends to the diameter reducing ties.
The indwelling catheter 50 extends from the distal end of the deployment device along the groove 51 in the fixed handle 10 and under the trigger wire release mechanism 8 . The indwelling catheter 50 extends through the aperture 55 into the lumen 42 between the guide wire catheter 2 and the fixed handle 10 to extend through the sliding handle mechanism.
A further hemostatic seal 70 is provided where the guide wire catheter 1 enters the trigger wire mechanism handle 10 and the trigger wires 38 and the indwelling catheter 50 pass through the hemostatic seal 40 to ensure a good hemostatic seal.
As can be seen in FIG. 6 the locking thumbscrew 18 has been removed and discarded and the sliding handle 17 has been moved onto the fixed handle 16 and the plunger pin 32 has slid back along the track 31 to engage into the recess 34 . At this stage the sliding handle cannot be moved forward again.
As the trigger wire release mechanisms 7 , 8 and 9 are on the trigger wire mechanism handle 10 which is fixed with respect to the fixed handle 16 then the proximal trigger wire 38 is not moved when the deployment catheter 19 and the sliding handle 17 is moved so that it remains in position and does not prematurely disengage.
In FIGS. 7 and 8 a proximal part of the stent graft deployment device is shown and includes the guide wire catheter 2 which extends the length of the deployment device and at the proximal end of the guide wire catheter 2 is the nose cone dilator 4 . Extending back from the nose cone dilator 4 and surrounding the guide wire catheter 2 is a trigger wire guide 72 . The trigger wire guide 72 is coaxial with the guide wire catheter 2 and defines a lumen 74 between them through which, in use, pass trigger wires 76 .
Just distal of the nose cone dilator 4 there are apertures 78 in the trigger wire guide 72 extending into the lumen 74 and out of which apertures 78 extend the trigger wires 76 in a loop 80 so that it can engage the zig zag stents of a stent graft (see FIG. 13 ) or sutures can be engaged around the loops 80 and into a stent graft (see FIG. 12 ). The trigger wires 76 continue along the lumen 74 to terminate within the region of the nose cone dilator 4 . When it is desired to release the proximal end of the stent graft the trigger wires 76 are pulled out.
FIG. 8 shows a cross sectional view along the line 8 - 8 ′ in FIG. 7 . It will be noted that the trigger wires 76 extend in the lumen 74 between the guide wire catheter 2 and the trigger wire guide 72 . The groove 61 in the nose cone 4 to receive the indwelling catheter 50 (see FIG. 3 ) can be seen in this drawing.
FIG. 9 shows a detailed view of one embodiment of distal retention of a stent graft onto the deployment device of FIG. 1 . In this view it will be noted that the stent graft 26 has a tubular body 80 supported by stents 25 and having a distally extending exposed stent 29 . The distally extending exposed stent 29 is received in a proximally opening capsule 21 at the proximal end of the deployment catheter 19 . A locking wire 48 extends from the trigger wire release mechanism 6 (see FIG. 1 ) and engages a strut 29 a of the exposed stent 29 before exiting through an aperture 49 in the capsule 21 and being passed into the lumen of the stent graft 26 . A diameter reducing tie release wire 40 passes through the lumen between the guide wire catheter 2 and the deployment catheter 19 and through the capsule 21 and extends to the stent graft 26 where it is stitched in and out of the graft material at intervals, such as at 47 , longitudinally along the graft as is shown in FIG. 3A and as is discussed below in relation to FIG. 21 to engage the diameter reducing ties. The indwelling catheter 50 exits the deployment catheter 19 through aperture 57 in the deployment catheter and passes through scalloped fenestration 66 into the lumen of the stent graft 26 forward to the nose cone dilator as is discussed in relation to FIG. 3 .
The capsule 21 is smaller in diameter than the deployment catheter 19 and is mounted off centre from the deployment catheter 19 so that sufficient space is provided beside the capsule on the side that the aperture 57 is in the deployment catheter 19 so that the indwelling catheter 50 can pass beside the capsule when the sheath (not shown) extends over the capsule 21 .
FIGS. 10 and 11 show an arrangement of a stent graft including a fenestration of the type suitable for the present invention. The stent graft 100 comprises a tubular body 102 of biocompatible graft material with a lumen 104 therethrough. The stent graft 100 has a distal end 106 and a proximal end 105 . The proximal end 105 has barbs 107 to assist with retention when the stent graft 100 is deployed into the thoracic aorta, for instance. The distal end 106 of the stent graft has distally extending exposed stent 108 and within the tubular body 102 there are proximal and distal internal stents 110 and several external stents 112 intermediate the proximal and distal ends. A fenestration 114 is provided towards the distal end 106 of the stent graft 100 . In this embodiment the fenestration 114 is in the form of an aperture.
Radiopaque or MRI opaque markers 116 are provided each side of the fenestration to enable visualisation of the fenestration to an accurate position with respect to a branch vessel.
A retention arrangement to hold the proximal end of the stent graft 26 onto the deployment device in this embodiment is a multiple retention system with multiple fastenings and is shown in detail in FIG. 12 . At three points around the periphery of the stent graft 26 , fastenings 90 , 91 and 92 respectively pull the material of the stent graft to fasten onto trigger wires 76 . The trigger wires 76 extend through a lumen 74 of the trigger wire guide 72 which fits around guide wire catheter 2 as discussed in relation to FIGS. 7 and 8 back to the trigger wire release mechanism generally shown as 6 in FIGS. 1 and 2 .
FIG. 13 shows a different retention arrangement in which the three points around the periphery of the stent graft 26 are directly engaged to the trigger wires 76 by the trigger wires 76 being passed through the material of the stent graft and more preferably around a bend of a stent of the stent graft as well as through the material of the stent graft. For clarity the stents are not shown in FIG. 13 . The trigger wires extend through a lumen 74 of the trigger wire guide 72 which fits around guide wire catheter 2 as discussed in relation to FIGS. 7 and 8 back to the trigger wire release mechanism generally shown as 6 in FIGS. 1 and 2 .
FIG. 14 shows a general view of a proximal end of a stent graft 26 when retained by the mechanism as discussed above. It will be seen that there are three lobes 95 of graft material around the trigger wire guide 72 and guide wire catheter 2 . The indwelling catheter can easily pass through one of these to the groove 61 in the node cone dilator 4 (see FIG. 3 ).
FIGS. 15 and 16 show an end on view of the proximal end of the stent graft 26 when mounted in an alternative manner onto a deployment device. FIG. 15 shows detail of the stent graft tubular body 26 constricted at three places by ties 90 a , 91 a and 92 a . As shown in FIG. 16 when the tie 91 a is released by removing the trigger wire 76 a , the end of the stent graft can open up to enable entry into the lumen of the stent graft. It will be noted that the loop of suture thread 91 a remains on the end of the stent graft 26 .
FIG. 17 shows an alternative arrangement of a stent graft of the type suitable for the present invention and including a scalloped fenestration. The stent graft 120 comprises a tubular body 122 of graft material with a lumen 124 therethrough. The distal end 126 of the stent graft has distally extending exposed stent 128 and within the tubular body 122 there are proximal and distal internal stents 130 and three external stents 132 intermediate the proximal distal ends. A fenestration 134 is provided at the distal end 126 of the stent graft 100 . In this embodiment the fenestration 134 is in the form of a scallop or cut out extending from the distal end 126 of the stent graft 120 . The fenestration 134 is aligned with the struts 136 of the distal, internal, self expanding, zig zag stent 130 so that the sides of the fenestration 134 can be stitched by stitching 138 to the struts 136 along at least part of their length.
FIG. 18 shows an alternative arrangement of scalloped fenestration on a stent graft. In this embodiment the scallop 140 is at the distal end of the tubular body 142 and the struts 144 and 145 of the distal self expanding stent either side of the scallop are shaped to give a more arch-like shape to the aperture. The edge of the scalloped fenestration 140 is stitched as at 146 to the strut to ensure that the scalloped fenestration 140 opens when the stent graft is released upon deployment.
FIG. 19 shows an alternative arrangement of a stent graft of the type suitable for the present invention including both a fenestration and a scalloped fenestration. The stent graft 150 comprises a tubular body 152 of graft material with a lumen 154 therethrough. The distal end 156 of the stent graft 150 has distally extending exposed stent 158 and within the tubular body 152 there are proximal and distal internal stents 160 and at least one external stent 162 intermediate the proximal distal ends. A fenestration 164 is provided towards the distal end 156 of the stent graft 150 . In this embodiment the fenestration 164 is in the form of an aperture. A scalloped fenestration 166 is also provided towards the distal end 156 of the stent graft 150 . This fenestration 166 is in the form of a scallop or cut out extending from the distal end 156 of the stent graft 68 . The fenestration 82 is aligned with the struts of the distal, internal, self expanding, zig zag stent 160 so that the sides of the fenestration 90 can be stitched by stitching to the struts along at least part of their length.
FIGS. 20 and 21 show two views of a stent graft mounted onto a delivery device according to an embodiment of the present invention and in particular in FIG. 21 showing the side of the stent graft upon which are the diameter reducing ties.
The part of the delivery device 170 shown includes part of a nose cone dilator 172 and a guide wire catheter 174 with a guide wire lumen 175 therethrough. A proximal fastening for a stent graft 176 of the type shown in FIG. 13 is used which gives a clover leaf type pattern at the proximal end 177 of the stent graft 176 such as that shown in FIG. 15 . At the distal end of the stent graft 176 a capsule 180 is mounted in an off set manner on a deployment catheter 182 . The capsule 180 receives a distally extending exposed stent 184 which is fastened to the stent graft 176 . The stent graft 176 includes internal stents at each end and external stents 185 intermediate the ends.
As can be seen in FIG. 20 an indwelling catheter 188 extends from an aperture 190 in the deployment catheter 182 and over the capsule 180 and into a fenestration 192 in the stent graft 176 . The indwelling catheter 188 extends through the lumen of the stent graft 176 and out of the proximal end 177 thereof and to the nose cone dilator 172 . A longitudinal groove 194 in the nose cone dilator 172 receives the indwelling catheter 188 .
An anchor trigger wire 200 extends along the lumen (not shown) of the deployment catheter 182 and engages a bend of the exposed stent 184 within the capsule 182 and exits the capsule 182 through aperture 201 and then extends along the outside of the capsule and is inserted into the graft material of the stent graft 176 .
The other side of the stent graft 176 is shown in FIG. 21 . On this side the diameter reducing ties 196 are provided to draw together some of the struts of the internal and external stents 185 so that the circumference and hence the diameter of the stent graft can be reduced to enable maneuverability after partial release of the stent graft after withdrawal of the sheath (not shown). The diameter reducing ties are placed on the side of the stent graft opposite to the fenestration or fenestrations. The diameter reducing ties are fastened to a release wire 198 which extends out of the capsule 180 and is stitched in and out of the graft material. As the diameter reducing ties 196 are tightened the struts of the stents 185 are drawn together and the graft material is corrugated between them.
FIG. 22 shows a general view of an alternative embodiment of deployment device according to the invention. In this drawing the same reference numeral will be used for corresponding components to those of FIG. 1 .
In FIG. 22 it will be seen that the deployment device 200 generally consists of a guide wire catheter 2 which extends the full length of the device from a Luer lock connector 3 for a syringe at the far distal end of the device to and through a nose cone dilator 4 at the proximal end. The nose cone dilator 4 is fixed to the guide wire catheter 2 and moves with it. To lock the guide wire catheter 2 with respect to the deployment device in general a pin vice 4 is provided.
The trigger wire release mechanism generally shown as 6 on a fixed handle 10 includes four trigger wire release mechanisms as will be discussed below. The trigger wire release mechanisms 6 slide on a portion of the fixed handle 10 and hence until such time as they are activated the trigger wire mechanisms 6 which are fixed by thumbscrews 11 remain fixed with respect to the fixed portion of the fixed handle 10 .
Immediately proximal of the trigger wire release mechanisms 6 is the sliding handle mechanism generally shown as 15 . The sliding handle mechanism 15 generally includes a fixed handle extension 16 and a sliding portion 17 the sliding portion 17 slides over the fixed handle extension 16 . A thumbscrew 18 fixes the sliding portion with respect to the fixed portion.
The fixed handle portion 16 is affixed to the trigger wire mechanism handle 10 by a screw threaded nut 24 .
The sliding portion of the handle 17 is fixed to the deployment catheter 19 by a mounting nut 20 . The deployment catheter 19 extends through to a capsule 21 at the proximal end of the deployment catheter 19 .
Over the deployment catheter 19 is a sheath manipulator 22 and a sheath 23 which slides with respect to the deployment catheter 19 and in the ready to deploy situation extends forward to the nose cone 3 to cover the stent graft 26 .
In the ready to deploy condition shown in FIG. 22 the sheath 23 assists in retaining the stent graft 26 which includes self-expanding stents 25 in a compressed condition. The proximal covered stent 27 is retained at 28 by a retention mechanism as will be discussed later and the distal exposed stent 29 on the stent graft 26 is retained within the capsule 21 on the deployment catheter 19 and by a distal retention mechanism.
For this release mechanism the handle include four trigger wire release grips 7 , 8 9 and 12 . The first grip 12 is fastened to the trigger wire 76 a (see FIG. 15 ) and by removal of the thumb screw 11 on release trigger wire release mechanism 12 , the trigger wire 76 a (see FIG. 15 ) can be completely withdrawn from the deployment device which releases the fastening 91 a so that the retention of the proximal end of the stent graft changes from that shown in FIG. 15 to that shown in FIG. 16 .
The trigger wire release mechanism 9 has a trigger wire which extends to the capsule at the proximal end of the deployment catheter and engages one of the loops of an exposed stent 29 of the stent graft 26 . When the thumb screw 11 on the retention mechanism 9 is removed, that trigger wire can be removed and the capsule can be removed from the exposed stent.
The trigger wire release mechanism 8 extends a trigger wire 45 to diameter reducing ties 43 on the stent graft 26 (see FIG. 3A ). When the thumb screw 11 on the trigger wire mechanism 8 is removed, the trigger mechanism 8 can be completely removed from the deployment device which releases the diameter reducing ties as discussed in detail in relation to FIG. 21 .
The trigger wire mechanism 7 has two trigger wires 76 connected to it and when this trigger wire release mechanism is removed the remaining proximal retention fastenings 90 a and 92 a can be released to release the proximal end of the stent graft as is discussed in relation to FIGS. 15 and 16 .
As can be seen in FIG. 16 the proximal end of the stent graft is partially open and a guide wire can be introduced through the larger lobe 97 via a cranial or brachial entry into the aorta so that it can extend into the lumen within the stent graft 26 and by careful manipulation extend out through a fenestration in the stent graft. To assist with placement of the guide wire the rotational, longitudinal position of the stent graft 26 can still be adjusted because the diameter reducing ties prevent the stent graft from fully expanding against the walls of the vessel.
An indwelling catheter 50 extends from the distal end of the deployment device along a groove 51 in the fixed handle 10 and under the trigger wire release mechanisms 7 , 8 , 9 and 12 . The indwelling catheter 50 has a auxiliary guide wire 53 extending through it. The indwelling catheter 50 and auxiliary guide wire 53 can be extended out of the stent graft after the stent graft has been partially released at its proximal end as discussed in relation to FIGS. 15 and 16 . The auxiliary guide wire 53 can then be extended through the indwelling catheter to be snared to enable trans-brachial access for placement of branch stents through the fenestrations in the stent graft.
It will be seen that by this invention there is provided a deployment device which ensures good control of the stent graft during deployment is possible by the use of an indwelling catheter and separate release mechanisms. In particular for fenestrated stent grafts a partial retention removal stage will assist with ensuring that access to the lumen of the stent graft to enable placement of a catheter through the stent graft and fenestration into a branch vessel is possible.
Throughout this specification various indications have been given as to the scope of the invention but the invention not limited to any one of these but may reside in two or more of these combined together. The examples are given for illustration only and not for limitation. | A stent graft introducer for intraluminal deployment of a stent graft ( 26 ), the introducer comprising a stent graft release mechanism ( 6 ) to allow partial release of the stent graft ( 26 ) when carried on the introducer, whereby control of the stent graft can be maintained while allowing access into the lumen of the stent graft from at least one end of the stent graft. The partial release can comprise partial release of one end of the stent graft. | 0 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority from U.S. Provisional Patent Application No. 61/709,746 filed Oct. 4, 2012, the contents of which are hereby incorporated herein by reference.
FIELD OF THE INVENTION
[0002] The present invention relates generally to data analysis, and more particularly to software, devices and methods for analysing, and optionally improving, knowledge bases and the handling of queries to such knowledge bases.
BACKGROUND OF THE INVENTION
[0003] In recent years, computerized searching of data has become prevalent. As the public Internet has grown, so has the need for indexing and organizing data.
[0004] One search technique that is particularly useful in searching contained amounts of information is disclosed in U.S. Pat. No. 7,171,409, the contents of which are hereby incorporated by reference. As disclosed therein, a knowledgebase may be searched by receiving a natural language query. Based on the query, the best one of many responses may be presented.
[0005] Using natural language queries to query a knowledgebase may be an effective way to extract information from the knowledge base. At the same time, the nature of a presented query may identify a deficiency or flaw in the content of the knowledgebase or in how it is being searched. Similarly, an analysis of many queries may provide insight into a perception or a behavior on the part of users making the queries.
[0006] Accordingly, there remains a need for effectively analyzing data derived from queries and using the analysis to extract further information, and possibly refine knowledge bases and search techniques.
SUMMARY OF THE INVENTION
[0007] In accordance with an aspect of the present disclosure, there is provided a computerized method of analyzing a knowledgebase comprising: assembling a collection of queries made by users to obtain information from the knowledgebase; identifying in each query, sets of collocated words in that query to form a list of collocated word sets in the collection; from the list, identifying and presenting frequently collocated word sets in the collection.
[0008] In accordance with another aspect of the present disclosure there is provided a computerized method of analyzing a knowledgebase. The method comprises assembling a collection of queries made by users to obtain information from the knowledgebase; identifying in each query in the collection in a first and second time interval, word sets in that query and theft frequency to form a first and second list of frequently used word sets in the collection in the first time interval and second time intervals respectively. For each word set in the first list and the second list, a relative difference between theft respective frequencies in the first list and second list is calculated. Each relative difference is scaled by a scale factor proportional to the frequency for that word set in the first or second interval to form scaled relative differences. A histogram of the scaled relative differences may be generated and presented. The histogram may be presented as a tag cloud.
[0009] Other aspects and features of the present invention will become apparent to those of ordinary skill in the art upon review of the following description of specific embodiments of the invention in conjunction with the accompanying figures.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] In the figures which illustrate by way of example only, embodiments of the present invention,
[0011] FIG. 1 illustrates a computer network and network interconnected computing device, operable to analyse query data and provide results, exemplary of an embodiment of the present invention;
[0012] FIG. 2 is a functional block diagram of software stored and executing at the device of FIG. 1 ;
[0013] FIG. 3 is a diagram illustrating a database schema for a database used by a device of FIG. 1 ;
[0014] FIG. 4 depicts a flow chart illustrating the execution of software at the device of FIG. 1 , exemplary of an embodiment of the present invention;
[0015] FIG. 5 is a diagram illustrating a database schema for a database used by a device of FIG. 1 ;
[0016] FIG. 6 is a flow chart illustrating the execution of software at the device of FIG. 1 , exemplary of an embodiment of the present invention;
[0017] FIG. 7 illustrates exemplary output provided by the device of FIG. 1 ;
[0018] FIG. 8 is a diagram illustrating a further database schema for a database used by a device of FIG. 1 ;
[0019] FIGS. 9-11 illustrate exemplary output provided by the device of FIG. 1
DETAILED DESCRIPTION
[0020] FIG. 1 illustrates a network interconnected computing device 12 . Computing device 12 which may be a conventional network server is a device exemplary of the present invention including software adapting it to operate in manners exemplary of embodiments of the present invention.
[0021] As illustrated, computing device 12 is in communication with a computer network 10 in communication with other computing devices such as end-user computing devices 14 and other computer servers (not specifically illustrated). Network 10 is preferably the public Internet, but could similarly be a private local area packet switched data network coupled to computing device 12 . So, network 10 could, for example, be an Internet protocol, X.25, IPX compliant or similar network.
[0022] Example end-user computing devices 14 are illustrated. End-user computing devices 14 are conventional network interconnected computers, used to access data from network interconnected servers, such as computing device 12 . Device 12 may, for example, take the form of a person computer, laptop, tablet, mobile phone, or other programmable computing device.
[0023] Example computing device 12 preferably includes a network interface physically connecting computing device 12 to data network 10 , and a processor coupled to conventional computer memory. Example computing device 12 may further include input and output peripherals such as a keyboard, display and mouse. As well, computing device 12 may include a peripheral usable to load software exemplary of the present invention into its memory for execution from a software readable medium, such as medium 20 . As such, computing device 12 includes a conventional filesystem, preferably controlled and administered by the operating system governing overall operation of computing device 12 . This filesystem preferably hosts search data in database 30 , and analysis software 46 exemplary of an embodiment of the present invention, as detailed below. In the illustrated embodiment, computing device 12 also includes hypertext transfer protocol (“HTTP”) files used to provide an administrator or other user with an interface to access computing device 12 .
[0024] As will become apparent, computing device 12 includes software 46 capable of analyzing search information, representative of natural language user queries to a knowledgebase. In particular, exemplary software 46 is capable of analyzing text queries to locate and analyze frequently used words, or sets of two or words (word clusters), and extract data therefrom that may be used to identify themes in queries presented by the user. In the depicted embodiment, the word clusters take the form of single words or collocated words in a query. In an embodiment, the word clusters are collocated word pairs occurring in the queries. In a further embodiment, the word clusters are adjacent words—and may be adjacent word pairs, or three, four or more adjacent words. Possibly, single words may also be considered and treated as word clusters.
[0025] In particular, computing device 12 maintains database 30 including a collection of user queries presented to search software used to query the content of a knowledgebase. In the depicted embodiment, computing device 12 may maintain a database of natural language queries presented to a natural language query interface. For example, computing device 12 may include a database that stores user queries presented to search software detailed in the '409 patent. In an alternate embodiment, database 30 may store an entire database containing a knowledgebase and queries made to that knowledgebase.
[0026] As disclosed in the '409 patent, natural language user queries may be received at a computing device and parsed. Stored Boolean expressions associated with candidate responses are applied to the user queries to identify one or more candidate responses that address the user query. One or more responses associated with the best matching Boolean expressions may be presented to the end user as a response to the query. As such, anticipated queries may be precisely answered from data in the knowledgebase. A system in accordance with the '409 patent is used by many consumer agencies—e.g. banks, merchants, service providers—in order to provide end-user customers with end-user support, by way of questions submitted over the Internet. Ideally, typical questions are predicted and lead to a single best response.
[0027] Computing device 12 receives the natural language queries that have been input by users to query the knowledgebase, and stores these in database 30 . The natural language queries may be received directly at computing device 12 , or may be provided to computing device 12 by way of network 10 , by way of another server. In any event, database 30 contains entries representative of the collection of user searches for information in a knowledgebase. Ideally, entries in database 30 include the entire collection of queries made to a knowledgebase.
[0028] The queries may be collected over time, and stored in one or more tables of database 30 . As such, database 30 may include all queries received during a particular time interval. Queries may be include multiple fields, that may used for search and indexing criteria, including date of receipt (DATE_STAMP); query content (QUERY); response (RESPONSE_ID); etc. Other fields (not illustrated) may also be maintained in database 30 .
[0029] Now, the knowledgebase typically contains information that is related—for example the knowledgebase could be an intranet site, the Internet site of a particular entity (e.g. corporation, partnership, or the like); a wiki maintained by an entity; a knowledgebase answering frequently asked questions; a social network feed-like a twitter feed, or the like. As noted, in a particular embodiment, the knowledgebase may be collection of answers to customer questions. As a consequence, proper analysis of natural language queries made to the knowledgebase may allow for improvement of the knowledgebase and search algorithms used by the knowledgebase. Likewise, the analysis may provide insight into the thoughts or wishes of the users, and allow for the provision of enhanced products or services to the users.
[0030] FIG. 2 illustrates a functional block diagram of software components preferably implemented at computing device 12 . As will be appreciated, software components embodying such functional blocks may be loaded from medium 20 ( FIG. 1 ) and stored within persistent memory at computing device 12 . Alternatively, the software components may reside at another computing device executed as a software as a service. Data to be processed may be provided from computing device 12 , and results provided to computing device 12 .
[0031] As illustrated, typical software components include operating system software 40 ; a database engine 42 ; analysis software 46 ; a presentation component 60 ; and an optional an http server application 44 , exemplary of embodiments of the present invention. Further, database 30 is again illustrated. Again database 30 may be stored within memory at computing device 12 . As well data files 48 used by search software 46 , presentation component 50 and http server application 44 are illustrated.
[0032] Operating system software 40 may, for example, be a Linux based operating system software; OS/X operating system; Microsoft operating system software, or the like. Operating system software 40 also includes a TCP/IP stack, allowing communication of computing device 12 with data network 10 . Database engine 42 may be a conventional relational or object oriented database engine, such as Microsoft SQL Server, Oracle, DB2, Sybase, Pervasive or any other database engine known to those of ordinary skill in the art. Database engine 42 thus typically includes an interface for interaction with operating system software 40 , and other application software, such as analysis software 46 . Database engine 42 is used to add, delete and modify records at database 30 . HTTP server application 44 may be an Apache, Cold Fusion, Postures or similar server application, also in communication with operating system software 30 and database engine 42 .
[0033] Optional HTTP server application 44 allows computing device 12 to act as a conventional http server, and thus provide a plurality of HTTP pages for access by network interconnected computing devices, such as end-user computing devices 14 . HTTP pages that make up these pages may be implemented using one of the conventional web page languages such as hypertext mark-up language (“HTML”), Java, javascript or the like. These pages may be stored within files 48 .
[0034] Analysis software 46 adapts computing device 12 , in combination with database engine 42 and operating system software 40 , to function in manners exemplary of embodiments of the present invention. Analysis software 46 may analyse stored user queries, and store analysis results to database 30 . Results may be further used to generate reports or other representation of the analysis by way of presentation component 50 and/or or present these to users by way of presentation component 50 , or to users by way of HTTP pages, or otherwise. Analysis software 46 may for example, include suitable CGI or Perl scripts; Java; Microsoft Visual Basic application, C/C++ applications; or similar applications created in conventional ways by those of ordinary skill in the art.
[0035] HTTP pages provided to computing devices 14 in communication with computing device 12 may provide permitted users at devices 14 access to analysis software 46 . The interface may be stored as HTML or similar data in files 48 .
[0036] Of course, any of the above components (e.g. software components, database, etc.) may be distributed over multiple computing devices.
[0037] An example organization of database 30 is illustrated in FIG. 3 . As illustrated, example database 30 includes three tables: query table 32 ; word table 34 ; and word cluster table 36 . A tabulated word cluster count for each unique word cluster in word table 34 may be stored in a fourth table 38 .
[0038] As illustrated, each entry of query table 32 may include a query (QUERY—in ASCII or similar text format); an identifier of a response that was returned to the query (RESPONSE_ID); the date of the query (DATE_STAMP); and a unique numerical identifier of the query (QUERY_ID). As will become apparent, each query stored in queries table 32 is used to populate WORDS table 34 , and COLLOCATION table 36 . In particular, each word in each query is used to create an entry in WORDS table 34 . Each entry in WORDS table 34 identifies a word used in a query (WORD—in ASCII or similar text format); the query that is the source of the word (by numerical query identifier in QUERY_ID); and a unique identifier of the word (in WORD _ID). Word cluster—i.e. words, word pairs (and optionally word triplet, quadruples, etc.) of each query are stored in COLLOCATION table 36 . The identity of the word cluster (i.e. word, word pair, triplet, etc. in ASCII or similar may be stored in WORD_CLUSTER). Again, in which query (in QUERY_ID) a particular word cluster may be found, as well as the individual words within the word cluster (WORD_ID_ 1 , WORD_ID_ 2 , WORD_ID_ 3 . . . —as referenced to table 34 ) may be stored in table 36 . Each word cluster may also be uniquely numerically identified in CLUSTER_ID. Additionally, for each unique word cluster in table 36 , a count may be stored in table 38 (COUNT) along with an identity of the cluster in ASCII (in WORD_CLUSTER).
[0039] Now, in operation, analysis software 46 processes each stored query in database 30 , to identify word clusters (in the illustrated example collocated word pairs) as illustrated in FIG. 4 . Specifically, for each entry of interest in table 32 , the text is retrieved in block S 402 and normalized in block S 404 . Normalization in block S 404 includes removing punctuation; converting the text to a uniform case (e.g. lower case); and removing contractions (e.g. can't →cannot). Optionally, common words like “the”, “a”, “an”, and others may be removed from the normalized query. Likewise, words may be stemmed—e.g. or reducing inflected (or sometimes derived) words to their stem (e.g. running, runs →run). Entries of table 32 may be processed as received.
[0040] In block S 406 , each word of the n words in the query may be added to table 34 , and thus tokenized. That is, for each word in the query is added to a separate entry of table 34 . Once all words in a query have been added to table 34 , collocated word pairs within a query are identified. Specifically, in block S 408 , for each word in a query, word pairs of that word and each remaining word within the query are constructed. Specifically for a query of n words (as normalized), collocated word pairs may be constructed by pair the j th word in the query with the j+1 st , j+2 nd . . . q th word, for j=1 to q, in the query. Each word pair so constructed may be stored in COLLOCATION table 36 . For consistency, each word pair in table 36 may be constructed with words in the pair in alphabetical order. As well, the identity of each word in a collocated word pair (by WORD _ID, as stored in table 34 ) may be stored in table 36 . At the conclusion of block S 408 , all the word pairs for an query entry in table 32 will have been added to table 36 . Table 36 will thus contain a list of word clusters (e.g. words, collocated word pairs, etc.) in the collection of queries in database 30 . Steps S 400 may be performed each time a new record is added to table 32 , or on demand for all queries in table 32 that have not been processed.
[0041] In block S 410 , table 38 may be updated with a count of each word pair. Specifically, for any word pair added to table 36 , a record for that word pair in table 38 may be queried (by WORD_CLUSTER) and an associated count (COUNT) may be updated to increase the count for that word cluster by one (1). If the word cluster does not yet exist in table 38 , it may be added.
[0042] Optionally, instead of searching for collocated pairs, software 46 may search for other word clusters, such as collocated triplets, or quadruples, or a combination of pairs and triplets, or pairs, triplets and quadruples. Alternatively, software 46 may also search for single words in the queries. Again, single words may be added to table 36 .
[0043] In the embodiment of FIGS. 3 and 4 , word clusters include any two (or more) word pairs that may be formed from a particular query, regardless of how proximate those words are within their associated query.
[0044] In an alternate embodiment, analysis software 46 processes each stored query in database 30 , to identify word clusters formed as one or more adjacent words in the query, as illustrated in FIG. 6 . A simplified database schema as depicted in FIG. 5 may be used to store analysis results. Specifically, for each new query entry in table 132 , the text is retrieved in block S 602 , normalized in block S 604 , and tokenized in block S 606 as described with reference to FIG. 4 .
[0045] The tokenized words in the query may be temporarily stored—in an array or other data structure. Once all words in a query have been added to the data structure, word clusters representing collocated words—in the form of adjacent word pairs, adjacent word triplets, or four five or more adjacent words, and possible single words—within a query are identified. Specifically, in blocks S 608 -S 616 , for each word in a query, word clusters of that word and its adjacent word; the adjacent two words; adjacent three words; up to the remaining adjacent words in the query are formed. Adjacency is established in a single direction within the query—from left to right. Each word duster so constructed may be stored in a suitable data structure—for example in table 136 ( FIG. 5 ) of database 30 . All clusters of length L, for L=1 to the length of the query k, may be so formed, by repeating block S 608 for all clusters of adjacent words of length 1 to k-j (where j is the position the first word in the clusters within the query, and k is the length of the query). At the conclusion of block S 616 , all word clusters formed of adjacent words in the query may be identified, counted and stored. Table 136 will thus contain a list of word clusters (e.g. adjacent words) in the collection of queries in database 30 , links to associated queries and the correct responses may be stored in table 134 . Steps S 600 may be performed each time a new record is added to table 132 , or on demand for all queries in table 132 that have not been processed.
[0046] Empirically, collocated pairs and triplets provide more useable information for analysis and presentation. If collocation of three, four or more words in a query is assessed, then shorter collocated word sets contained within longer ones need not be retained in table 36 or 136 (e.g. single words or two word sets contained in any set of three collocated words need not be stored). As noted, single words may also be treated as word clusters.
[0047] Of course, other collocation or similar extraction techniques may be used to produce slightly different outputs from the same set of queries.
[0048] In any event, after performing blocks S 400 of FIG. 4 , or S 600 of FIG. 6 , table 38 /table 136 of database 30 will include a list of all collocated word clusters (pairs and optionally singletons, triplets, quadruples, etc.) in the collection of queries in database 30 , and the number of occurrences of each word pair in the set of queries stored in table 32 /table 132 .
[0049] This data may be output for visualization by presentation component 50 . For example, the data may be output in CSV or similar format for review by a user. Each word, word pair, etc. and its frequency may be extracted from table 38 and output. Preferably, the data is output as a histogram for further graphical presentation. For example, a histogram of the ten (or twenty—or arbitrarily many) most frequently appearing words or word pairs in table 38 /table 136 may be output as a word cloud. To do so, entries of table 38 /table 136 may be sorted by COUNT field and the desired number of associated word clusters (from the WORD_CLUSTER field) may be provided to visualization component 50 .
[0050] Presentation component 50 may, for example, include a tag cloud generation tool. Example Tag cloud generation tools, include Wordle. Tag clouds typically show more important (i.e. more frequent) terms in larger fonts, or in differing colours. In any event, tag clouds may be used to quickly identify frequently collocated word clusters (i.e. word pairs) in queries stored in database 30 . The tag cloud generation may simply be provided with the word pairs of interest, and their count in database 30 .
[0051] As such, tag clouds may be used to identify themes in queries in database 30 , and thus frequent questions in an associated knowledgebase, or deficiencies in the knowledgebase.
[0052] Conveniently, as word clusters are linked to the queries from which they originate (through QUERY_ID), each word pair as presented in the histogram may be used to further present the underlying queries within the queries in database 30 in which the word pair occurs. To this end, presented CSV data may include the queries from which the word pairs originate. Likewise, the presented tag cloud could include links that result in lists of query terms that contain the word pair. The links, could for example, cause execution of an SQL query on table 132 to retrieve the associated quer(ies) for the word pair. Similarly, each query could further link to the response that was used to answer the query, through for example, the RESPONSE_ID of the record in the QUERIES table, which could further be retrieved through a suitable script.
[0053] An example tag cloud, is depicted in FIG. 7 . This tag cloud was generated from the following queries in database 30
[0000]
fx idt ouf of balance
cprref bcc
eft return debit
rrs requestor info.
cprref telephone maintenance
fx currency code
pda identification for new account
sdb remove account
special arrangement
cprref telephone maintenance
bus access to deposited funds
ips redeem
ips features of ergic
poa transaction
cprref telephone maintenance
loss report ...... sent link
nsl asked to change password for Sentra Persaud SP00319
nsl asked to change password for Sentra Persaud SP00319
pda reduce cops joint
IPS issue joint
cprref telephone maintenance
pda sign - change name from married to maiden
dispute
cprref telephone maintenance .. spoke to her earlier
tfsa discretionary pricing
ips reference number
op password format
legal
Bist
cprref collections
estate
cprref visa
bizline visa
abgl commonly used numbers
[0054] Optionally, a user interface may allow a user to further refine the analysis, by for example limiting the analysed records to specific dates (by, for example, filtering to records in table 36 resulting from queries in the date range). The user interface may be presented as an HTML page by way of HTTP server 44 .
[0055] In a further example depicted in FIGS. 9 to 11 , software 46 may be used to generate comparative information to assess themes at particular times or over particular time intervals.
[0056] For example, the analysis of some arbitrary set of queries at time T 1 is illustrated below Table 1. For simplicity, the actual queries from which the word cluster counts illustrated in Table 1 are derived are not illustrated.
[0000]
TABLE 1
Cluster (Theme)
Count T1
credit card
1100
credit limit
150
new credit card
344
Cancel
111
cancel credit card
80
Reward points
219
Redeem points
75
increase limit
112
Application form
2364
Fraud
908
fraud protection
700
Statement
353
pay balance
143
current balance
456
Dispute charge
45
Second card
2
lost card
178
Stolen
123
Payment
709
miss payment
42
one-day offer
347
TOTAL QUESTIONS
7500
[0057] Received queries may again be analysed at time T 2 and the resulting twenty-three themes illustrated below are identified Table 2.
[0000]
TABLE 2
Cluster (Theme)
Count T2
credit card
1367
credit limit
265
new credit card
550
Cancel
89
cancel credit card
71
Reward points
645
Redeem points
456
increase limit
123
Application form
2399
Fraud
523
fraud protection
213
Statement
500
pay balance
177
current balance
790
Dispute charge
12
Second card
67
lost card
209
Stolen
167
Payment
900
miss payment
67
one-day offer
1
spousal card
187
TOTAL QUESTIONS
8500
[0058] Of note, the example word cluster counts at T 1 are obtained from an analysis of 7500 queries. Example word cluster counts at T 2 are obtained from an analysis of 8500 queries.
[0059] As described, queries at T 1 and T 2 are identified. Queries at T 1 and at T 2 may actually represent queries received over some time interval with T 1 and T 2 equal to T 1f -T 1i and T 2f -T 2i , respectively, where T 1i , T 2i represent the beginning of the intervals T 1 and T 2 , respectively and T 1f and T 2f represent the end of those intervals T 1 and T 2 , respectively. Corresponding records may be retrieved from database 30 , and steps S 400 may be performed.
[0060] Tables 234 and 236 depicted in FIG. 8 , like table 134 ( FIG. 5 ) may be populated for intervals T 1 , T 2 and thus would include word/cluster counters counts specific to the interval T 1 , T 2 . As well, the interval may be stored in table 234 .
[0061] The identified themes for intervals T 1 and T 2 may be visualized as suitable histograms depicted in FIGS. 9 and 10 . Again, visualization component 50 may be used to generate the histograms. Notably histograms of FIGS. 9 and 10 are in the form of word clouds (in the form of bubbles) and depict more prominent themes in larger font (or as larger graphical sets—i.e. bubbles), with less prominent themes depicted in smaller font (or as smaller graphical sets).
[0062] Now, interestingly, in order to further analyse the data at times T 1 and T 2 , a histogram of change or deltas (Δ) from T 1 to T 2 may also be calculated and presented.
[0063] In order to meaningfully calculate such a delta, the relative change in counts from time/interval T 1 and T 2 may be determined. To do this, absolute counts at T 1 may be normalized taking into account that the analysis at T 1 results from an analysis of 7,500 queries. Counts at T 2 can be similarly normalized taking into account that the analysis at T 2 reflects 8,500 queries.
[0064] Thus, a measure of the relative difference for any count of a word cluster from T 1 to T 2 for any word cluster (e.g word, word pair, triplet, etc.) may be expressed as
[0000]
CountT
2
(
Cluster
i
)
TotalCountT
2
-
CountT
1
(
Cluster
i
)
TotalCountT
1
where CountT 2 (Cluster i ) is the raw count of a specific word cluster—Cluster i at T 2 and CountT 1 (Cluster i ) is the raw count of the same specific word cluster—Cluster i at T 1 . TotalCountT 1 , TotalCountT 2 , represent the total number of queries analysed at/for intervals/times T 1 and T 2 , respectively.
[0066] The results are illustrated below in TABLE 3.
[0000]
TABLE 3
Cluster (Theme)
Count T1
Count T2
Raw Delta
credit card
1100
1367
0.014156863
credit limit
150
265
0.011176471
new credit card
344
550
0.018839216
Cancel
111
89
−0.004329412
Cancel credit card
80
71
−0.002313725
reward points
219
645
0.046682353
redeem points
75
456
0.043647059
increase limit
112
123
−0.000462745
application form
2364
2399
−0.032964706
Fraud
908
523
−0.059537255
fraud protection
700
213
−0.06827451
Statement
353
500
0.011756863
pay balance
143
177
0.001756863
current balance
456
790
0.032141176
dispute charge
45
12
−0.004588235
second card
2
67
0.007615686
lost card
178
209
0.000854902
Stolen
123
167
0.003247059
Payment
709
900
0.01134902
miss payment
42
67
0.002282353
one-day offer
347
1
−0.04614902
spousal card
0
187
0.022
TOTAL QUESTIONS
7500
8500
[0067] As will be appreciated, the relative difference may be more directly calculated as
[0000]
CountT
2
(
Cluster
i
)
-
CountT
1
(
Cluster
i
)
TotalCountT
2
(
orTotalCountT
1
)
[0068] Possibly, the relative difference (raw delta) could be graphically or otherwise presented for further consideration. This calculation, however, over-emphasizes small absolute changes that amount to high relative differences from T 1 to T 2 .
[0069] Put another way, a change of, for example 100/1000 to 300/2000 for one theme is equal in percentage count change to one of 5/1000 to 15/2000 in another theme. The fact that the former theme has raw count values (100, 300) of a larger magnitude than the latter theme (5, 15) means that the change in the former theme is likely more significant and should appear larger in any graphical depiction of change (e.g. theme cloud).
[0070] As such, the relative difference may further scaled logarithmically to de-emphasize small absolute changes in the count for any particular cluster between times T 1 and T 2 .
[0071] To this end, example logarithmic scaling may be performed as follows:
[0000]
scaled
Δ
=
(
[
CountT
2
(
Cluster
i
)
TotalCountT
2
-
CountT
1
(
Cluster
i
)
TotalCountT
1
]
log
10
(
max
(
Count
1
(
cluster
i
)
,
CountT
2
(
cluster
i
)
)
1.5
max
(
CountT
1
(
Cluster
i
)
TotalCountT
1
,
CountT
2
(
Cluster
i
)
TotalCountT
2
)
)
3
[0072] Notably,
[0000]
max
(
CountT
1
(
Cluster
i
)
TotalCountT
1
,
CountT
2
(
Cluster
i
)
TotalCountT
2
)
represents the maximum of the ratio of counts (expressed as a fraction of the total queries being counted) for the themes (clusters) at T 1 and T 2 .
[0000]
[
CountT
2
(
Cluster
i
)
TotalCountT
2
-
CountT
1
(
Cluster
i
)
TotalCountT
1
max
(
CountT
1
(
Cluster
i
)
TotalCountT
1
,
CountT
2
(
Cluster
i
)
TotalCountT
2
)
]
thus calculates the relative difference of the count of Cluster i between interval T 1 and T 2 . The maximum (max) function is used in the denominator to ensure equal relative difference in either direction (i.e., increasing or decreasing) will have the same absolute value. An increase from 10/100 to 20/150 will thus have the same absolute value as a change from 20/150 to 10/100.
[0075] Now, log 10(max(countT 1 (Cluster i )countT 2 (Cluster i ))) 1.5 calculates order of magnitude of the larger of the raw count of clusters at T 1 and T 2 . Again, the maximum function ensures that equivalent increases and decrease return equal (absolute) values, The exponent (1.5) acts as a multiplier used to exaggerate the magnitude effect of the logarithm function.
[0076] log 10(max(countT 1 (Cluster i ),countT 2 (Cluster i ))) 1.5 thus acts as a scale factor that is proportional to the count that has changed, and more particular to a multiple of the logarithm of that count, In this was changes In small counts, are scaled by a smaller scale factor than changes in larger counts. As will be appreciated other scale factors could similarly accomplish such scaling
[0077] The additional exponent (3) in
[0000]
[
[
CountT
2
(
Cluster
i
)
TotalCountT
2
-
CountT
1
(
Cluster
i
)
TotalCountT
1
]
log
10
(
max
(
countT
1
(
cluster
i
)
,
countT
2
(
cluster
i
)
)
1.5
max
(
CountT
1
(
Cluster
i
)
TotalCountT
1
,
CountT
2
(
Cluster
i
)
TotalCountT
2
)
]
3
provides a further numeric spread between the typical lowest computed delta values in any dataset and the typical highest computed data values in any dataset, and preserves the sign of the relative difference.
[0079] The resulting scaled relative difference values are depicted in TABLE 4
[0000]
TABLE 4
THEME
Count T 1
Count T 2
Scaled Delta
credit card
1100
1367
0.116788553
credit limit
150
265
2.472987167
new credit card
344
550
2.304057802
Cancel
111
89
−0.626512978
cancel credit card
80
71
−0.184678476
reward points
219
645
24.31689101
redeem points
75
456
43.89690274
increase limit
112
123
−0.000820587
application form
2364
2399
−0.274493225
Fraud
908
523
−15.66178099
fraud protection
700
213
−43.26164271
Statement
353
500
0.696005015
pay balance
143
177
0.022993793
current balance
456
790
4.963088638
dispute charge
45
12
−4.294992112
second card
2
67
13.551677
lost card
178
209
0.00185518
Stolen
123
167
0.164269198
Payment
709
900
0.161217407
miss payment
42
67
0.364765973
one-day offer
347
1
−65.87005352
spousal card
0
187
40.15144876
TOTAL QUESTIONS
7500
8500
[0080] Conveniently, scaled relative difference values (ScaledDelta(Cluster i )) may be presented by presentation component 50 as a histogram (e.g. word cloud) corresponding to the word clouds generated at T 1 and T 2 .
[0081] An example histogram representing changes in word cluster frequency from T 1 to T 2 is illustrated hi FIG. 11 . As will be appreciated, word clusters (themes) that are trending—i.e. changing frequency/count. Further conveniently, positive and negative relative differences may be presented in contrasting colours—for example values that are negative (i.e. negative change) may be represented by presentation software 50 using a particular colour or font while changes that are positive may be represented in a further colour or font, thus allowing an analyst to determine those queries that are trending (i.e. increasing in frequency) and those that are falling off (i.e. decreasing in frequency).
[0082] Additionally, scaled relative differences of word cluster counts that have counts equal to (or near) zero in either interval T 1 or T 2 may be marked as new themes (e.g. “spousal card” and “second card” in the above example), or as dropped-off themes (e.g. “one day offer”). Similar scaled relative differences of word cluster counts that are below a threshold need not/are not illustrated.
[0083] Possibly, graphic logos or icons could be used to identify new themes; themes of increasing or decreasing change; or themes that have dropped off. Additionally, mousing or cursing over a particular tag/cloud or bubble may provide additional information about the relative change, and possibly absolute counts reflected by the bubble.
[0084] Conveniently, the histogram in the form of a word cloud/histogram may be viewed in overlying relationship or separately to the histogram/word clouds formed at T 1 and T 2 exemplified in FIGS. 9 and 10 .
[0085] Of course, the above described embodiments are intended to be illustrative only and in no way limiting. The described embodiments of carrying out the invention are susceptible to many modifications of form, arrangement of parts, details and order of operation. The invention, rather, is intended to encompass ail such modification within its scope, as defined by the claims. | A computerized method of analyzing a knowledgebase comprising; assembling a collection of queries made by users to obtain information from the knowledgebase; identifying in each query, sets of collocated words in that query to form a list of collocated word sets in the collection; from the list, identifying and presenting frequently collocated word sets in the collection. Likewise, a histogram of scaled relative difference between the frequency of word sets at first and second time intervales may be presented. | 6 |
BACKGROUND
[0001] 1. Field
[0002] Considering the present invention of clean energy generation from wave power, for encouraging active investment and research activities to the wave power generator, power generation system is to have relatively high conversion efficiency from wave energy and complementing irregular output from uncertainty of environment by nature, and to enhance the practicality and the value thereof as a clean energy resource, especially by virtue of the improved return on investment thereof.
[0003] 2. Description of the Related Art
[0004] Our future is being threatened by exhaustion of fossil fuel resources, increasing cost pressure of energy due to reduced production and cost advancing pressure from oil-producing countries, and serious environmental pollution coming out from energy consumption.
[0005] In addition, conventional power generation system using fossil fuels, there are various power generation systems using various kinds of energy resources such as nuclear energy, tidal energy, water energy, wind energy, solar energy, bio energy, and so on.
[0006] However, nuclear energy even having economic feasibility has been restrictively developed only in some countries due to the Nuclear Nonproliferation Treaty and radioactive contamination, meanwhile water energy and tidal energy require proper site location satisfying system requirements, anticipated excessive investment and long-term construction period, while solar energy and wind energy require storage cell due to intermittent generation and higher cost.
[0007] Accordingly, development of wave power generation system using clean energy is still needed.
[0008] Considering those systems consuming fossil fuels, future-oriented new power generation systems using clean energy resources must be competitive in construction costs and operation cost to the conventional electric power systems including land occupations, anticipative investments, construction periods, social costs from environmental pollution, and so on. In addition, the wave power generation system must have high annual operation rate and be free from expensive storage equipment or auxiliary power generation.
[0009] Meanwhile, since water having heavier mass has higher kinetic energy than air having lighter mass the technology converting kinetic energy of moving seawater, i.e., research of generating electricity from wave power is now in advance.
[0010] In particular, considering that most countries have long coastal lines faced to ocean, energy resources from sea wave are out of count. However, frequency and wave power in near shore and offshore have high fluctuations according to environment of the locations and seasons, whereas relatively lower wave height often occurs according to season's weather condition.
[0011] Accordingly, if the disadvantage of practice caused by lower wave height and uneven wave period could be eliminated, uncountable wave power will be secured at no cost.
[0012] Technologies of converting wave power into energy have been opened already as an oscillating water column type, a movable body type (including a raft type), a raft conversion type, a shoulder cam type, an energy amplification and concentration type and air turbine type.
[0013] The oscillating water column type is most commonly used, but has a number of drawbacks. For example, the oscillating water column type takes long time to construct a large-scale bottom structure and uses inefficient air turbine, leading to cost ineffectiveness and necessarily changing output power due to a change in atmospheric pressure. In the case of the raft conversion type, an oil pressure pump with relatively less number of strokes is cost-ineffective and considered unsafe, so that it is no more a thing of interest. Both the oscillating water column type and the raft conversion type are available to generate power only when a wave height reaches a certain level. In addition, both of them are not efficient in energy conversion, and are adapted in a small range of usable wave.
[0014] As a raft is the most adequate medium to convert wave energy into useful energy, using mass movement of the raft, so that the raft conversion type may be the most promising method to generate power using wave energy. However, there are still many issues blocking the development of the raft conversion type, including low efficiency of the conversion type, variability of seasonal output power, concerns over stability against an abnormal wave and a gap in expenses between wave power generation and fossil-fuel power generation. Therefore, more researches and development need to be done to address the above troubling problems.
SUMMARY
[0015] The following description relates to providing a wave power generator which has a relatively high energy conversion efficiency with an increased investment-to-efficiency rate, so that the practicality and value of wave may be improved as a clean energy source.
[0016] The above objectives may be achieved by a wave power generator including one or more raft vessels, each having in a central point thereof a node that moves freely according to wave height and leads a flow of fluid inside of the raft vessel with a constant water level; and an energy generating unit connected in series to a vertical axis C on a cross section of the node of each raft vessel and configured to generate energy using kinetic energy of the raft vessel.
[0017] At this time, the wave power generator may further include an air balance tank configured to connect an end of the first raft vessel and an end of a second raft vessel, each raft vessel constituting the one or more raft vessels, spaced apart from one another and connected to each other; connection lines configured to connect the air balance tank to the first raft vessel and the second raft vessel; an air compressor connected to the air balance tank; and a controller configured to control internal air pressure of the air balance tank via the air compressor.
[0018] The air balance tank may be a convex U-type tank.
[0019] The raft vessel further may include a piezoelectric element for generation of electricity at one end thereof.
[0020] The raft vessel may have a length which is half a wave cycle and a height which is two times higher than a wave height, and wetted parts inside of the raft vessel may be coated or treated with less-resistant laminated surface.
[0021] The energy generating unit may include a gear box, a multipolar generator and a cross-flow water turbine with a sirocco fan, with the latter directly connected to the vertical axis C on the cross section of the node of the raft vessel.
[0022] The wave power generator may further include guide walls formed in surroundings of the cross-flow water turbine to guide fluid flowing into the water turbine.
[0023] Other features and aspects will be apparent from the following detailed description, the drawings, and the claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0024] FIG. 1 is a diagram illustrating movement of a raft vessel on a sea wave and movement of fluid inside of the raft vessel according to an exemplary embodiment of the present invention;
[0025] FIG. 2 is a schematic cross-sectional view of a generating system;
[0026] FIG. 3 is a plan view of FIG. 2 ;
[0027] FIG. 4 is a conceptual plan view illustrating an air balance tank;
[0028] FIG. 5 is a P-P line cross-sectional view of FIG. 4 ;
[0029] FIG. 6 is a block diagram illustrating a method for controlling a wave power generator according to an exemplary embodiment of the present invention; and
[0030] FIG. 7 is a comparative diagram illustrating comparison of transferring wind power energy and wave power energy.
[0031] Throughout the drawings and the detailed description, unless otherwise described, the same drawing reference numerals will be understood to refer to the same elements, features, and structures. The relative size and depiction of these elements may be exaggerated for clarity, illustration, and convenience.
DETAILED DESCRIPTION
[0032] The following description is provided to assist the reader in gaining a comprehensive understanding of the methods, apparatuses, and/or systems described herein. Accordingly, various changes, modifications, and equivalents of the methods, apparatuses, and/or systems described herein will suggest themselves to those of ordinary skill in the art. Also, descriptions of well-known functions and constructions may be omitted for increased clarity and conciseness.
[0033] FIG. 1 is a diagram illustrating movement of a raft vessel on a sea wave and movement of fluid inside of the raft vessel according to an exemplary embodiment of the present invention; FIG. 2 is a schematic cross-sectional view illustrating a generating system; FIG. 3 is a plan view of FIG. 2 ; FIG. 4 is a conceptual plan view of an air balance tank; FIG. 5 is a P-P line cross sectional view of FIG. 4 ; FIG. 6 is a block diagram illustrating a method for controlling a wave power generator according to an exemplary embodiment of the present invention; and FIG. 7 is a comparative diagram illustrating comparison transferring wind power energy and wave power energy, respectively.
[0034] The present invention is provided under a condition that water holds 800 times greater energy than air since the mass of water is greater than that of air.
[0035] A general consensus is that using a flow of fluid (water) in a raft vessel 11 is more effective than using air vibration in order to convert wave power into useful energy, and the present invention is based on the general consensus.
[0036] Kinetic energy (p) of fluid is acquired using the following [Equation 1].
[0000] P ( W )=1/2 ρAV 3 [Equation 1]
[0037] P: Kinetic Energy of Fluid
[0038] ρ: Density of Fluid
[0039] A: Flow Cross Section of Fluid
[0040] V: Flow Velocity
[0041] FIG. 1 is a diagram illustrating movement of a raft vessel on a sea wave and movement of fluid inside of the raft vessel. In FIG. 1 , (a) indicates a tranquil state without a waveform, (b) shows a state with a waveform tilted upward to the left, and (c) points out a state with a waveform tilted upward to the right.
[0042] Referring to FIG. 1 , if fluid, that is, water, fills only half the raft vessel 11 , to control mass of the raft vessel 11 , the fluid moves according to displacement movement of the raft vessel 11 led by a waveform, as shown in FIG. 1 .
[0043] In this case, a central part of the raft vessel 11 is a node N or a node axis N with constant water level. On the basis of the node N, reciprocating movement of water occurs according to displacement movement of the raft vessel 11 led by a waveform. That is, when two ends A and B of the raft vessel 11 moves from locations shown in (a) of FIG. 1 to locations shown in (b) or (c) of FIG. 1 , fluid inside of the raft vessel 11 moves along together. In other words, when the fluid of the raft vessel moves from (a) of FIG. 1 to (b) or (c) in FIG. 1 , the fluid volume Si is the same as the fluid volume S 2 with constant water level.
[0044] In the case where the raft vessel 11 has a length L which is half a wave cycle and a height H which is two times higher than a wave height, water inside of the raft vessel 11 may flow most effectively.
[0045] Theoretically, energy of flowing water is proportional to the cubed value of a flow velocity of the water as shown in the above [Equation 1]. In addition, the steeper inclination of a flow cross section of water, the faster a flow velocity of water is
[0046] Specifically, while an inclination angle of the raft vessel 11 gradually changes according to a waveform and a wave cycle, water returns to a horizontal state at a faster rate, and thus, the flow velocity does not rapidly change at the location of the node N. Thus, the flow velocity is determined by a volume of water which moves to either end of the raft vessel 11 according to inclination of a wave form during a wave cycle.
[0047] However, a safety measure, such as conduction, is required, since fluid inside of the raft vessel 11 may change and preponderate a center of mass of the raft vessel 11 and increase an underwater depth of the raft vessel 11 , increasing a value of an inclination angle of the raft vessel 11 to be greater than an inclination angle of a corresponding waveform.
[0048] However, such technical problems may be addressed if the raft vessel is provided with excessive buoyancy and an air balance tank 40 to both ends thereof, as described in the following. Specifically, the air balance tank 40 is designed, in response to an abnormal buoyancy of the raft vessel 11 , to prevent emergence of one end of the raft vessel 11 having relatively less mass on water surface using an attractive force led by a negative force which occurs between water surface and the raft vessel 11 when the raft vessel 11 floats abnormally.
[0049] In addition, instability of the independent raft vessel 11 against an unexpected abnormal wave may be minimized by repellent force of a lever L (See, FIG. 4 ) connecting a plurality of the raft vessels 11 . The connection technique of the lever L may be referred in Korean Patent Application No. 10-2009-0007890, invented by the same inventor of the present invention.
[0050] In conclusion, the most stable and effective energy conversion method may be installing a water turbine 12 (as of today, a cross flow water turbine is known for the highest efficiency), which rotates at a location of the node N in one direction, regardless of in which direction water flows, in order to convert fluid energy of water into electrical energy, and then generating electrical power using a piezoelectric element which is installed at one end of the raft vessel 11 with significant water pressure led by water crash energy and water level change with reference to FIGS. 2 and 3 .
[0051] Again, referring to FIG. 1 , as the raft vessel 11 becomes inclined due to a wave, water inside of the raft vessel 11 flows toward each end alternatively, according to a wave cycle based on the node N. As a result, a flow velocity V may be achieved on a cross section of the node N, and such flow velocity V is represented by [Equation 1] as below:
[0000] Flow Velocity (V)=Change Rate of Volume (dv)/Wave Cycle (s)/Cross Section of Node (a) [Equation 2]
[0052] That is, wave power energy is transferred to become a flow of fluid inside of the raft vessel 11 , so that the wave power energy is transformed into a flow velocity V on a flow path of a cross section a.
[0053] Meanwhile, as illustrated in FIG. 2 , it is possible to generate output power by connecting an energy generating unit 20 , which includes a water turbine 21 , a gear box 23 and a multipolar generator, to a vertical axis C on a cross section of the node N of the raft vessel 11 .
[0054] In addition, guide walls 22 may be prepared in surroundings of the water turbine 21 to guide fluid flowing into the water turbine 21 so as to improve efficiency of the water turbine 21 . At this time, configuration, structure and an angle of the guide walls 22 are not limited as shown in FIG. 3 , but may be determined through a hydrodynamic review and a miniature experiment. That is, claims of the present invention are not necessarily limited as shown in the schematic diagrams of FIGS. 2 and 3 .
[0055] In addition, wetted parts of the raft vessel 11 may be coated or treated with a less-resistant laminated surface in order to streamline water flow.
[0056] As illustrated in FIGS. 4 and 5 , a pair of raft vessels 11 , that is, a first raft vessel 11 and a second raft vessel 11 , is prepared and then connected to each other via the lever L. In addition, a convex U-type air balance tank 40 is installed to connect an end of the first raft vessel 11 to an end of the second raft vessel 11 . Next, an air compressor 45 and a controller 50 in association with the air compressor 45 control internal air pressure of the air balance tank 40 so as to use the internal air pressure as excessive buoyancy. If the internal air pressure is reduced, a reduced air pressure may serve as ballast due to an attractive force led by a negative pressure. Ballast refers to water which fills a ballast tank to keep the balance of a ship.
[0057] At this time, a plurality of the air balance tanks 40 may be installed in parallel between the first and the second raft vessels 11 . In this case, connection lines 46 connect each of the plurality of the air balance tanks 40 to the air compressor 45 .
[0058] For your reference, when an upside-down bowl is put on water surface, it is hard to lift the bowl due to atmospheric pressure. That is, it is difficult to pick the bowl up the water surface because water attracts the bowl. The air balance tank 40 of the present invention is designed based on this principle. In the above example, the bowl may be picked up by filling inside of the bowl with air. Similarly, internal air pressure of the air balance tank 40 may be controlled by the air compressor 45 and the controller 50 in association with the air compressor 45 .
[0059] The controller 50 includes a Central Processing Unit (CPU) 51 , a memory 52 and a support circuit 53 , as illustrated in FIG. 6 .
[0060] The CPU 51 may be one of various computer processors which are able to be applied in industries in order to control a wave power generator of the present invention. The memory 52 interacts with an operation of the CPU 51 . That is, the memory 52 is a readable recording medium and may be installed in a local or remote area. The memory 52 is at least one or more memories, such as a Random Access Memory (RAM), a Read Only Memory, a floppy disk, hard disk and arbitrary memory which is easy to handle and stores data in a digital form. In addition, the support circuit 53 interactively supports typical processor operations of the CPU 51 . The support circuit 53 may include a cache, a power supply, a clock circuit, an input/output circuit and a sub-system.
[0061] For example, the memory 52 may store overall processes occurring in a wave power generator, especially a process to control air pressure of the air balance tank 40 in the air compressor 45 . Typically, the memory 52 may store a software routine. The software routine may be stored and executed in another CPU (not illustrated). According to an exemplary embodiment of the present invention, the processes are executed by a software routine. However, at least some of the processes may be executed by hardware. As such, the processes of the present invention may be executed by software able to be implemented in a computer system, hardware such as an integrated circuit, or a combination of software and hardware.
[0062] For your reference, wind power is considered as an example comparable to wave power. Comparison of transferring wind power energy and wave power energy is provided with reference to FIG. 7 .
[0063] Wind power energy has little to do with fetch distance and is determined by a wind velocity of an area where a wind turbine is installed. In addition, the wind power energy is not accumulated even though wind is generated for a long time, and, if there is no wind, the energy disappears.
[0064] On the other hand, in spite of occurring due to wind power, wave power is accumulated and transferred on a basis of particle movement of water according to fetch distance and time from an ocean. That is, as illustrated in FIG. 7 , valid wind velocity does not necessarily lead to an occurrence of wave in coastal areas. For this reason, a valid operational time period of a wind turbine is shorter than a valid operational time period of a water turbine.
[0065] In conclusion, waves are generated by wind blowing on the ocean and transferred from a relatively remote area to a coastal area, so that the wave has greater energy and lasts for a longer period than wind blowing on a coastal area. Therefore, in the long run, making investment and efforts to develop a technology of wave power generation may be much more efficient and lucrative than those for wind power generation.
[0066] According to the above exemplary embodiments of the present invention, wave power generation is relatively efficient in energy conversion, so that active investment and research may be promoted by overcoming uncertainties of the nature. Most of all, with an increased investment-to-efficiency rate, the wave power may be expected to become a highly practical and valuable clean energy source.
[0067] Although not mentioned in the above exemplary embodiments of the present invention, the present invention may be used with a method disclosed in Korean Patent Application No. 10-2009-0007890 invented by the same inventor of the present invention. In this case, if the efficiency of a water turbine 21 increases, the most efficient, stable and cost-effective way to generate clean energy.
[0068] A number of examples have been described above. Nevertheless, it will be understood that various modifications may be made. For example, suitable results may be achieved if the described techniques are performed in a different order and/or if components in a described system, architecture, device, or circuit are combined in a different manner and/or replaced or supplemented by other components or their equivalents. Accordingly, other implementations are within the scope of the following claims. | The present invention relates to a wave power generator, and more specifically, to a wave power generator that can promote more aggressive investment and research activities by overcoming the uncertainties of natural environment through the relatively high energy conversion efficiency thereof, and enhance the practicality and the value thereof as a clean energy source by increasing the investment-to-efficiency rate. To this end, the present invention comprises: one or more raft vessels, each having in a central point thereof a node that moves freely according to wave height and leads a flow of fluid inside of the raft vessel with a constant water level; and an energy generating unit connected in series to a vertical axis C on a cross section of the node of each raft vessel and configured to generate energy using kinetic energy of the raft vessel. | 5 |
FIELD OF THE INVENTION
This invention relates generally to web printing press equipment and more particularly to devices for removing scrap material, or "chips," produced in operation of rotary cutters, or "sheeters," of such equipment.
BACKGROUND OF THE INVENTION
Web printing presses at their output end are normally coupled to a "sheeter" device for cutting a printed product from a continuous web into brochures, pamphlets, etc., of a desired length (units). The sheeter may comprise one or more sets of cooperating knife and anvil rollers between which the web is fed. Knives are disposed longitudinally on one or both of the rollers, extending radially outward from the circumference of the roller and arranged to come into slight contact, or "kiss," with the opposing roller. The knives are spaced apart around the circumference of the roller in a manner such as to make cuts at desired locations with scrap pieces or "chips" being transversely cut between the end of one unit and the beginning of the next unit. These transversely cut chips must be removed from the cutting area and disposed of as waste. Removal of chips from such devices has been carried out by providing pins protruding from a roller of a rotary cutter, or sheeter, the pins being arranged to impale the chips as they are being cut. As the roller rotates, it carries the pins with impaled chips so they can be released and conveyed to a container for disposal.
Various arrangements for removing pin-impaled chips from cutter rollers are disclosed in prior art patents, exemplified by U.S. Pat. No. 4,846,030, issued Jul. 11, 1989, to McMahon et al., which discloses apparatus wherein impaled chips are removed in an arcuate path, scraped off onto a moving belt, and conveyed to a receptacle. U.S. Pat. No. 3,893,359, issued Jul. 8, 1975, to Gregoire, provides for removing impaled chips from a roller by use of spaced-apart fingers adjacent to the back side of the roller, the fingers stripping the chips from the pins as they pass between the fingers. Chip removal devices that rely on mechanical parts such as fingers, combs, or the like for physical removal present disadvantages in that precise adjustment and synchronization are required for their operation, and they tend to be expensive to manufacture and install. They also may interfere with access to other parts of the overall system.
Air jets or high pressure gas streams for removal of scrap cut from webs of material are disclosed in several prior patents. U.S. Pat. No. 3,252,366, issued May 24, 1966, to Karr, shows air jets for directing high velocity air to the cutting area of a slitter device for trimming a strip from the edge of a traveling web. U.S. Pat. No. 3,670,612, issued Jun. 20, 1972, to Johnson et al., discloses use of air under pressure to blow away scrap pieces generated in cutting cards from a web. While these and other patents show various ways of applying air streams for the purpose of removing scrap material generated by a rotary cutter, none of them discloses or suggests the present invention which includes using a flow channel spaced along the length of the chip-carrying roller and having defined features by means of which a high velocity is imparted to an air stream being drawn through the flow channel.
SUMMARY OF THE INVENTION
The present invention is directed to an apparatus for removing and disposing of scrap chips impaled on or otherwise carried on a roller rotating away from the cutting region of a rotary cutter. In particular, the chips may be produced as scrap by transverse cutting of printed paper units from a continuous web after the web has passed through a printing press.
The apparatus comprises a pneumatic baffle which has a curved edge, which may be circular, elliptical, or parabolic in shape. This edge is positioned parallel to and spaced apart from the chip carrying roller a distance such as 3/4 inch. The pneumatic baffle is connected to other elements of a chute so that air may be drawn by means such as a centrifugal fan through the flow channel created between the roller and the pneumatic baffle. As air is drawn toward the flow channel, it begins to accelerate (gains velocity). This increase in velocity causes a peak velocity and minimum pressure (less than ambient, sometimes called vacuum or suction) at the minimum flow point. The operation of the paper chip removal system is based on this simple principle, which is the creation of a low pressure region by forcing air through narrow openings, producing the force which strips the chip from the small metal pins on the roller. As soon as the chip is removed, it is immediately accelerated into the flow channel and sucked through the fan to a disposal bin. A key point which aids in the efficient operation of the chip removal is the use of gentle, curved surfaces at the entrance of the flow channel. This feature allows the air to accelerate smoothly and stay attached to the surfaces (much like the air accelerating over the upper surface of a low speed aircraft wing). This smooth acceleration avoids separation regions (pockets of "dead" air) where recirculation can trap the chip, now allowing it to be sucked into the fan duct.
Apparatus embodying the invention is more effective and forceful than mechanical stripping devices, as well as being more economical, easier to install, and less intrusive to access to other components of a web printing press. Substantial improvement is also shown over prior approaches based on blowing of air jets or pressurized air onto scrap pieces to remove them from the cutting area.
It is, therefore, an object of this invention to provide an apparatus for removing paper chips from impalement on a roller that does not require stripping by mechanical components.
Another object is to provide an air stream chip removal apparatus that forcefully pulls the chips away from pins on the roller.
Yet another object is to provide a chip removal apparatus that readily conveys removed chips to a container for disposal.
Other objects and advantages of the invention will be apparent from the following detailed description of appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of portions of a web printing press showing cooperative cutting rollers and chip removal apparatus of this invention in place.
FIG. 2 is a sectional view taken through line 2--2 of FIG. 1.
FIG. 3 is a schematic representation showing air flow effects in operation of the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIG. 1 of the drawings, there is shown a rotary cutter 10 which is the output element of a web printing press. The cutter has cooperating generally cylindrical rollers, a knife roller 12 being disposed over an anvil/knife roller 14. The rollers are mounted for rotation on spaced-apart vertical end walls 16, 18.
Roller 12 is provided with elongated knives 20 mounted in blocks 22 which in turn are disposed in slots 24 and extend parallel to one another along the length of the roller. The knives protrude outward a distance such as 0.45 inch from the knife roller surface so as to make slight contact with the anvil roller. Anvil roller 14 may also have knives 26 mounted in blocks 28 disposed in slots 30 of the roller. Impalement pins 32 are also mounted in the block spaced apart from knives 26. In operation of the cutter, an incoming web (not shown) from a web printing press is fed between rollers of the rotary cutter, and transverse cuts defining ends of the product units are made by knives 20 and 26 at locations such that a chip 34 between units is produced. Simultaneous with making the cuts, pins 32 are projected into the chips, impaling them for being conveyed by the anvil roller away from the cutting area. Rollers 12 and 14 rotate in opposite directions, roller 12 moving clockwise when viewed from wall 16 so as to carry the knives upward away from the cutting area, and roller 14 moving counterclockwise, carrying the knives and pins with impaled chips downward and away from the cutting area. The chips are thus brought to a location above the chip removal apparatus of the present invention. Units of finished product are grasped by nip rollers (not shown) immediately before cuts are made and are carried by these rollers for final handling by conventional devices.
Chip removal according to the present invention is carried out by providing a pneumatic baffle 36 in spaced-apart and parallel relation to the surface of roller 14, edge 38 of the baffle and roller surface 40 defining an elongated flow channel 42 through which an air stream is drawn as discussed below. Baffle 36 is mounted on cross member 37 at the top of outer wall 44 of a chute 46 defined by the outer wall, end plates 48, 50 and inner wall 52 and tapered sections 54 communicating the chute with circular duct 56. Inner edge 38 of baffle 36 has gentle curved surface which may be circular, elliptical, or parabolic in cross section so as to provide the desired flow characteristics in the flow channel. Spacing of the baffle edge from the roller surface may be adjusted as desired by loosening knob 58 which engages the end of the baffle, allowing movement toward and away from the roller. As shown in FIG. 1, the baffle may be inclined downward along its length at an angle of approximately 45 degrees, although this angle is not critical. For chips having a size typically produced by rotary cut that is 1/4 inch to 1 1/4 inches wide and 2 to 26 inches long, a spacing of the baffle edge from the roller surface of 3/8 inch to 1 1/2 inches, and preferably about 3/4 inch may be used, with wider spacing being used for bigger chips.
Inner wall 52 of chute 42 is preferably located with its top edge 60 spaced apart from roller surface 40 a distance such as to allow knives and pins in the roller to slightly clear the edge when rotating. Wider spacing would detract from obtaining the desired air flow pattern. End plates and tapered portions of the chute are not critical except that they are preferably arranged to allow high-velocity flow without introduction of a substantial air flow at the ends of the flow channel.
Duct 56 is connected to an air source which may be the input side 62 of a centrifugal blower 64. Upon being sucked into the blower, chips are projected outward from the blower through duct 66 and are conveyed away to a suitable hopper (not shown) for disposal.
Operation of the paper chip removal system is based on the creation of a low pressure region by forcing air through a narrow opening, producing the force which strips the chips from the small metal pins on the cutting roller. As soon as the chip is removed, it is immediately accelerated into the flow channel and sucked through the fan duct to a disposal bin. A key point which aids in the efficient operation of the tab is the use of gently curved surfaces at the entrance of the flow channel. This feature allows the air to accelerate smoothly and stay attached to the surfaces (much like the air accelerating over the upper surface of a low speed aircraft wing). This smooth acceleration avoids separation regions (pockets of "dead" air) where recirculation can trap the chip, not allowing it to be sucked into the fan duct. The removal mechanism is based on being able to create the lowest pressure possible in the flow channel at the correct point on the cutting roller, which creates the least interference with the continuous discharge of the finished product while at the same time having the gap width large enough to accomodate the chip. The peak suction pressure in the flow channel increases rapidly with a decreasing channel width so that the narrowest as possible channel is desired, which may accommodate free movement of the paper chip.
Because of the nature of the flow in the channel, the relation between the air pressure and velocity is given by the well-known Bernoulli equation: ##EQU1## where P c is the stagnation pressure, P s is the static pressure, ρ s is the air density at the static pressure, and V is the air velocity. The stagnation pressure in the situation encountered is that pressure in the region which the air is drawn from, i.e., the ambient (atmospheric) pressure. Since the velocity is low, the difference in the air density computed at the static pressure and that computed at the ambient pressure is negligible, the ambient value is used. Rearranging equation 1, the velocity is computed as: ##EQU2## Using ρ s =0.078 lb./ft 3 , referencing the manometer board to p, the velocity can be expressed as: where p s is the experimental measured pressure on the manometer expressed in inches of the oil that was used in the manometer tube.
Once the chip leaves the cutting roller, it is accelerated into the channel by the aerodynamic drag which creates a force on the chip. Since the chip leaves the cutting roller from the upstream side (because it is still being held at the bottom by the small metal pins), it immediately offers a flat surface perpendicular to the air stream. FIG. 3 illustrates this point. The drag on a flat plate normal to an air stream is found by applying the Bernoulli equation. The pressure on the front of chip 34 is: ##EQU3## and on the back side is
p.sub.s
The force on the chip is the difference in these pressures multiplied by the surface area on which the pressure difference is being applied, hence:
Force=F=[p s +ρ s V a 2 -p s ] times frontal area (equation 5) Since the area of the chip is simply its length (1) times its width (w), the force on the chip is: ##EQU4## expressing the air density as lb/ft 3 , g c =32.2 ft/sec 2 , velocity as ft/sec, 1 in ft, and w in ft yields a force on the chip in pounds (lb). As the chip accelerates, its velocity approaches that of the air stream so that the effective force is a function of the velocity difference between the chip (V t ) and air stream (V a ), hence equation 6 is modified to: To illustrate how fast the chip accelerates into the flow channel, Newton's second law of motion is used:
F=mass×acceleration=ma=mdV.sub.t /dt (equation 8)
where m is the mass of the chip, V a =velocity of the chip, and dv t /dt represents the rate of change of the chip's velocity with time, i.e., its acceleration. Substituting equation 7 into equation 8 and rearranging gives: ##EQU5## Assuming V a to be nearly constant in the channel and letting V t =0 at time t=0, integration of the above equation gives:
t=[2mg.sub.c /(ρ.sub.s 1wV.sub.a)]×[(V.sub.a /V.sub.t)/(1-V.sub.t /V.sub.a)] (equation 10)
where mg c is the paper chip weight, pounds; ρ is the ambient air density, pounds/ft 3 (0.075#/ft 3 ); 1w is the chip rectangular area, ft 2 ; V a is the primary flow channel air flow speed, ft/sec; and V t is the paper chip velocity at any instant of time, ft/sec. The behavior of the paper chip under the above assumption again shows the criticality of generating the largest peak pressure (largest air velocity) as possible in the primary flow channel. Inspection of equation 8 demonstrates this since the time to accelerate the chip (that is, to remove it quickly from the cutting roller) gets less as the air flow velocity increases.
Velocity measurements taken on an air flow channel 18 inches in length and having widths of 1/2 inch and 3/4 inch between a roller and a baffle having a curved edge by means of an air velocity meter, Model No. 443, manufactured by Kurz Instruments, Inc. The air stream was sucked through the channel by means of being connected to a 5-inch diameter round duct, connected in turn to the input side of a centrifugal fan, Cincinnati Fan Company Model No. PB 12A, rated at 1060 cubic feet per minute at 6 inches static pressure. Velocities of 8,500 and 7,500 feet per minute, respectively, were obtained, such velocities providing highly effective removal of chips.
While the invention is illustrated above with respect to a specific embodiment and explanations, it is not to be understood as so limited, but is limited only as indicated by the appended claims. | Apparatus for removing and disposing of scrap paper chips impaled on a roller rotating away from the cutting region of a rotary cutter has a pneumatic baffle plate located a distance of 3/8 to 11/2 inches away from the roller, defining a narrow flow channel through which an air stream is sucked by a centrifugal fan. The baffle is spaced apart from the roller a distance such as to impart a high velocity to the air stream due to aerodynamic effects, causing chips to be forcibly removed from the roller when the chips reach an area above the flow channel. The baffle along with a chute that supports it and duct leading to the fan provide an enclosed channel for movement of the chips. The baffle edge adjacent the roller is provided with a curved surface to provide smooth flow of the air stream. The output of the fan has an air duct connected for conveying the chips to disposal. | 8 |
CROSS-REFERENCE TO RELATED PATENT APPLICATIONS
This application is a Continuation of U.S. application No. 10/312,214, filed, Dec. 20, 2002, now U.S. Pat. No. 7,658,983, that claims the benefit of International Application No. PCT/BE01/00107, filed Jun. 21, 2001, that claims the benefit of European Application Nos. 00870138.5 filed, Jun. 21, 2000, and 00870270.6 filed, Nov. 13, 2000, the entire teachings and disclosure of which are incorporated herein by reference thereto.
OBJECT OF THE INVENTION
The present invention relates to a fire protective barrier designed to be applied along the inside of metallic or composite structures, such as aircraft cockpits, boat hulls or other means of transport.
The present invention likewise relates to vehicles such as aircraft, boats, trains etc. that use a fire protective barrier of this kind.
TECHNOLOGICAL BACKGROUND
Metallic and composite structures such as aircraft cockpits or boat hulls are usually covered on the inside with protection having thermal and acoustic barrier characteristics in order to insulate the inside of the cockpit or of the hull from the outside environment.
To this end, proposals have been made for protection systems, which are usually in the form of a mat consisting essentially of one or several layers of glass fibres enclosed in a sheath. This sheath can be produced from any type of material. Preferably, it is a film made of an organic material, such as polyester, polyimide etc. having at least hydrophobic characteristics and acting in certain cases as a water-tight barrier. By way of example, one may mention as a material used to produce the sheath aluminised or unaluminised mylar®, tedlar®, which is produced in a film of PVF, kapton®, which is a film produced from polyimide (registered trademarks of Dupont), or other coverings, such as polyester or polyamide films, such as textril®, which is a polyester film reinforced with polyethylene fibres made by the Jehier company. These films forming the sheath must be produced from materials that allow the customary textile treatments: stitching, bonding, welding etc. and have mechanical characteristics such as resistance to tearing etc.
On the other hand, reflecting a concern to minimise weight, the density of these various materials should be as low as possible while at the same time allowing superior mechanical characteristics to be achieved. The weight per unit area of this type of protection is preferably less than 100 g/m 2 .
It is absolutely essential to protect as far as possible the passengers inside an aircraft from the risk of ignition of the fuel generally coming from external engines. Indeed, when it ignites, this fuel, such as kerosene, reaches temperatures well above 1000° C. Due to this fact, it is advisable to protect the elements of metallic and composite structures forming aircraft cockpits, boat hulls, outside structures of trains etc.
To this end, the authorities and, in particular, the FAA (Federal Aviation Administration) have established relatively strict fire protection standards. However, the standards to which aircraft manufacturers have to conform are continually evolving and are becoming ever more stringent, reflecting a concern of increased safety of travellers.
The fireproofing characteristics of the protection systems described above, which belong to the prior art, are nowadays found to be inadequate. The transport department of the FAA has therefore attempted to publish test criteria appropriate to the new requirements. In particular, the characteristics of resistance to the “burn-through test” and the “inflammability test” were redefined in September 2000 in standard 14 CFR, part 25 et al.
In particular, the “burn-through” test consists in subjecting the mat of fibres and its sheath to the flame of a burner. The said burner supplies an impinging flame at a temperature of around 1150° C. The sample is thus subjected to a heat flux of 149 kW/m 2 . The product concerned will satisfy the requirements of the FAA if it succeeds in resisting penetration by the said flame for 4 minutes and if the heat flux produced by the sample is less than 23 kW/m 2 , measured at a distance of 30.5 cm (12 inches) from the impingement surface.
The inflammability test (ASTM-E 648), which consists in subjecting a sample measuring 1000 mm in length and 250 mm in width to a radiant panel sloping at 30° in front of the sample and in the presence of a pilot flame. The radiant panel produces a heat flux of 18 kW/m 2 and ignition is effected by means of a pilot flame. The criteria for passing the test are the absence of flames within a radius of 51 mm around the point of application and the absence of post-combustion after extinction of the pilot flame for a specific test period.
Aircraft manufacturers have likewise defined certain mechanical specifications, such as flexibility and tensile strength, and their variation, obtained as a result of standardised conditioning or ageing of the samples.
On the other hand, the prior art, in particular the document EP-A-0370337, has disclosed the use of an impregnated mica paper, possibly bonded to a support based on woven or nonwoven glass fibres, aramid fibres, carbon fibres or some other type, such as a fireproofing covering with a low rate of heat release for construction elements in applications subject to relatively stringent standards in this matter, such as the aeronautical industry, the automotive industry, interior decoration etc.
Although this type of use for mica paper initially satisfied the standards in force in the 1980s (ATS 10 333-001, directive FAR 25—OSU chamber), this type of covering does not satisfy the new safety standards, such as those defined above.
It is likewise known, in particular from the documents EP-A-0949367, FR-A-2 384 337, EP-A-0406467 and US-4 514 466, that mica and, in particular, mica paper is a good electrical insulator and has good heat resistance. Nevertheless, these documents do not mention the use of mica for a fire protective barrier applied along a metallic or composite structure such as an aircraft cockpit, a boat hull or the outside structure of a train etc.
It will furthermore be noted that, in all the prior-art applications, the conventional mica paper has a weight per unit area close to 100 g/m 2 .
Aims of the Invention
The present invention aims to propose a protection product which has at least the same acoustic and thermal insulation characteristics as the prior-art products and equivalent behaviour as an anti-condensation barrier.
In particular, the present invention aims to propose a product for use as a fireproofing barrier which satisfies the new requirements of the FAA, that is to say which meets the standards defined by regulation 14 CFR, part 25.
More particularly, the present invention aims to propose a protection product which has satisfactory behaviour in the “burn-through” test and in the inflammability test, which are defined in this regulation.
Moreover, the present invention aims to allow solutions which increase the ultimate weight of the material as little as possible, that is to say which allow the provision of a sheath that has a total weight per unit area of less than 100 g/m 2 .
Main Characteristic Elements of the Invention
The present invention relates to a protection product having thermal and acoustic barrier characteristics designed to be applied along metallic and composite structures, such as aircraft cockpits, boat hulls or train structures, essentially in the form of a mat consisting of one or several fibre layers, preferably glass fibres, enclosed in a sheath, characterised in that the sheath comprises at least one first support having moisture-tightness and anticondensation characteristics and preferably made of an organic material, and an impregnated mica paper.
According to a first embodiment, the sheath comprising the mica paper and the first support is produced in the form of a single layer, in which the mica paper adheres directly to the support.
According to a second embodiment, the sheath is in the form of a multi-layer complex comprising, on the one hand, the support having the required moisture-tightness and anticondensation characteristics and, on the other hand, a mica paper, possibly adhering to a second, dedicated support.
The mica paper is advantageously laminated to a second, dedicated support, preferably to a fabric support such as glass silk or a film.
The first support is advantageously a film or a fabric.
The weight of the mica paper per unit area is preferably less than 50 g/m 2 ; preferably less than 45 g/m 2 ; preferably less than 40 g/m 2 ; preferably less than 35 g/m 2 ; and preferably less than 30 g/m 2 . It is particularly preferred that the weight of the mica paper per unit area is less than 25 g/m 2 and preferably less than 20 g/m 2 .
Finally, the present invention relates to a metallic or composite structure such as an aircraft cockpit, a boat hull or the outside structure of a train, to which the product according to the invention is applied.
It is particularly surprising that the use of such thin mica paper, that is to say with a weight per unit area of less than 50 g/m 2 , has completely satisfactory characteristics, complying with the anti-inflammability and “burn-through” tests.
It is highly probable that the reason for this is that, to produce such papers, it is necessary to use a pulp of mica flakes of which 90% by volume will be less than 800 μm in size. Moreover, these flakes will preferably have a large form factor (that is to say diameter divided by thickness), and preferably a form factor greater than 1000. It should be noted that the mica paper will be produced by customary techniques described in the prior art and impregnated with different types of resin, e.g. silicone.
DETAILED DESCRIPTION OF THE INVENTION
The present invention will be described in greater detail with reference to the examples which follow. In these examples, a “mica paper” produced by conventional techniques is used in each case.
The term “mica paper” is intended to mean a sheet produced by the usual papermaking techniques, which comprises 100% mica in the form of directional flakes. The flakes are usually either of the phlogopite or calcined or uncalcined muscovite type, or are in the form of a mixture of the two, or of the fluorophlogopite type, when synthetic mica is used.
The general technique consists in reducing “scraps” of mica to the state of flakes, the “scraps” being the physical form in which mica ore is extracted from mines. This can be achieved, for example, by mechanical disintegration with water and processing of the pulp thus obtained on a machine similar to papermaking machines in order to make a mica paper. Currently, there are several types of mica paper on the market. These depend essentially on the nature of the ore. Muscovite mica papers consisting entirely of calcined or uncalcined muscovite mica ore, phlogopite mica paper consisting entirely of phlogopite mica ore and mica papers produced from a mixture of different ores are known. In certain cases, vermiculite is furthermore used, being added to other materials to make mica paper.
The use of synthetic mica to create a mica paper is also known.
This mica paper is used as a primary material for the manufacture of tapes, sheets, laminates (micanite). To do this, the mica paper is usually impregnated with organic binders (resins) or inorganic binders and/or bonded to a mechanically strong flexible support in order to confer the desired physical properties on the end product.
The level of impregnation of mica papers with organic binders and, in particular, with silicone resins, is usually between 5 and 25%.
The originality of the mica paper used according to the present invention resides in the fact that its weight per unit area is relatively low and preferably less than 50 g/m 2 .
On the other hand, a glass fibre felt will be produced in a conventional manner and wrapped in a sheath consisting of at least one textile support and a mica paper according to the present invention. The sheath is referred to below as the finished product.
According to a first embodiment, the said finished product can be in a multi-layer form, that is to say that, in a conventional manner, it comprises a film of organic material having hydrophobic characteristics and acting as a water-tight and vapour-tight barrier, and a mica paper, possibly attached to a dedicated support.
According to another embodiment, the said finished product can be in a single-layer form and consist of a mica paper laminated directly onto a film having the required hydrophobic characteristics.
EXAMPLE 1
A finished product intended for the production of the sheath is produced, comprising a mica paper, a textile support and a resin. To this end, the following constituents are used:
a muscovite mica paper with a weight per unit area of 25 g/m 2 , a glass fabric with a weight per unit area of 24 g/m 2 formed by 26 warp yarns/cm and 15 weft yarns/cm, the titer of the yarns being 5.5 tex in both the warp and weft yarns, and a silicone resin of the phenylmethyl silicone type, such as the resin D.C. 805 from the Dow Corning company.
The mica paper used consists of flakes of muscovite mica and is defined by the following particle distribution: 90% by volume are less than 800 μm in size and 10% by volume are less than 80 μm in size. Moreover, their form factor will be greater than 1000. The characteristics of the mica paper are as follows:
weight per unit area: 25 g/m 2 thickness: 0.016 mm tensile strength: 4 N/cm air porosity: 2200 s/100 cm 3 oil penetration: 4 s.
To produce the finished product, the glass fibre fabric is impregnated with a solution of silicone resin in a toluene solvent medium containing 15% dissolved solids. The mica paper is positioned directly on the impregnated glass fibre fabric. This then absorbs a part of the resin. After evaporation of the solvent in drying ovens provided for this purpose, the product obtained is rolled up.
In this way, a product consisting of a mica paper laminated onto a glass fibre fabric is produced.
The finished product has the following characteristics:
total weight: 60 g/m 2 thickness: 0.059 mm binder content: 20% content of volatiles: 0.2% IEC flexibility: 9 N/m tensile strength: 104 N/cm dielectric strength: 1.08 KV/layer
When the product is subjected to ageing tests corresponding to the EADS Airbus specification, the following results are obtained for materials intended to meet the specifications of the “burn-through” test after conditioning at 70° C./98% relative humidity for 500 hours:
total variation in mass: −0.35% variation in tensile strength: −4%
These values are well below the limits specified by EADS Airbus, which accepts a loss of up to 10% in these same properties.
A sample is then subjected to a flame test as described below:
three samples of the product are conditioned at ambient temperature and 50% relative humidity for a minimum of 24 hours, a sample measuring 18 cm×18 cm is fixed by its four sides on a metallic frame with a width of 1 cm, leaving a very slightly tensioned square surface area of 17 cm×17 cm, the sample is exposed horizontally to the flame of a bunsen burner with a 1-cm diameter nozzle. The total height of the flame should be 4 cm and the sample should be placed between the oxidising and the reducing limit of the flame. This gives a contact temperature between the flame and the sample of 1100° C., the flame is applied to the sample for 10 minutes, and a check is made to ensure that the flame does not pass through the sample throughout the test.
The same method is employed for all three samples. If none of the samples as described in this example has been passed through by the flame after 10 minutes of testing, the product fulfils its role of flame protection perfectly. Even after having extended the tests by 30 minutes, the mica paper/glass fibre fabric product is not pierced by the flame.
“Burn-through” tests according to the standard CFR 14, part 25 were performed on an insulating mat consisting of two layers of glass fibres, a fire barrier consisting of a sheet of the mica/glass fibre fabric product as described above, and a skin of reinforced polyester. After the 4 minutes required for the test, the mica has not been perforated by the flame and the heat flux levels measured are less than 0.8 W/cm 2 and have thus remained well below the maximum value accepted in the specification of the standard, which is 2 W/cm 2 . The product thus complies with standard 14 CFR, part 25.
EXAMPLE 2
A finished product intended to form the sheath consisting of a mica paper, a support, a resin and an adhesive is produced. To this end, use is made of the following materials:
a muscovite mica paper weighing 20 g/m 2 , a polyvinylfluoride (PVF) film such as Tedlar® TFM05AL2 from Dupont de Nemours with a thickness of 12.5μ and a weight of 18 g/m 2 , a silicone resin of the methyl silicone type, such as the resin Wacker K from the Wacker company, and a silicone adhesive of the PSA (Pressure Sensitive Adhesive) type, such as the type DC 280 A from the Dow Corning company.
The mica paper used is of the same type as that used in example 1 and has the following characteristics:
weight per unit area: 20 g/m 2 thickness: 0.014 mm tensile strength: 3 N/cm air porosity: 2000 s/100 cm 3 oil penetration: 4 s.
To produce the finished product, two steps are performed:
1. a step in which the mica paper is reinforced: to do this, the mica paper is impregnated with a 10% solution of silicone resin K in a solvent medium, and a mica paper reinforced with 9% of dry silicone resin is obtained, and 2. a laminating step, which can be performed in an advantageous manner by two different techniques:
a. the previously reinforced mica paper is coated with a 14% solution of silicone adhesive 280A in a solvent medium. After evaporation of the solvent in drying ovens, a PVF film is laminated onto the mica coated with the silicone adhesive; b. or the PVF film is coated with a 5% solution of silicone adhesive 280A in a solvent medium. After evaporation of the solvent in drying ovens, the previously reinforced mica paper is laminated onto the PVF film coated with the silicone adhesive.
A product made up of a mica paper laminated onto a PVF film is obtained in this way. The finished product has the following characteristics:
total weight: 48 g/m thickness: 0.050 mm binder content: 20% content of volatiles: 0.2%
The results of the ageing tests under humid conditions as specified in the first example meet the EADS specifications.
In the flame tests as described in example 1, an excellent result is likewise obtained inasmuch as the flame does not pass through the mica paper/Tedlar® film product after the 10 minutes of testing.
EXAMPLE 3
A variant of the product is produced by the same method as that described in example 2, but replacing the Tedlar® PVF film with a 6-μ Mylar® polyester film obtained from the Dupont de Nemours company.
The results obtained are comparable to those in the preceding examples.
EXAMPLE 4
Another method of implementation consists in bonding the film onto the mica paper by means of spots of adhesive rather than by means of a continuous film of adhesive. To do this, use is made of well-known coating techniques, e.g. coating by means of an engraved cylinder, which makes it possible to deposit the adhesive in the form of spots on the support. | A protection product has thermal and acoustic barrier characteristics such that it satisfies the requirements of the standard 14 CFR, part 25 issued by the Federal Aviation Administration. The product is designed to be applied along metallic and composite structures, such as aircraft cockpits, boat hulls or the outside structures of trains or of other means of transport. The product is essentially in the form of a “mat” consisting of one or several fibre layers, preferably glass fibres, enclosed in a sheath. The sheath generally comprises at least one first support, preferably made of an organic material having sealing and anti-condensation properties, and an impregnated mica paper. The mica paper preferably has a weight per unit area of less than 50 g/m 2 and comprises flakes of mica with a form factor greater than 1000. | 8 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates generally to systems and techniques for selecting seats for a ticketed event, such as sporting events (e.g., baseball, basketball, football, hockey, auto racing), a concert, movie or theatrical performance, television talk shows, award shows, speeches, religious ceremonies, graduations or an airplane, boat, train or bus trip. More particularly, the present invention relates to a system and method for allocating seats for a ticketed event.
[0003] 2. Description of the Related Art
[0004] This section is intended to provide a background or context. The description herein may include concepts that could be pursued, but are not necessarily ones that have been previously conceived or pursued. Therefore, unless otherwise indicated herein, what is described in this section is not prior art to the claims in this application and is not admitted to be prior art by inclusion in this section.
[0005] A variety of different ticket reservation systems have been used to reserve and/or sell tickets for events, such as sporting events (e.g., baseball, basketball, football, hockey, auto racing), concerts, movie or theatrical performance, television talk shows, award shows, speeches, religious ceremonies, graduations or an airplane, boat, train or bus trip or any other event. Some reservation systems allow the purchaser to select the exact seat at the event. Other reservation systems select the purchased seats in the next available seats for a particular seating area or seating category, such as balcony seats, floor seats, or in the case of a baseball game, for example, seats behind home plate. Some events may have designated sections of seats which form different areas or categories of pricing for tickets. However, existing reservation systems can result in fragmented seating as reserved seats may surround a small number of unsold seats. Such isolated seats may be difficult to sell or reserve. This process potentially reduces the total number of seats that may be sold for the event. Further, the isolated seats may be close to other unsold seats and several such open seats could be sold to a group wanting to sit near each other. Current ticket reservation systems cannot identify such arrangements and potentially do not maximize ticket sales as a result.
[0006] In some situations, ticketed events are attended by larger groups of people wanting to sit near each other. However, due to the fragmentation of reserved seats, it can be difficult to identify groupings of multiple seats that are available for reservation. As such, larger groups of people either must purchase tickets for seats in less desirable, and thus more available seating areas or, alternatively, the groups must break up into smaller groups of people, or alternatively, not purchase tickets.
[0007] U.S. Patent Application No. 2004/0181438 entitled “System and Method for Dynamic Seat Allocation” describes a system and method for dynamic seat allocation. The system dynamically allocates seat assignments using a matrix having a plurality of available seats, a first seating arrangement using fewer than the entire plurality of available seats, the first seating arrangement based on a first seating request, a subsequent seating request, and logic for revising the first seating arrangement to develop a proposed seating arrangement to accommodate the first seating request and the second seating request. Nevertheless, this system and method may cause confusion because seat assignments are changing up until the event or a short time before the event begins, and potentially will not maximize ticket sales as a result.
[0008] U.S. Patent Application No. 2003/0069764 entitled “Selling Best Available Seats at a Public Facility” describes a virtual ticket control system that controls admission of customers to a public facility. The virtual ticket control system includes 1) a plurality of terminal devices disposed at entry points to the public facility, a first one of the terminal devices for establishing a communication link to a virtual ticket device used by a customer and receiving a virtual ticket transmitted by the virtual ticket device; and 2) a virtual ticket authentication controller for receiving the received virtual ticket from the first terminal device and determining if a unique identifier associated with the received virtual ticket matches one of a plurality of stored unique identifiers associated with a plurality of authorized virtual ticket records stored in a memory associated with the virtual ticket authentication controller. This system includes an option to purchase the best seat in the facility that remains unsold and available when the customer arrives at the event. However, this system also potentially will not maximize ticket sales because the customer does not know where his/her or seat will be until entering the event. Further, there is nothing that accounts for multiple seats for groups where the seats are proximate to each other but not necessarily in the same row.
[0009] There is a need to have improved systems for determining the best group of seats available at a ticketed event. Further, there is a need to identify ticketing opportunities where ticketed seats are contiguous but not necessarily in the same row. Even further, there is a need to expedite the ticket purchasing process to quickly assure customers buying groups of tickets that seats are located near each other and informing them of the location of their seats.
SUMMARY OF THE INVENTION
[0010] One exemplary embodiment relates to a method of allocating seats to a ticketed event. The method can include receiving a request for a number of seats at a ticketed event, selecting a first seat wherein the first seat is determined to be a best unassigned seat at the ticketed event, and determining a best grouping of seats wherein the best grouping of seats includes the number of seats requested and further wherein the best grouping of seats comprises the best unassigned seat at the ticketed event.
[0011] Another exemplary embodiment relates to a system that identifies groupings of available seats to be allocated for a ticketed event. The system can include a communication interface and a programmed processor. The communication interface receives a request for a number of seats at a ticketed event. The programmed processor determines a best grouping of seats wherein the best grouping of seats includes the number of seats requested and further wherein the best grouping of seats comprises a best unassigned seat at the ticketed event.
[0012] Another exemplary embodiment relates to a system that allocates seats for a ticketed event. The system includes means for receiving a request for a number of seats at a ticketed event and means for determining a best grouping of seats wherein the best grouping of seats includes the number of seats requested and further wherein the best grouping of seats comprises a best unassigned seat at the ticketed event.
BRIEF DESCRIPTION OF DRAWINGS
[0013] FIG. 1 is a general diagram depicting a system enabling a ticket purchaser to obtain tickets for groupings of seats to a ticketed event via a network in accordance with an exemplary embodiment.
[0014] FIG. 2 is a flow diagram depicting operations performed in a process of allocating seats for a ticketed event in accordance with an exemplary embodiment.
[0015] FIG. 3 is a flow diagram depicting operations performed in a process of presenting groups of available seats for a ticketed event in accordance with an exemplary embodiment.
[0016] FIG. 4 is a diagram of a section of seats for a ticketed event with a certain number of seats being available for reservation or purchase for the ticketed event in accordance with an exemplary embodiment.
[0017] FIG. 5 is a diagram of a section of seats for a ticketed event with a certain number of seats being available for reservation or purchase for the ticketed event in accordance with yet another exemplary embodiment.
DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS
[0018] FIG. 1 illustrates a system including a processor 12 coupled to an interface 14 and a database 16 . The processor 12 , interface 14 , and database 16 can be part of a computer server system. The interface 14 is coupled to a network 18 . The network 18 can be the Internet or any other network. The database 16 preferably contains seating charts for a plurality of venues where ticketed events occur, such as sporting events, musical concerts, entertainment presentations, religious gatherings, and other events where attendees to the event are assigned to selected seats in the venue. The interface 14 can be computer software, hardware, or a combination of software and hardware.
[0019] In at least one embodiment, a person desiring to purchase tickets to a ticketed event selects an event using a computer by means of an Internet web site or using a telephone service. The Internet web site, telephone service, or other input system is coupled to the network 18 for communication of information relating to the selection of tickets. For example, the ticket purchaser uses the network 18 to communicate the number of tickets he or she desires to purchase. The ticketing service presents the ticket purchaser with an option of a grouping of seats based on the number of tickets indicated by the purchaser and a best grouping selection made by the processor 12 . If the purchaser selects the proposed grouping of seats, the ticketing transaction process proceeds. If the purchaser does not select the proposed grouping of seats, another grouping of seats can be identified and presented or the purchaser can end the ticketing session without purchasing tickets.
[0020] A wide range of implementations may be used to present the seating information. For example, a graphical representation of the seats at a ticketed event can be presented with some indication of available and unavailable seats, such as different coloring or shading or a textual indication such as an “X” in the representations of seats that are not available. Alternatively, the seating information can be presented by seat section and number. For example, available seats may be communicated as seats A 4 , B 4 , and B 5 in section 104 of an arena. Other presentation techniques can also be used.
[0021] FIG. 2 illustrates a flow diagram depicting operations in a process of allocating seats for a ticketed event. Additional, fewer, or different operations may be performed depending on the embodiment. In an operation 22 , a ticket servicing computer receives a request for a number of tickets to a specified ticketed event. By way of example, the ticket servicing computer can be a server computer coupled to a network of computers, such as the Internet. In an operation 24 , the ticket servicing computer identifies a best seat available at a ticketed event. Generally, the best seat available is the seat that is closest to the stage, playing field, or court. Best seat definitions can be changed based on the ticketed event. Some events may have different locations for the best seats. The best seat for a movie performance may not be the best seat for a rock concert. Further, the best seat definition can be set or adjusted by the ticket purchaser. Different purchasers may have different opinions as to the location of the best seats at the ticketed event. Some purchasers may prefer balcony seats over floor seats. Similarly, some baseball fans may prefer seats along the first or third base lines instead of behind home plate.
[0022] In an operation 26 , the ticket servicing computer identifies a grouping of available seats at the ticketed event where the grouping includes the identified best seat and the requested number of seats. In an exemplary embodiment, a grouping of seats is considered a number of seats where each seat shares a common boundary with at least one other seat in the group, meaning the seats are next to each other in the same row (to the left or right), next to each other in adjacent rows (behind or in front), or diagonally next to each other in different rows but adjacent rows. If there is not a grouping of seats with the identified best seat and the requested number of seats, the ticket servicing computer identifies a next best seat and a grouping of seats including this next best seat. Such processing continues until a grouping of seats including the number of seats requested is found.
[0023] By way of further illustration, FIG. 3 depicts a flow diagram of operations performed in a process of presenting groups of available seats for a ticketed event. Additional, fewer, or different operations may be performed depending on the embodiment. In an operation 32 , a request for a group of seats is received from a purchaser. This request can be communicated in many different ways. For example, the request can be input into an Internet web site. The request can also be entered into a computer system by a ticket agent or box office employee. In an operation 34 , a best grouping of seats based on the number of seats selected by the purchaser is determined. Seats are grouped based on availability and proximity. That is, only seats that are still available for purchase can be grouped and seats are only grouped if they are near each other. In an exemplary embodiment, proximity is determined by determining if seats share a boundary or are in any way contiguous. A seat shares a boundary with another seat, or is contiguous, if the seat is immediately adjacent (left, right, back, or front) or adjacent diagonally (back left, back right, front left, front right). The best seat definition can be set by the ticket purchaser or the ticker seller. Different ticket purchasers may consider different types of seats better than others. Further, the type of seats considered “best” by the purchaser may change depending on the event. For example, best seats for one ticket purchaser may be third base line seats for one baseball game and seats behind home plate for another baseball game.
[0024] In an operation 36 , the determined best grouping of seats is presented to the purchaser. This presentation can be done graphically using a graphical user interface in the case of an Internet application. The presentation can also be done using textual symbols communicated to a computer, cell phone, personal digital assistant (PDA), or other device. Alternatively, the presentation can be done by automated process over the telephone or by a live operator or ticket agent. Other presentation techniques may also be used.
[0025] In an operation 38 , the purchaser communicates whether he or she selects the presented grouping of seats for purchase for the ticketed event. If the purchaser indicates that the grouping of seats will be purchased, an operation 40 is performed in which the selected grouping of seats are marked as unavailable and a purchase transaction is processed. If the purchaser indicates that the grouping of seats will not be purchased, an operation 42 is performed in which a different grouping of best seats is identified based on the number of seats selected by the purchaser. The process of finding a grouping of seats continues until the purchaser makes a purchase, the purchaser ends the session, or all grouping options have been presented for the ticketed event. In alternative embodiments, more than one groupings of seats can be presented to the purchaser at once from which the purchaser can select the grouping he or she wants.
[0026] FIG. 4 illustrates a section 46 of seats for a ticketed event with a certain number of seats being available for reservation or purchase for the ticketed event. For illustration purposes, unavailable seats are depicted with an “X” and available seats are depicted with an “O”. In section 46 , seats A 6 , B 4 , B 5 , C 3 , C 4 , C 5 , D 4 , and D 6 are part of the same grouping of seats because each one shares at least one common boundary with another seat in the grouping. Seats A 6 and B 5 , for example, share a diagonal boundary. As such, these seats are available for a grouping of eight ticketed persons.
[0027] FIG. 5 illustrates a section 54 of seats for a ticketed event with a certain number of seats being available for reservation or purchase for the ticketed event. As with FIG. 4 , for illustration purposes, unavailable seats are depicted with an “X” and available seats are depicted with an “O”. In section 54 , seat C 1 is available but does not share a boundary with another available seat and, therefore, cannot be included in a grouping of more than one seat. In contrast, seats E 2 and E 3 share boundaries with seats F 1 and F 4 , respectively. Seat F 4 shares a boundary with seat E 5 . Accordingly, a grouping of thirteen seats is available—seats F 1 , E 2 , E 3 , F 4 , E 5 , E 6 , D 6 , D 7 , C 6 , C 7 , B 8 , E 8 , and F 8 . This grouping of thirteen seats can be presented to a purchasers desiring to purchase thirteen tickets as a group or the grouping can be divided into sub-groups for purchaser seeking groups of six and seven tickets or other various combinations.
[0028] While several embodiments of the invention have been described, it is to be understood that modifications and changes will occur to those skilled in the art to which the invention pertains. For example, a computer system has been described that identifies seats that are adjoining or sharing a common boundary. The computer system can also identify seats meeting other selection criteria to form a grouping of seats that may not be adjoining or sharing a common boundary (e.g., same section of a stadium, same priced tickets). Accordingly, the claims appended to this specification are intended to define the invention precisely. | A system and method relates to allocating seats to a ticketed event. The method can include receiving a request for a number of seats at a ticketed event, selecting a first seat wherein the first seat is determined to be a best unassigned seat at the ticketed event, and determining a best grouping of seats wherein the best grouping of seats includes the number of seats requested and further wherein the best grouping of seats comprises the best unassigned seat at the ticketed event. | 6 |
FIELD OF THE INVENTION
The invention relates to electroless deposition of metal layers on non-conducting, generally amorphous substrate materials and more particularly to selective deposition of metal on fibrous structures using a process to deactivate catalytic species in selected areas not requiring deposition of electroless metal.
BACKGROUND OF THE INVENTION
Methods for electroless deposition of metals on a variety of substrate materials have been known since the earliest use of aldehydes to precipitate silver from solutions containing silver salts. More recently, the use of electroless plating methods has received attention following the discovery that some alloys, such as electroless deposited nickel phosphorus alloys, possess unique properties, and because of the growing use of such methods for plating plastics, and manufacturing optical, electronic and optoelectronic devices. Optical communication represents an area of use wherein selective coating of metal on glass facilitates hermetically sealed soldered connection of optical fiber ends to ferrule bodies.
Electroless plating solutions usually contain a metal salt, a reducing agent, a pH adjuster, a complexing agent, and one or more additives to control properties including bath stability, film properties, and metal deposition rate. An ideal electroless plating solution deposits metal only on an immersed article, never as a film on the sides of the tank or as a fine powder. All parts of an immersed article must have been thoroughly cleaned before plating. The presence of dirt or oxide on an article may either interfere with uniform deposition or lead to loss of adhesion of the metal deposit.
Application of metal to non-conductors requires the presence of a seed material in contact with the surface of a thoroughly cleaned article to provide a catalytic site for electroless metal deposition. Activation of a surface of non-conducting and dielectric materials for electroless metal plating commonly uses solutions containing acidic stannous chloride and acidic palladium chloride. The original catalysts were separate solutions with acidic stannous chloride acting as a reducing agent for subsequently applied palladium chloride to produce catalytic sites of metallic palladium at the surface of a cleaned article. It is the physical presence and chemical activity of the palladium that is a prerequisite for initiation of the electroless plating process. The two-step catalyst system may be replaced by a catalyst solution containing pre-reacted palladium and stannous chlorides.
U.S. Pat. No. 3,632,435 confirms the use of tin and palladium salts for surface activation and further includes the use of salts of other noble metals in the place of palladium. This reference also addresses deactivation or masking of selected portions of a catalyzed surface that was activated using stannous and palladium ions as previously described. Deactivation, in this case, involves the application of destabilizing agents. One category of destabilizing agents includes polyvalent hydrolysable metal ions, such as lead, iron and aluminum, which have the capacity to oxidize stannous ions to stannic ions. Stannic ions do not react with palladium solutions to produce catalytic sites of elemental palladium for deposition of electroless metal layers.
Chelating agents for noble metals include organic compounds, e.g. dibasic acids, containing acid functionality to provide another type of destabilizing agent according to U.S. Pat. No. 3,632,435. The acidic chelating agent acts primarily on the noble metal, e.g. palladium, of a catalyzed surface to mask its catalytic behavior thereby preventing electroless metal deposition in treated areas. Acid treatment may be used in other cases to facilitate electroless plating of an overcoat plating on metal conductors while preventing metal deposition on dielectric material surrounding the metal conductors. U.S. Pat. No. 5,167,992 uses a deactivator acid solution to remove noble metal ions from dielectric surfaces after treatment with solutions of noble metal salts. Suitable deactivator acids include organic acids and inorganic acids. It should be noted that an activator solution according to U.S. Pat. No. 5,167,992 contains no tin and that deactivation involves removal of ionic not elemental noble metal.
Other methods for selective electroless plating of non-conducting substrates include imagewise exposure of photoresists followed by development and activation of exposed areas of a substrate. Such methods, as taught by U.S. Pat. Nos. 3,672,925 and 4,448,804, are beyond the scope of the present invention.
The use of optical fiber signal carriers frequently involves sealing an optical fiber into the bore of an optical fiber connecting component such as a ferrule. Preferably the optical fiber becomes hermetically sealed within the component as described in U.S. Pat. Nos. 4,707,065 and 5,793,916. In each case, the optical fiber has a surface layer of metal, usually gold, suitable for bonding and sealing with a low melting metal, preferably solder.
An article published in the Proceedings of the 2000 Electronic Components and Technology Conference (Watson, J. E. et al, 2000 Proceedings. 50 th Electronic Components and Technology Conference, May 21-24, 2000, p. 250-5.) describes the use of electroless plating for applying metal to the surface of an optical fiber. An assembly of a metallized fiber sealed into a ferrule was tested to assess the strength of the fiber and how an assembly might fail. U.S. Pat. No. 5,380,559 describes activation of a single fiber end and a plurality of optical fiber ends for more consistent electroless metal deposition using stannous fluoride instead of stannous chloride to generate catalytic sites of elemental palladium. According to the reference (U.S. Pat. No. 5,380,559), with the standard use of stannous chloride, for electroless plating, it is not possible to obtain reproducible, uniform plating of electroless nickel on silica fibers.
In view of the use of electroless plating processes for coating non-conductive surfaces with metal, and the use of such processes with optical fibers and related components, there is a need for application of electroless metal to selected areas of an optical fiber end prior to sealing a fiber into an optical connecting component using solder. The present invention has been developed as a simplified selective electroless metallizing process with improved efficiency as a further benefit to the user. These enhancements and benefits are described in greater detail hereinbelow with respect to several alternative embodiments of the present invention.
SUMMARY OF THE INVENTION
This invention provides an electroless plating process for sequential surface masking and deposition of nickel and gold onto single and multiple fibers using aqueous chemistry. The process includes a sensitization of a surface of a fiber, preferably an optical fiber, using a dilute aqueous solution of stannous chloride in de-ionized water. Subsequent treatment includes immersion of the sensitized optical fiber in an aqueous solution of palladium chloride/hydrochloric acid followed by selective deactivation of the treated fiber during a second immersion of a fiber in an aqueous solution of stannous chloride. During electroless plating from commercially available electroless nickel and optionally immersion gold solutions, metal deposits only on areas of an optical fiber surface that remain activated. The formation of hermetic solder joints to the metallized fiber may be determined by helium leak testing. After soldering, solder pull-test strengths typically range from 1.4-2.3 kg (3-5 pounds), depending on the type of solder used.
For treatment of non conducting substrates, including individual fibers, especially optical fibers, the present invention provides a process for applying a metal to selected areas of a non-conducting substrate. The process comprises the steps of providing a non-conducting substrate having an uncoated portion to be treated with a sensitizer solution to provide a sensitized portion of the non-conducting substrate. Covering the sensitized portion with an activator solution provides an activated portion of the non-conducting substrate. Coating at least a section of the activated portion with a stannous salt solution forms at least one activated area and at least one deactivated area within the activated portion of the non-conducting substrate to produce a masked portion therefrom. Upon immersing the masked portion of the non-conducting substrate in an electroless plating bath metal deposits on the activated area to provide a selectively metallized non-conducting substrate. As indicated previously this process provides selectively metallized non-conducting fibers including selectively metallized optical fibers.
A process for applying a metal to selected areas of a plurality of optical fibers comprises a sequence of steps including providing a plurality of optical fibers having uncoated portions in an array having a separation between fibers and sensitizing the surface of each uncoated portion using a sensitizer solution. This provides sensitized portions of the plurality of optical fibers for treatment with an activator solution to provide activated portions of the plurality of optical fibers. Coating at least a section of each of the activated portions with a stannous salt solution forms at least one activated area and at least one deactivated area within each of the activated portions to provide masked portions therefrom. Immersing the masked portions of the plurality of optical fibers in an electroless plating bath deposits a metal on the activated area of each of the activated portions to provide selectively metallized fibers.
The present invention further provides a selectively metallized article including a non-conducting substrate, preferably an optical fiber, wherein production of the selectively metallized article uses a process as previously described. The process comprises the steps of providing a non-conducting substrate having an uncoated portion to be treated with a sensitizer solution to provide a sensitized portion of the non-conducting substrate. Covering the sensitized portion with an activator solution provides an activated portion of the non-conducting substrate. Coating at least a section of the activated portion with a stannous salt solution forms at least one activated area and at least one deactivated area within the activated portion of the non-conducting substrate to produce a masked portion therefrom. Upon immersing the masked portion of the non-conducting substrate in an electroless plating bath metal deposits on the activated area to provide the selectively metallized article.
Definitions
The following definitions clarify the meaning of terms used herein:
The terms “buffer” or “buffering” refer to a protective material extruded directly on the coating of an optical fiber to protect it from the environment and reduce damage by impact or other forms of physical stress.
Use of the terms “coating” or “fiber coating” refers to a material put on a fiber during the draw process to protect it from the environment and handling.
The terms “stripping” or “fiber stripping” refer to the removal of buffer and coating materials surrounding an optical fiber to expose the bare surface of the fiber.
The term “sensitization” refers to the process of applying a sensitizing solution, such as stannous chloride, to an optical fiber to form an adherent sensitizer coating that remains on the fiber after rinsing to provide a sensitized fiber.
As used herein the term “activation” refers to immersion of a sensitized fiber in an activator solution of palladium. Reference to palladium also implies the use of an alternate noble metal solution for activation. During immersion, the sensitizer coating of e.g. stannous chloride reacts with the palladium solution causing deposition of elemental palladium corresponding to the area covered by the adherent sensitizer coating.
Use of the term “catalytic site” refers to a palladium atom, or cluster of palladium atoms sufficient to initiate deposition of a metal from an electroless metal plating solution.
The terms “selective deactivation” or “masking” refers to treating selected catalytic sites to make them ineffective for initiating electroless metal plating.
Use of the term “hermetic sealing” refers to a substantially impervious seal, preferably a soldered seal, between a metallized surface of an optical fiber and the inside surface of a through-hole formed in a fiber interconnection component such as a ferrule.
The metallization process, according to the present invention may be applied advantageously to substrates of thermosetting or thermoplastic resins, silica, doped silica or glass.
The beneficial effects described above apply generally to the exemplary devices and mechanisms disclosed herein of selectively metallized optical fibers. The specific structures through which these benefits are delivered will be described in detail hereinbelow.
DETAILED DESCRIPTION OF THE INVENTION
The invention embodies a reproducible electroless plating process for selective metallization of non conducting substrates including filaments, preferably in the form of optical fibers. Metallized optical fibers according to the present invention exhibit greater strength than current product that uses a sputtered titanium/platinum/gold coating. Also, the metallization process provides optical fibers having a surface coating of metal in selected areas to allow solder bonding of fibers to other surfaces.
Optical fiber processing, according to the present invention, includes the steps of immersing bare portions of an optical fiber to be metallized in a solution of from about 5.0 g/L to about 20 g/L, preferably 10 g/L stannous chloride, in acidified de-ionized water containing 40 ml of 35% hydrochloric acid per liter. A rinse with de-ionized water removes any unadsorbed stannous chloride. Upon immersion of the stannous chloride treated portion of an optical fiber in an aqueous activating solution of palladium chloride in hydrochloric acid, stannous ions reduce palladium ions to provide catalytic sites of elemental palladium for electroless metal deposition. Preferably the palladium chloride solution contains from about 0.1 g/L to about 0.5 g/L, preferably 0.25 g/L palladium chloride in dilute aqueous hydrochloric acid. Acid strength may vary from greater than 0.01 M to less than 0.1 M, preferably 0.03 M hydrochloric acid. After rinsing in de-ionized water, selected areas of the activated surface of an optical fiber lose their activity upon contact with an acidified aqueous solution of stannous chloride. Without intending to limit the stannous chloride deactivator solution to a particular composition, palladium deactivation may use a solution of the same chemical composition as that used originally to sensitize an optical fiber. Selective deactivation of areas of an activated optical fiber may also be referred to herein as masking of the optical fiber. When immersed in an electroless nickel plating bath, metallic nickel deposits only on those areas of the optical fiber that remain activated with elemental palladium. Nickel plating continues for a period sufficient to produce a surface layer of nickel from about 1 to about 20 μm, preferably about 3 to about 5 μm thick. Following removal from the nickel electroless plating bath, and rinsing in water, previously metallized portions of an optical fiber receive a thin layer of a metal such as gold to provide a protective covering over the nickel layer. The gold layer deposits during dipping of the selectively nickel-plated fiber into an immersion gold bath for a period sufficient to form a gold coating about 0.1 to about 1 μm thick, preferably about 0.7 μm thick over the nickel layer. A final rinse in de-ionized water provides a gold coated metallized optical fiber suitable for forming a soldered hermetic seal.
A metallization process according to the present invention may be applied to individual optical fibers or to a plurality of fibers. Holders are preferred for arranging a plurality of fibers in a suitable array having bared ends of fibers exposed following removal of protective fiber coating. The holders provide fixtures that facilitate sequential transfer of attached fibers through the chemical treatment baths and de-ionized water rinse baths needed to produce nickel and gold plated metallized optical fibers. Suitable optical fiber holders allow positioning of the fibers so that only a desired length, or masked portion, of each fiber end becomes submerged in the treatment solution or de-ionized rinse water. Use of a plurality of fibers or filaments increases the output of selectively metallized optical fibers. Uniformity of positioning of a selectively metallized optical fiber portion, produced by simultaneous processing of a plurality of fibers, requires a minimum separation of 1 mm between individual fibers. Further reduction of spacing could result in uneven metallization due either to fibers touching each other or to the effect of surface tension that impairs fluid penetration of liquid treatment compositions into an array of close-packed fiber ends.
Although electroless metallization processes according to the present invention may be used with any of a variety of optical fibers, exemplary fibers include telecommunications-grade single-mode fibers and polarization-maintaining fibers. A preferred single-mode fiber is available from Corning Inc. as SMF28, which has a dual acrylate buffer over a 125 μm diameter glass fiber.
A preliminary step to electroless metallization of an optical fiber is the removal of the polymer buffer and/or coating from a prescribed length of either an individual fiber or a plurality of fibers. Reference to a prescribed length may include a central section of a fiber, but commonly pertains to an optical fiber end. The acrylate buffer over a SMF28 fiber is readily dissolved by hot, about 95% concentrated sulfuric acid solution. The time for removal of the buffer and/or coating varies with the temperature of the acid but is preferably about 60 seconds at 150° C. Following complete removal of the polymer jacket or buffer, rinsing of the bare fiber involves dipping it in de-ionized water for about 60 seconds, then drying it for about 60 seconds under ambient conditions.
Once stripped, the bare portions of the fibers are treated with a solution of stannous chloride (e.g. 10 g stannous chloride in a liter of 0.4M hydrochloric acid) by immersion for about 3-6 minutes at ambient temperature. Adhesion of the stannous chloride to the surface of the optical fiber occurs without any physical abrasion of the fiber surface. Stannous chloride is available in crystalline form from Sigma-Aldrich Corporation of St. Louis, Mo. Use of the term sensitizer or sensitizing solution herein refers to the stannous chloride solution which, after application to an optical fiber and drying, provides a layer of stannous ions on the fiber surface. Optical fibers coated in this way may be referred to as sensitized fibers or as having sensitized portions. Solutions of stannous chloride according to the present invention remain active for several weeks without protection from the ambient environment as by storing under gaseous nitrogen. Regardless of previous reports, stannous chloride sensitization according to the present invention yields uniform metal plating of bare optical fibers.
Activation of the surface of a sensitized optical fiber occurs, after rinsing the fiber with de-ionized water, by immersion of the sensitized portion of the fiber in an activating solution containing 0.25 g of palladium chloride per liter of 0.03M hydrochloric acid in de-ionized water. The surface of the optical fiber becomes activated for electroless metallization during reduction of palladium ions to elemental palladium by reaction of palladium chloride with stannous chloride deposited on a sensitized fiber or a sensitized portion of an optical fiber. At this stage, the surface of the activated portion of the fiber has a covering of catalytic sites of palladium. Conversion of a sensitized fiber to an activated fiber requires from about 3-6 minutes of immersion in the palladium chloride activation solution. Palladium chloride was a 99.9 percent palladium (II) chloride obtainable from Sigma-Aldrich Corporation of St. Louis, Mo.
A distinguishing feature of the present invention is the discovery that the activated surface of an optical fiber may be deactivated, after rinsing with de-ionized water, by dipping the fiber in a second stannous chloride bath. Stannous chloride deactivator solutions of various concentrations have been found effective, including the same composition as the stannous chloride sensitizing solution. The deactivation step according to the present invention facilitates selective masking of a portion of an activated fiber whereby subsequent electroless metal deposition takes place only over areas of the fiber surface that remain activated after treatment with tin(II) solution. Use of tin(II) deactivation produces a masked fiber by dipping an activated optical fiber in a solution of acidified stannous chloride for about 1-60 seconds, preferably about 15 seconds. This obviates the need for the traditional use of a strippable, protective polymer coating for masking areas of a fiber surface, as taught by U.S. Pat. No. 5,380,559. Whereas tin solutions have been known for sensitization, as previously described, the use of solutions of stannous salts, for surface deactivation to electroless metal deposition, improves fiber masking by reducing the number of steps to produce a selectively metallized optical fiber.
A masked optical fiber includes one or more activated areas and one or more deactivated areas. Following a de-ionized water rinse, for about 10-20 seconds, and fiber drying under ambient conditions, for about 40-90 seconds, preferably 60 seconds, metal coating of the activated areas occurs during immersion of the masked portion of a fiber in an electroless metal plating bath. Application of a suitable thickness of metal requires immersion for about 10-20 minutes at about 80-90° C., preferably about 88° C. The nickel plating solution is preferably NIMUDEN SX, a two-part plating solution commercially available from Uyemura International Corporation. The two-part composition consists of a part A, containing nickel sulfate and part M containing sodium hypophosphite. In preparation for electroless nickel plating addition of part A and part M to 18 MΩ de-ionized water provides a solution having a pH from about 4.5 to about 4.8. Preferably the resulting solution has a pH of 4.6 and contains 5.5% by volume NIMUDEN SX part A, 10% by volume NIMUDEN SX part M and 84.5% de-ionized water.
The thickness of electroless plated nickel continues to increase the longer the activated material remains in contact with the nickel plating solution. A nickel thickness of about 3 μm is sufficient for soldering with a commonly used tin solder containing a ratio of 97% tin to 3% silver. Therefore, 20 minutes immersion in the nickel bath, to give about 5 μm nickel deposit, would be a conservative compromise for all potential solders. Whenever part M of the nickel solution includes hypophosphite ion as the reducing agent, phosphorus is deposited at the catalytic surface and is incorporated into the nickel to form a nickel-phosphorous alloy. The nickel deposit from the above solution included phosphorous in an amount of from 9 to 11 weight percent.
Nickel-plated fibers produced according to the present invention may require the application of a layer of gold to improve compatibility of metallized optical fibers with the low melting alloys used to form solder seals. Application of the required gold layer follows an extended rinse of a nickel coated fiber in de-ionized water. Rinsing continues for between about 30-120 seconds, preferably about 60 seconds to remove any residual nickel ions from the surface of the metallized portion of the optical fiber. A preferred immersion gold solution for developing a suitable thickness of gold in contact with the nickel coated portion of an optical fiber is AURUNA-511 available from Uyemura International Corporation. This commercially available solution, supplied as a concentrate, requires about a four-fold dilution to provide the operative gold plating solution. Also, the gold plating is self-limiting. Immersion for about 8 minutes with gentle stirring in an 85° C. temperature controlled gold solution bath gives a gold deposit about 0.7 μm thick. The gold-plated portions of the fiber are finally rinsed with water, and dried.
A specific example of a flow chart of an embodiment of the above process may be summarized as follows. The embodiment involves an array of a plurality of fibers subjected to a sequence of processes including solution treatments and rinses preferably with de-ionized water.
(a) providing an array including a plurality of optical fibers;
(b) stripping the buffer coat from the plurality of fibers using a strong acid solution, preferably a hot, about 95% concentrated sulfuric acid solution heated to a temperature of 150° C. to provide a plurality of stripped fibers;
(c) rinsing the stripped fibers with de-ionized water;
(d) drying the stripped fibers;
(e) sensitizing the surface of each of the plurality of stripped fibers using a solution containing a stannous salt to provide tin coated sensitized fibers;
(f) rinsing the sensitized fibers with de-ionized water;
(g) treating the sensitized fibers with a solution containing a palladium salt to form a layer of catalytic palladium on the surface of each of the sensitized fibers to provide activated fibers;
(h) rinsing the activated fibers with de-ionized water;
(i) dipping the activated fibers in a solution containing a stannous salt until a selected length of each of the catalytic fibers is covered by the stannous salt solution to produce a plurality of masked fibers;
(j) rinsing the masked fibers with de-ionized water
(k) drying the masked fibers;
(l) depositing electroless nickel from a plating bath at a temperature of 88° C. to provide metal coated fibers;
(m) rinsing the metal coated fibers with de-ionized water;
(n) optionally applying an immersion gold coating to the metal coated fibers to provide gold plated fibers; and
(o) rinsing the gold plated fibers with de-ionized water.
Metal layer thicknesses were determined from scanning electron microscope (SEM) micrographs of cross sections of polished ends of metallized fibers held in epoxy mounting blocks. The thickness of the metal coating was determined by direct measurement from the micrographs.
Interconnection of metallized optical fibers according to the present invention uses ferrule bodies included as components of optical fiber connectors. Ferrule bodies may comprise a metal alloy including iron, cobalt and nickel, preferably KOVAR® alloy having a low coefficient of thermal expansion. Optical fibers having surface coatings of either nickel-phosphorus or gold may be sealed in to KOVAR® ferrules using a soft solder to form a hermetic seal around the fiber, inside the ferrule. Formation of a soldered hermetic seal involved threading a metal plated optical fiber into a ferrule 1 mm long having a through-hole 190 μm in diameter. During the soldering process the ferrule was placed with the through-hole in a vertical orientation. A pocket around the fiber hole or through-hole held an annular solder preform. The solder preform melted at an elevated temperature produced by controlled heating of the KOVAR® ferrule preferably using an electric current. Hermetic seal formation occurred during observation of the condition of the solder preform. The heating current was discontinued upon evidence of solder flow into the joint around the optical fiber. Seal formation typically requires from about 4-5 seconds.
Solder pull strengths and hermeticity tests of plated fibers indicate hermetic solder joints (based on helium leak tests to about 10 −9 atm cc/sec) even after temperature cycling. Pull strengths may vary with the solder used but are typically in the range of about 1.0-1.75 kg (2.5-3.5 pounds) for 80% gold/20% tin solder. The rigidity of gold/tin solder favors its use in high reliability products but it may also develop higher stress concentration at the edge of the solder joint.
Additional advantages and modifications will readily occur to those skilled in the art. Accordingly, various modifications may be made without departing from the spirit or scope of the general inventive concept as defined by the appended claims and their equivalents.
EXPERIMENTAL
Solution Preparation
Acid Stripping Solution:
Removal of protective layers from an optical fiber preferably requires the use of a concentrated acid solution containing about 95% sulfuric acid. The rate of optical fiber stripping varies with temperature and is preferably about 60 seconds at 150° C.
Sensitizer Solution:
A 10 g quantity of stannous chloride was added to 200 ml of 2M hydrochloric acid in de-ionized water. Upon dilution to 1 liter, with de-ionized water, this provided the sensitizer solution included in the electroless metallization process according to the present invention.
Activator Solution:
Palladium chloride (0.25 g) was added to 100 ml of 0.3M hydrochloric acid. The resulting solution, diluted to 1 liter, provided the activator solution for application to a stannous chloride sensitized optical fiber.
Deactivator Solution:
Acidic deactivator solution compositions may vary in amounts of tin salt per liter of hydrochloric acid, e.g. from between about 0.5 g to about 200 g stannous chloride. Solutions may be prepared using hydrochloric acid of varying strengths including from about 0.05M to 5M. Lower tin or acid concentrations may lead to incomplete masking. Higher tin or acid concentrations may cause unwanted masking of areas above the solution interface.
Electroless Nickel Plating Solution:
A commercially available electroless nickel plating solution, NIMUDEN SX from Uyemura International Corporation, was used to deposit a nickel-phosphorus composition on activated portions of optical fibers.
Immersion Gold Solution:
AURUNA-511 immersion gold from Uyemura International Corporation provided the optional gold coating needed in some cases for successful solder seal formation.
Properties of Metallized Fibers
Metal coating weight/thickness:
The nickel layer was about 2.0 μm to about 3.0 μm thick comprising a nickel—phosphorus alloy containing from about 9 wt % to about 11 wt % phosphorus.
The immersion gold layer had a thickness from about 0.3 μm to about 0.7 μm.
Solderability:
Metallized optical fibers were sealed inside KOVAR® ferrules, as previously described, using a solder composition of 80% Au/20% Sn at a temperature of 320° C.±15° C.
Hermetic sealing:
Metallized fibers sealed into KOVAR® ferrules passed an open face leak test down to 1×10 −8 atm cc/sec of helium.
Fiber pull data:
Metallized fibers soldered in a gold plated KOVAR® standard 14-pin package have a minimum pull strength of 350 g with no separation of the metallization from the fiber. | A process for applying a metal to selected areas of non conducting substrates, including individual fibers, particularly optical fibers, comprises the steps of providing a non-conducting substrate having an uncoated portion to be treated with a sensitizer solution to provide a sensitized portion of the non-conducting substrate. Covering the sensitized portion with an activator solution provides an activated portion of the non-conducting substrate. Coating at least a section of the activated portion with a stannous salt solution forms at least one activated area and at least one deactivated area within the activated portion of the non-conducting substrate to produce a masked portion therefrom. Upon immersing the masked portion of the non-conducting substrate in an electroless plating bath, metal deposits on the activated area to provide a selectively metallized non-conducting substrate. This process provides selectively metallized articles including selectively metallized optical fibers. | 2 |
This is a divisional of application(s) Ser. No. 08/578,246 filed on Dec. 26, 1995 now U.S. Pat. No. 5,772,841.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention pertains to handling sheets of paper, and more particularly to apparatus and methods for sealing a folded sheet of paper to itself.
2. Description of the Prior Art
Numerous types of business forms have been developed over the years. Many kinds of business forms are used as mailers. An example of a multi-page mailer type business form may be seen in U.S. Pat. No. 5,167,739.
Business forms are usually constructed as sheets of paper having patterns of pressure sensitive adhesive applied to one surface. The sheets are folded in a desired manner by a folding machine such that certain portions of the sheet come into facing contact with the adhesive. The folded sheets are then pressed together, which causes them to adhere to each other along the patterns of adhesive.
Prior equipment for pressing folded sheets together include the reversing machines of U.S. Pat. Nos. 5,133,828; 5,290,385; and 5,300,177. In those machines, a force biases one or more rollers into contact with mating rollers. A folded sheet is fed in a first direction into a roller nip until the sheet has almost completely passed through the nip. Then the rollers are reversed to drive the sheet through the nip again in the opposite direction. The biasing force is strong enough to activate the adhesive and thus create a finished business form.
A primary disadvantage of the machines of the foregoing patents is the noise produced by the contacting rollers when no folded sheets are in the nips. Another disadvantage is that the finished forms leave the machines at the same locations that they entered the machines. Consequently, second folded sheets cannot be fed to the nips until the previous forms have been discharged and removed from the nips.
U.S. Pat. No. 5,169,489 shows a pressure sealer system having four nips, two at one level and two at a higher level. The rollers of each nip are pressed together by spring biasing devices. Folded sheets are fed in a first direction between the two lower nips. Thereafter, the folded sheets pass to a higher elevation and reverse direction to pass through the two higher nips. Because of the four nip and reversing construction, the machine of the 5,169,489 patent is quite complicated as well as undesirably noisy. In addition, the reversing direction of the folded sheets complicates both the feeding of the folded sheets into the machine and the removal of the completed business forms from the machine.
U.S. Pat. No. 5,183,527 describes a seal module in which one roller of a nip is spring biased to be non-parallel to another roller when no form is present. When a form is fed to the nip, the form forces the rollers against the force of the spring into a parallel relationship. The forms travel in one direction in the downstream direction through the seal module. There is no adjustment for the linear distance between the rollers, thus limiting the versatility of the seal module. In addition, initial setup of the seal module can be rather tricky.
U.S. Pat. No. 5,397,427 discloses a pressure seal system in which two rollers of a nip are pressed into contact with each other by a biasing force. Forms passing through the nip are acted on by the biasing force but spread the rollers apart as they pass through the nip. The forms pass in one direction through the pressure sealer. The amount of noise as well as the wear on the rollers are important disadvantages of the seal system of the 5,397,427 patent.
Thus, a need exists for improvements in machines that seal folded business forms.
SUMMARY OF THE INVENTION
In accordance with the present invention, an in-line pressure sealer is provided that produces forms in a simpler, quieter, and more efficient manner than was previously possible. This is accomplished by apparatus that includes two pairs of rollers that are biased away from each other to adjustable but positively maintained distances between them.
One pair of rollers, consisting of first and second rollers, serve as input rollers that form an infeed nip. The other pair of rollers, consisting of third and fourth rollers, form an outfeed nip. Each roller is mounted at its opposite ends for rotation in respective blocks. The blocks are received in a frame. According to one aspect of the invention, the blocks of the infeed rollers are received in first slots in the frame, and the outfeed roller blocks are received in second slots in the frame.
The blocks of the first and third rollers are stationarily located against ends of the associated frame slots. The blocks of the second and fourth rollers are free to slide in the frame slots. Springs bias the blocks of the second and fourth rollers away from the blocks of the first and third rollers. Positive stops limit the motions of the blocks of the second and fourth rollers and thus the clearances between the infeed rollers and the outfeed rollers. The locations of the positive stops for the infeed and outfeed rollers are independently adjustable relative to the frame.
An infeed roller is driven by a conventional electric motor, suitable pulleys, and a belt. An outfeed roller is driven by the driven infeed roller. In turn, the driven outfeed roller drives the other infeed and outfeed rollers. A folded sheet fed in a downstream direction to the infeed nip is propelled through that nip in the same downstream direction to the outfeed nip. The outfeed nip discharges a completed form from the pressure sealer in the same downstream direction as the folded sheet was fed to the infeed nip.
The clearances between the infeed and outfeed rollers are set to suit a particular folded sheet and strips of pressure sensitive adhesive applied to the sheet. For example, the clearance of the infeed rollers can be set to burst the bubbles of the pressure sensitive adhesive. The clearance of the outfeed rollers can then be set to activate the adhesive such that the facing portions of the folded sheet adhere to each other along the adhesive strips. As a result, a completed and properly sealed form is discharged from the outfeed rollers.
Because the rollers never touch, operation of the invention is very quiet. Further, since the springs maintain the clearances between the rollers when no forms are present, the non-contacting nature of the rollers precludes the possibility that they can produce wear on each other.
To guide the folded sheets to the infeed and outfeed nips, the in-line pressure sealer further comprises a pair of cross-pieces that are joined to the frame. One cross-piece is located a short distance upstream of the infeed nip, and the second cross-piece is located between the two nips. The crosspieces have respective flat surfaces that are coplanar with each other and with a plane that extends between the two nips. The folded sheets are guided to the infeed nips by the first cross-piece, and the second cross-piece guides the folded sheets from the infeed nip to the outfeed nip.
The method and apparatus of the invention, using pairs of non-contacting rollers having adjustably fixed clearances therebetween, thus discharges completed forms from the outfeed nip in the same direction as folded sheets are fed to the infeed nip. The clearances between the rollers of each pair can be adjusted independently of each other to suit different sheet stocks and adhesives.
Other advantages, benefits, and features of the present invention will become apparent to those skilled in the art upon reading the detailed description of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a partially broken top view of the invention.
FIG. 2 is a cross sectional view taken along line 2--2 of FIG. 1.
FIG. 3 is a cross sectional view on an enlarged scale taken along line 3--3 of FIG. 1 and rotated 90 degrees counterclockwise.
FIG. 4 is a cross sectional view on an enlarged scale taken along line 4--4 of FIG. 1.
FIG. 5 is a perspective view of a typical sheet with strips of pressure sensitive adhesive applied thereto that can be processed into a completed business form by the present invention.
FIG. 6 is a front view of the sheet of FIG. 5 folded into a Z fold.
FIG. 7 is a top view of FIG. 6.
FIG. 8 is an end view of a completed business form processed by the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Although the disclosure hereof is detailed and exact to enable those skilled in the art to practice the invention, the physical embodiments herein disclosed merely exemplify the invention, which may be embodied in other specific structure. The scope of the invention is defined in the claims appended hereto.
Referring first to FIGS. 1-4, an in-line pressure sealer 1 is illustrated that includes the present invention. The in-line pressure sealer 1 is particularly useful for sealing folded sheets of paper into completed business forms, but it will be understood that the invention is not limited to form processing applications.
The in-line pressure sealer 1 is located downstream from a conventional folding machine 7. I have found that a model D-590 Auto-Folder machine manufactured by Duplo U.S.A. Corporation of Santa Ana, Calif., works very well with the in-line pressure sealer. In the folding machine 7, sheets of paper having preselected patterns of pressure sensitive adhesive applied to one or both surfaces are folded along desired fold lines. By way of example, FIG. 5 shows a sheet of paper 9 having four strips 11, 14 and 12, 13 of pressure sensitive adhesive applied to opposite surfaces 15 and 17, respectively, along the sheet edges 19 and 21. Although not shown, similar strips of pressure sensitive adhesive can also be applied along the sheet edges 20 and 22. In the folding machine, the sheet 9 is folded along fold lines 23 and 25 into a Z folded sheet 3, FIGS. 6 and 7. The folded sheet 3 is fed in the downstream direction 27, FIG. 1, by belts, not shown, on the folding machine to the in-line pressure sealer 1. The downstream direction 27 relative to the folded sheet is in the direction of arrow 27' in FIG. 7.
In the construction illustrated in FIGS. 1-4, the in-line pressure sealer 1 is comprised of a frame 29 that includes a base plate 33. The base plate 33 is attached in any convenient manner to the folding machine 7. Secured to the base plate by conventional fasteners 34 are a pair of parallel channels 35. Two vertically oriented side plates 37 rest on the base plate and are fastened each to a channel 35 by fasteners 38. There is a side cover 39 mounted by means of a main panel 40 to each channel on the opposite side thereof as the corresponding side plate 37. The side covers 39 are held in place by fasteners 42. Each side cover has a short bent-over panel 41 that is screwed to the end of an associated side plate by fasteners 44. An L-shaped top cover 43 rests on and extends between the short panels 41 and bent-over top tabs 45 of the side covers.
Each side plate 37 is fabricated with first and second vertically oriented slots 47 and 49, respectively, extending from the side plate top surface 51. Slidingly received in the first slot 47 of each side plate are upper and lower infeed bearing blocks 53 and 55, respectively. Both infeed bearing blocks 53 and 55 have oppositely extending flanges 57 and 59, respectively, thereby giving the bearing blocks a T-shaped cross section (FIG. 1). There is a bore 61 through each upper infeed bearing block, and a similar bore 63 extends through each lower infeed bearing block. Similar outfeed bearing blocks 65 and 67 are received in the slots 49 of each side plate. The upper outfeed bearing blocks 65 have respective flanges 69 and bores 71; the lower outfeed bearing blocks 67 have similar flanges and bores. A cap 77 is mounted by screws 79 to the top surface 51 of each side plate. The bearing block flanges 57, 59, and 69 guide the bearing blocks in the side plate slots 47 and 49.
Interposed between the upper and lower infeed bearing blocks 53 and 55, respectively, in each side plate 37 is a compression spring 81. Similar springs 83 are located between the outfeed bearing blocks 65 and 67. The springs 81 and 83 fit within counterbores 84 in the bearing blocks. Adjusting bolts 85 and 87 are threaded into each cap 77 and bear against associated upper infeed and outfeed bearing blocks 53 and 65, respectively.
The adjusting bolts 85 and 87 and the springs 81 and 83 cooperate to locate the bearing blocks 53, 55 and 65, 67 relative to each other. Specifically, the springs 81 bias the infeed bearing blocks away from each other. The end surfaces 89 of the first side plate slots 47 contact the lower infeed bearing blocks and locate them at fixed locations. The adjusting bolts 85 locate the upper bearing blocks 53. By adjusting the adjusting bolts 85, the locations of the upper bearing blocks relative to the lower bearing blocks is adjusted. Consequently, the center distance between the bores 61 and 63 is also adjusted by the adjusting bolts 85. The identical situation occurs for the outfeed bearing blocks 65 and 67, the springs 83, and the adjusting bolts 87.
Rotatably mounted in the bores 61 of the two upper infeed bearing blocks 53 by means of roller bearings 89 is an upper infeed roller 91. Similarly, there is a lower infeed roller 93 between the bearing blocks 55, an upper outfeed roller 95 between the bearing blocks 65, and a lower outfeed roller 97 between the bearing blocks 67. The upper and lower infeed rollers 91 and 93, respectively, cooperate to form an infeed nip. The upper and lower outfeed rollers 95 and 97, respectively, cooperate to form an outfeed nip. The clearance between the infeed rollers is set by adjusting the adjusting bolts 85; the clearance between the outfeed rollers is set by adjusting the adjusting bolts 87.
The in-line pressure sealer 1 also includes a pair of cross-pieces 99 and 101. Both cross-pieces 99 and 101 extend between and are joined to the side plates 37 by means of right angle tabs 102 and screws 105. The cross-pieces have respective horizontal surfaces 103 that are located generally coplanar with each other and generally coplanar with a plane extending between the infeed and outfeed nips. The cross-piece 99 is located on the upstream side of the infeed nip, and the cross-piece 101 is located between the infeed and outfeed nips.
To rotate the rollers 91, 93, 95, and 97, the inline pressure sealer 1 further includes an electric motor 106. A suitable motor is a 1/6 horsepower motor manufactured by Minneapolis Electronic Technology of Minneapolis, Minn. In the preferred embodiment, the motor 106 is fixed to the underside of the base plate 33 by means of motor feet 108 and screws 110. There is a drive pulley 107 on the motor shaft 109. A similar driven pulley 111 is connected to one end 112 of the lower infeed roller 93. An infeed belt 113 is trained over the pulleys 107 and 111. Connected to the second end 115 of the lower infeed roller is a pulley 117; a similar pulley 119 is connected to the lower outfeed roller 97. An outfeed belt 121 is trained over the pulleys 117 and 119.
Also connected to the lower outfeed roller 97 adjacent the pulley 119 is another pulley 122. There is a similar pulley 124 on the upper infeed roller 91. A first idler pulley 125 is rotatably mounted on a stub shaft 127 that is threaded or otherwise held in the side plate 37 between the slots 47 and 49. A second idler pulley 129 is rotatably mounted on a stub shaft 131 threaded into the side plate between the slot 47 and the folding machine 7. A long double sided timing belt 133 is trained over the pulleys 122, 124, 125, and 129, as best shown in FIG. 2. At the opposite end of the upper infeed roller 91 as the pulley 124 is a pulley 135. The corresponding end of the upper outfeed roller 95 also has a pulley 137. A timing belt 139 is trained over the pulleys 135 and 137. Accordingly, energization of the motor 106 causes rotation of all the rollers 91, 93, 95, and 97.
In operation, the clearances between the infeed rollers 91, 93 and the outfeed rollers 95, 97 are set by the adjusting bolts 85 and 87 to suit the particular folded sheet 3 and adhesive strips 11 and 13 that are to be processed into a completed business form. Specifically, the clearance between the infeed rollers is set at a sufficiently close spacing so as to actuate the pressure sensitive adhesive on the folded sheet. The clearance between the outfeed rollers is set to cause adhesion of the activated adhesive to the facing portion of the folded sheet. For clarity, the clearances of the nips are shown greatly exaggerated in the drawings.
As a typical example, the clearance between the infeed rollers is set at 0.004 inches, and the clearance between the outfeed rollers is set at 0.001 inches. Those settings are made by adjusting the adjusting bolts 85 and 87. The springs 81 and 83 hold the rollers 91, 93 and 95, 97, respectively, apart at the clearances set by the adjusting bolts. Jam nuts 123 on the adjusting bolts maintain the desired settings. Because of the springs, the two infeed rollers never touch each other, nor do the outfeed rollers touch each other.
When electrical power is applied to the motor 106, the rollers 91, 93, 95, and 97 rotate together at the same speed. Due to the nip clearances made possible by the adjusting bolts 85 and 87 and the springs 81 and 83, the operation of the in-line pressure sealer 1 is very quiet. Further, the lack of roller contact at the nips eliminates wear of the rollers due to each other and also eliminates roller expansion from heat.
Folded sheets 3 are continuously fed by the folding machine 7 in the downstream direction 27 to the in-line pressure sealer 1. The folding machine belts deposit the folded sheets onto the cross-piece 101, which guides the folded sheet leading edge to the infeed nip. The small clearance between the infeed rollers 91 and 93 causes the folded sheet to be simultaneously propelled downstream and squeezed between the infeed rollers to activate the pressure sensitive adhesive on the folded sheet. The leading edge of the folded sheet is guided by the crosspiece 103 to the outfeed nip. The operation of the outfeed rollers is substantially similar to that of the infeed rollers to complete the process of adhering the folded sheet to itself and produce a completed business form. The in-line pressure sealer can accept and process the folded sheets at the same rate they are fed to it by the folding machine. The business forms emerge from the outfeed nip in the downstream direction 27. From the in-line pressure sealer, the business forms are collected by known equipment for further handling.
In summary, the results and advantages of business forms can now be more fully realized. The in-line pressure sealer 1 provides both the force to seal sheets 3 that are folded by a folding machine 7 and the ability to handle folded sheets and adhesive strips of different thicknesses. This desirable result comes from using the combined functions of the adjusting bolts 85 and 87 and the springs 81 and 83. The springs bias the infeed bearing blocks 53, 55 and the outfeed bearing blocks 65, 67 away from each other to positive stops adjustably set by the adjusting bolts. The adjusting bolts are set to suit a particular folded sheet and adhesive strip, but the springs maintain the desired nip clearances even when no folded sheet is present. As a result, the infeed rollers 91, 93 and the outfeed rollers 95, 97 never contact each other. The result is a very quiet and long lasting machine that can maintain the production rates of the folding machine.
It will also be recognized that in addition to the superior performance of the in-line pressure sealer 1, its construction is such as to cost no more than traditional pressure sealing machines. Also, since it is made of rugged components having a simple design, and since the rollers never contact each other during operation, the need for maintenance is minimal.
Thus, it is apparent that there has been provided, in accordance with the invention, an in-line pressure sealer that fully satisfies the aims and advantages set forth above. While the invention has been described in conjunction with specific embodiments thereof, it is evident that many alternatives, modifications, and variations will be apparent to those skilled in the art in light of the foregoing description. Accordingly, it is intended to embrace all such alternatives, modifications, and variations as fall within the spirit and broad scope of the appended claims. | An in-line pressure sealer processes folded sheets with pressure sensitive adhesive into finished business forms. The in-line pressure sealer has pairs of infeed and outfeed rollers, each with a predetermined clearance therebetween. The clearances are adjustably set by means of screws coacting with a frame and with bearing blocks that rotatably mount the rollers. The infeed and outfeed clearances are adjustable independently of each other. The rollers of each pair are biased away from each other to maintain the clearances when no form is present between the rollers. The folded sheets are guided to the infeed rollers by a first cross-piece and to the outfeed rollers by a second cross-piece. A motor, acting through suitable pulleys and belts, drives the infeed and outfeed rollers. | 8 |
CROSS REFERENCE TO RELATED APPLICATIONS
The present application claims priority to European Patent Office application No. 12172024.7 EP filed Jun. 14, 2012, the entire content of which is hereby incorporated herein by reference.
FIELD OF INVENTION
The invention describes a nacelle test apparatus for testing a wind turbine nacelle, and a method of testing a wind turbine nacelle.
BACKGROUND OF INVENTION
A wind turbine generally comprises a generator housed in a nacelle, mounted on top of a tower so that the nacelle is situated relatively high above ground or sea level. A high tower is preferred, since wind speed increases with increasing altitude. Wind turbine towers can exceed 70 m in height. A tower is generally a closed structure to provide structural stability and to afford protection for components arranged in the tower itself, such as electrical systems, cooling arrangements, control equipment, etc. One type of widely used tower construction comprises a number of steel sections connected together and mounted to a foundation. Another type of tower structure is made of concrete, for example reinforced concrete sections stacked one on top of the other, or cast in situ. The nacelle is generally mounted to the top of the tower by means of a yaw ring, so that the nacelle can be moved in order to have the rotor face into the wind. Here, the term “rotor” is to be understood as an arrangement of rotor blades connected to a hub, which in turn is mounted to a rotatable component of the generator such as a shaft or field, depending on the type of generator that is used.
The combined weight of the nacelle, generator and rotor rests on the top of the tower, which is usually simply regarded as a weight-bearing structure. However, regardless of the manner in which the tower was constructed, the tower is not entirely rigid, and can oscillate in any direction of a horizontal plane, for example a horizontal plane through the top of the tower, and the tower can oscillate sideways as a result of the forces acting on it during operation of the wind turbine or as a result of high winds. The vibrations or oscillations can ultimately compromise the structural stability of the wind turbine, since repeated vibration can result in fatigue. Furthermore, vibrations of the nacelle can also manifest as unacceptably loud levels of acoustic noise. The nature and extent of the oscillations are difficult to predict before commencing the actual construction of a wind turbine. Usually, complex simulation programs are used to model various aspects of wind turbine construction, and the results of a software simulation are used to refine various design aspects. However, such software simulations are only of limited use, since the results depend entirely on the accuracy of the modelling input information, and it is simply not possible to exactly model every aspect of a tower, nacelle, generator and rotor under every conceivable operating condition. As a result, when the wind turbine has been constructed and put into operation, it may be observed to perform poorly under certain conditions, with detrimental side effects that cannot be corrected. Particularly in the case of a wind park comprising many wind turbines, for example an offshore wind park, a favourable performance of the wind turbines is of great importance—in all weather conditions and for all levels of power output.
SUMMARY OF INVENTION
It is therefore an object of the invention to provide an improved way of predicting the behaviour of a wind turbine before its construction.
This object is achieved by the nacelle test apparatus of the claims; and by the method of the claims of testing a wind turbine nacelle.
According to the invention, the nacelle test apparatus for testing a wind turbine nacelle comprises a physical tower model apparatus realised to model the behaviour of a wind turbine tower; and/or a physical rotor model apparatus realised to model the behaviour of a wind turbine rotor; and an exciter apparatus for exciting the physical model apparatus.
An advantage of the nacelle test apparatus according to the invention is that it can be used to identify and correct design deficiencies in various components of a wind turbine before actual construction of the wind turbine, so that damage to the nacelle and/or generator can be avoided. The nacelle test apparatus makes it possible to improve the nacelle design from the outset, avoiding costs that would otherwise arise from the detrimental side effects of prolonged vibrations such as material fatigue. Furthermore, the nacelle test apparatus according to the invention can be constructed at any convenient location, for example at the generator or nacelle manufacturing site. Furthermore, the behaviour of a tower or a rotor can be translated very accurately into compact physical models, so that the test apparatus according to the invention can be realised in an economical manner.
According to the invention, the method of testing a wind turbine nacelle comprises mounting the nacelle onto a physical tower model apparatus, which physical tower model apparatus is realised to model the behaviour of a wind turbine tower; and/or mounting a physical rotor model apparatus to a hub of the nacelle, which physical rotor model apparatus is realised to model the behaviour of a number of wind turbine blades; and exciting the physical tower model apparatus and/or the physical rotor model apparatus.
An advantage of the method according to the invention is that the testing can be carried out very conveniently, without first having to transport a nacelle to an already constructed tower. Results of the test procedures can be conveniently analysed on site, and corrective measures can be quickly carried out and re-tested, so that a nacelle design can be optimised even before construction of a wind turbine. The method therefore can contribute to a reduction in the costs of a wind turbine, which savings become even more significant if a wind park with many wind turbines is to be constructed. The method according to the invention can also be used to trouble-shoot an existing wind turbine design, by using the same nacelle type and carrying out a test procedure to reproduce an already observed problem and to identify its cause. In this way, existing designs can be corrected or improved.
Particularly advantageous embodiments and features of the invention are given by the dependent claims, as revealed in the following description. Features of different claim categories may be combined as appropriate to give further embodiments not described herein.
In the following, but without restricting the invention in any way, the term “wind turbine rotor” is to be understood to mean the wind turbine blades mounted to a spinner or hub, since these are collectively caused to rotate by the wind. The rotation of the spinner is transferred either to a shaft or to a field arrangement of the generator, depending on the generator design.
The nacelle test apparatus can be realised to model various constructional and behavioural aspects of a wind turbine. A wind turbine tower can be regarded as a “long spring” with the same length as the tower and bearing the weight of the nacelle, generator, and rotor. For example, an 80 m tower can be regarded as a long spring with a length of 80 m or so. The invention makes use of the fact that a suitable constellation of “short springs” can provide an equivalent model for a long spring. Therefore, in a particularly preferred embodiment of the invention, the physical tower model apparatus comprises an arrangement of spring elements chosen to mimic spring characteristics of a wind turbine tower. A physical model of the long spring can therefore be constructed. The test apparatus (or “test rig” in the following) preferably comprises a tower exciter apparatus realised to excite the spring element arrangement in order to mimic the physical behaviour of the tower itself.
In a preferred embodiment of the invention, the spring element arrangement comprises a plurality of upright spring elements in a suitable constellation. For example, it may be determined that a long spring can be modelled by several hundred short springs arranged in a circular constellation corresponding to the circular cross-section of the upper level of the tower.
In a vertical direction, a wind turbine tower will exhibit essentially no movement, whereas an upper region of the tower can sway or vibrate sideways to a significant extent. To predict the performance of the tower in real life, this behaviour should be considered by any tower model. Therefore, in a further preferred embodiment of the invention, a spring element is realised to comprise a low stiffness in a horizontal direction and a high stiffness in a vertical direction, whereby the “vertical” direction corresponds to the vertical orientation of the tower, and the “horizontal” direction relates to a horizontal plane of oscillation of the tower, as indicated in the introduction.
A wind turbine tower may also twist slightly about its vertical axis on account of the loading, whereby the amount of torsional movement or “twist” will be greatest at the highest point of the tower, i.e. the level at which the nacelle is mounted to the tower. Therefore, in a further preferred embodiment of the invention, the spring element is preferably realised so that it can model the torsional movement of a tower. To this end, a spring element can be realised to comprise a high stiffness in a radial direction and a low torsional stiffness in a tangential direction. A set of such spring elements could be arranged in a circular constellation such that a spring element exhibits a low stiffness along a tangent to the circle, and a high stiffness along a radius of the circle.
A spring element can be obtained by using a tension bar, i.e. a bar of metal with dimensions and material properties chosen to obtain the desired spring properties. The tension bar is preferably also realised for mounting securely in a suitable apparatus to which the nacelle can be mounted, and which can be acted upon by the exciter apparatus.
A long spring can then be modelled using many such simple short springs. However, the number of short springs required to reliably model a long tower may be difficult to accommodate in a test rig. Therefore, in a particularly preferred embodiment of the invention, a spring element comprises a bundle of upright plates or tension bars connected together. The invention makes use of the fact that the behaviour of a group of short springs can be modelled accurately by effectively combining them to give a single short spring. Therefore, a circular constellation of several hundred finite element short spring models can be “translated” into an equivalent physical formation of a few tens of short spring elements. Such a spring element can be obtained by using a type of leaf spring e.g. a composite bar comprising layers of flat metal plates of the same size with dimensions and material properties chosen to obtain the desired spring properties. Such a spring element is preferably also realised for mounting securely in a suitable apparatus to which the nacelle can be mounted, and which can be acted upon by the exciter apparatus. For example, the metal plates can be fastened together using bolts and a clamp that is also used to connect the spring element to part of the test apparatus.
The test rig can be realised in a number of ways to simulate the real-life behaviour of a nacelle mounted on top of a tower. In a “rotational mode”, in which a rotational movement of the tower top about its own axis should be simulated, the arrangement of the short springs is preferably aligned about the centre of a circle corresponding to the tower's vertical axis, i.e. in a circular constellation as mentioned above. In a “translational mode”, in which lateral or sideways displacement of the tower is to be simulated, the short springs can be arranged in a square or rectangular arrangement.
As indicated above, a short spring should be realised so that it can be secured in the test rig, in such a way that the spring element arrangement can be excited by the tower exciter apparatus. Therefore, in a preferred embodiment of the invention, the physical tower model apparatus comprises at least one horizontal plate for connecting to the upright spring elements of the spring element arrangement, and wherein the tower exciter apparatus is realised to apply a lateral force to the horizontal plate. For example, the upright spring elements can be arranged in a square formation about the edges of a square metal plate onto which the nacelle is mounted, and the tower exciter apparatus can be realised to apply an impulse or periodic force to one or more sides of the plate. In this way, a controlled lateral displacement of groups of the spring elements is achieved, and this lateral displacement, mimicking the oscillatory behaviour of the tower, is transferred to the nacelle. Measuring instruments or sensors can be arranged at appropriate locations in or on the nacelle to monitor the effects of the vibrations induced by the test rig.
Preferably, the “tower”, i.e. the spring element arrangement, should be excited to realistically mimic the behaviour of a real wind turbine tower. Therefore, in a particularly preferred embodiment of the invention, the tower exciter apparatus is realised to vibrate the physical tower model apparatus at a specific frequency or in a specific frequency range, so that the nacelle, mounted on the test rig, is also caused to vibrate at that frequency or in that frequency range. For example, a physical tower model apparatus modelling an 80 m tower can be caused to vibrate at a frequency between 0.2 Hz and 0.5 Hz, which is a typical frequency range for a tower of that height. However, to speed up the testing so that results can be obtained more quickly, the frequencies can be scaled up by a suitable factor, for example by a factor of 10, which gives frequencies between 2 Hz and 5 Hz for the above typical frequency range.
The nacelle could be mounted or connected to the test rig in any suitable manner. However, since forces from the tower are generally transferred to the nacelle through its yaw ring, i.e. the interface between tower and nacelle, in a preferred embodiment of the invention the physical tower model apparatus comprises a yaw interface realised for connecting the nacelle to the spring element arrangement. In this way, the nacelle can be connected to the test rig in the same manner that it would be connected to a tower in real life, and the vibration loading will be transferred realistically to the nacelle. This allows a very precise observation of the effects of the vibrations during operation of the test rig.
The design of a nacelle is usually adapted to suit the design of the generator that will be used, and the constructional parameters of the tower to which it will be mounted. For example, a large generator will generally require a higher tower with relatively large upper diameter, while a smaller generator can be mounted on a tower with a relatively small upper diameter. A test rig can be constructed to suit a particular tower and nacelle design. However, in a preferred embodiment of the invention, the yaw interface is realised to be adapted to a number of different nacelle designs. For example, the yaw interface can be realised to accommodate circular adapter rings of different diameters and with appropriate arrangements of bolts. The test rig is preferably realised so that an adapter ring can be mounted with relatively little effort, for example by securing it to the upper plate of the spring element arrangement. The yaw ring of a particular nacelle can then simply be lifted onto the appropriate adapter ring already in place on the test rig, and secured as if it were being secured to the top of a tower.
During operation of the wind turbine, the wind exerts a force on the rotor blades, which are usually pitched so that as much energy as possible can be extracted from the wind. As mentioned in the introduction, the wind speed increases with increasing distance from ground or sea level. Particularly in the case of a very large rotor, a rotor plane (i.e. the circular disc described by a rotor blade as it rotates through a full circle) can have a diameter in the order of 120 m or more, the difference in wind speed between an upper region and a lower region of the rotor plane can be considerable. Therefore, the hub is generally not evenly loaded. The uneven loading can have detrimental effect on other components that are directly connected to the hub, for example the rotor housing of a generator with direct-drive transmission, or the shaft and gearbox of a generator with geared transmission. Therefore, in a particularly preferred embodiment of the invention, the physical rotor model apparatus comprises a rotation mass realised for mounting to a hub of the nacelle, and a hub exciter apparatus realised to excite the physical rotor model apparatus. The physical rotor model apparatus preferably comprises a means for simulating the uneven loading of the hub. In a further preferred embodiment of the invention, therefore, the physical rotor model apparatus comprises a rotating mass of a sufficient weight, mounted to the hub so that, when it rotates, an uneven rotating load is exerted on the hub to mimic the performance of the rotor blades during operation of the wind turbine.
A wind turbine is generally constructed at a location with reliable wind patterns, i.e. favourably high wind speeds from a prevailing direction. As a result, the rotor of such a wind turbine mostly faces into the direction of the prevailing winds, and the tower will mostly vibrate according to a specific pattern. Therefore, in a particularly preferred embodiment of the invention, the step of exciting the physical tower model apparatus comprises inducing a vibration of the nacelle in a specific direction. In this way, the loads that will mostly be exerted on the nacelle can be reliably modelled and mimicked.
Of course, the wind direction can change, particularly in turbulent or gusty wind conditions. Therefore, in another preferred embodiment of the invention, the step of exciting the physical tower model apparatus comprises altering the direction of vibration of the nacelle.
Therefore, the tower apparatus exciter of the test rig according to the invention is preferably realised to apply impulse or periodic forces to the spring element arrangement from a number of different directions. For example, the tower apparatus exciter can be realised to be movable. It can be used to apply forces to the spring element arrangement from one side, and then moved around to apply forces to the spring element arrangement from a different side. However, in a particularly preferred embodiment of the invention, the tower apparatus exciter comprises a plurality of exciter elements arranged about the spring element arrangement, so that at any one time, impulse or periodic forces can be applied to the spring element arrangement from a number of different directions. This allows a more realistic excitation of the “tower”, and a more precise modelling of its behaviour and the effects on the nacelle.
Generally, when the wind changes direction, this is detected in some way and the yaw drive is actuated to turn the rotor to face into the wind. The tower top oscillations will also alter, for example the oscillations caused by the first wind direction will die down, while oscillations caused by the new wind direction will build up. During and after the yawing procedure, therefore, a nacelle on top of a wind turbine tower will be subject to various oscillations at different directions and different frequencies. In a particularly preferred embodiment of the invention, therefore, the method comprises the step of yawing the nacelle while the spring element arrangement is subject to excitations in a plurality of directions.
The method according to the invention preferably comprises the step of measuring a load exerted on a component in or on the nacelle as a result of an excitation of the physical tower model apparatus and/or the physical rotor model apparatus. The observed results can be interpreted to determine improvements that should be made to the structural design of the tower, the nacelle, the generator, etc., for example whether additional reinforcement or damping is needed at a particular region of the nacelle. Such design corrections can be carried out relatively quickly, and the test rig can used again to determine their effectiveness. The test rig according to the invention can therefore be used to identify and correct design problems before the wind turbine is actually constructed.
BRIEF DESCRIPTION OF THE DRAWINGS
Other objects and features of the present invention will become apparent from the following detailed descriptions considered in conjunction with the accompanying drawings. It is to be understood, however, that the drawings are designed solely for the purposes of illustration and not as a definition of the limits of the invention.
FIG. 1 shows a typical wind turbine construction;
FIG. 2 shows a finite element model of a nacelle test apparatus according to the invention;
FIG. 3 shows a nacelle test apparatus according to an embodiment of the invention;
FIG. 4 shows an embodiment of a spring element for use in the nacelle test apparatus of FIG. 3 ;
FIG. 5 shows an embodiment of a rotor hub exciter apparatus for use in the nacelle test apparatus of FIG. 3 ;
FIG. 6 shows a nacelle mounted on the nacelle test apparatus of FIG. 3 ;
FIG. 7 shows an alternative embodiment of a tower model apparatus for use in a nacelle test apparatus of the invention.
In the diagrams, like numbers refer to like objects throughout. Objects in the diagrams are not necessarily drawn to scale.
DETAILED DESCRIPTION OF INVENTION
FIG. 1 shows a typical wind turbine construction, with a nacelle 11 mounted on top of a tower 12 . The diagram is not to scale, and the tower 12 can be considerably higher than indicated. The nacelle 11 can rotated relative to the tower 12 by means of a yaw ring 110 . A cooling arrangement 111 is mounted at the rear of the nacelle 11 to cool the generator components during operation. To extract as much energy as possible out of the wind, the nacelle 11 is turned so that a rotor 13 , comprising a number of blades 130 mounted onto a spinner 131 or hub 131 , faces directly into the wind. During operation of the wind turbine, the tower 12 sways or oscillates sideways, as indicated—in an exaggerated manner—by the dotted and dashed lines close to the tower top. These oscillations can have a detrimental effect on the structural stability of the wind turbine, since repeated vibrations can result in material fatigue manifesting in various components of the wind turbine.
FIG. 2 shows a finite element model 4 used to develop the nacelle test apparatus according to the invention. The tower is modelled by a circular formation of short springs 40 . The rotor is modelled by a three blade models 42 connected to a hub model 43 , which act to “turn” a shaft model 41 . This finite element model 4 can provide a favourable close representation of the corresponding “real life” components of the wind turbine. To convert the finite element model 4 into a physical apparatus, the inventors replaced the short springs 40 by a number of physical spring elements to obtain a physical tower model, and replaced the blade and hub models 42 , 43 by a rotating mass to obtain a physical rotor model.
An embodiment of a test rig 1 with such a tower model 2 is shown in FIG. 3 . The tower model 2 comprises a spring element arrangement 21 , which effectively comprises two square horizontal plates 23 , 24 between which is mounted a square formation of upright spring elements 22 . This embodiment of the test rig 1 can be used to good effect in simulating lateral displacements of the “tower”.
The test rig 1 comprises a tower model exciter 20 , comprising a number of displacement blocks 20 which can be displaced in defined directions D 1 , D 2 to apply lateral impulse or periodic forces to the horizontal plates 23 , 24 . A displacement block 20 can be a solid block of a suitable massive material such as concrete and can be moved by a suitably powerful motor (not shown). To this end, the displacement block 20 may be mounted on rails or rollers so that it can be relatively easily displaced in a lateral direction D 1 , D 2 .
The test rig 1 also comprises a yaw interface 26 for connecting to a nacelle, and for implementing the yawing function, for example with the usually yaw drive for actuating a yaw ring to turn the nacelle. Here, the yaw interface 26 is realised as a rigid annular component secured to the upper horizontal plate 23 . A yaw ring 111 is mounted to the yaw interface 26 , so that a nacelle can be lowered into place and secured in the usual manner. The yaw interface 26 can be adapted to receive yaw rings of different diameters so that different nacelles can be tested using this test rig 1 . The test rig 1 can be secured firmly to the ground in a foundation 25 , so that the vertical stiffness of a wind turbine tower is reliably mimicked even when large forces are exerted by the tower model exciter on the tower model 2 . By activating a yaw drive, the nacelle can be made to rotate, so that its position relative to the force directions D 1 , D 2 can be changed.
The lateral displacement of the top of a wind turbine tower in a translational simulation mode is modelled by the square formation of spring elements 22 . Each spring element 22 comprises a number of flat tension bars 220 , as shown in FIG. 4 . In this example, the tension bars 220 are arranged in two upright groups of five bars 220 on each side, joined together at top and bottom by connecting means 221 , which in turn can be bolted to the inside surfaces of the opposing horizontal mounting plates 23 , 24 that were described in FIG. 3 above. The combination of the stiff tension bars 220 and the connecting means 221 provide a spring element 22 that is essentially infinitely stiff in the vertical direction Y and a radial direction Z, and flexible to a desired degree only in a specific horizontal direction X. Of course, the number of tension bars 220 that is used will depend on the number of spring elements chosen to represent the finite element short springs that in turn collectively model the “long spring” of the wind turbine tower.
FIG. 5 shows a simplified representation of an embodiment of a rotor hub exciter apparatus 3 for use in the test rig 1 of FIG. 3 . The rotor hub exciter apparatus 3 need only model the uneven or eccentric loading of the rotor and pass this on to a shaft or field arrangement of the generator, depending on the generator design. To this end, the rotor hub exciter apparatus 3 comprises a mass 31 mounted on a shaft 32 . The shaft can be turned by a rotor model exciter so that the mass 31 rotates to simulate the eccentric loading of a “real life” rotor.
FIG. 6 shows a nacelle 11 mounted on the nacelle test apparatus 1 of FIG. 3 . The test rig 1 is firmly secured in a foundation 25 , so that only the lateral displacement of the “tower” 2 or tower model apparatus 2 is transferred to the nacelle when the tower model exciter 20 is activated. A “rotor” 3 or rotor model apparatus 3 is mounted to the spinner 131 , and a rotor model exciter 30 causes a mass to rotate in an eccentric manner about a central shaft in the direction R shown, in this case using a drive belt 33 , thus simulating the presence of a set of rotor blades in motion. During testing, a yaw drive of the nacelle 11 can be activated to yaw the nacelle 11 , while at the same time applying impulse or periodic displacements in one or both lateral directions D 1 , D 2 .
FIG. 7 shows a circular arrangement of spring elements 22 of another embodiment of a tower model apparatus 2 of the test rig. Here, the spring elements 22 are arranged so that they can better model a torsional movement of the tower top. To simulate a torsional displacement D T , indicated by the curved arrow, the test rig comprises a suitable exciter (not shown) that can displace the upper plate 23 of the test rig relative to the lower plate 24 by applying a force F at a suitable point. The torsional displacement D T is made possible by the lower tangential stiffness of the spring elements 22 (corresponding to direction X in FIG. 4 ). The displacement is also restricted to a torsional displacement on account of the high degree of radial stiffness (corresponding to direction Z in FIG. 4 ) of the spring elements 22 . In this way, a “twisting” of the top of a wind turbine tower can be simulated in a rotational mode.
Clearly, using the test rig of the invention, the real-life working conditions of a wind turbine can be simulated very realistically, and before its actual construction. Furthermore, the exciters can be operated for any length of time at reasonably high speeds, so that side-effects of prolonged oscillation such as material fatigue can be detected in a relatively short time. In real life, it may take years for material fatigue to manifest. The test rig according to the invention allows such material fatigue to be identified very quickly, so that measures can be taken to avoid it. To this end, sensors and measuring devices for measuring stress and strain can be placed at appropriate points in or on the nacelle to measure the effects of the vibrations and loading when the exciter apparatus is activated. The frequency of vibration during a simulation is not limited to a real-life frequency, which is generally quite low, but can be increased so that reliable information can be collected in a relatively short period of time. For example, a simulation can be set up to run over a period of a few hours, a few days, or even a few weeks, simulating behaviour that would occur over a period of several months or even years. The information collected in this way can be interpreted to determine any design corrections that should be carried out before actual construction of the wind turbine.
Although the present invention has been disclosed in the form of preferred embodiments and variations thereon, it will be understood that numerous additional modifications and variations could be made thereto without departing from the scope of the invention. For example, the test rig according to the invention can be used to test the effects of tower oscillation on any structure that is to be mounted on top of a high tower.
For the sake of clarity, it is to be understood that the use of “a” or “an” throughout this application does not exclude a plurality, and “comprising” does not exclude other steps or elements. | A nacelle test apparatus for testing a wind turbine nacelle is provided. The test apparatus includes a physical tower model apparatus realized to model the behavior of a wind turbine tower and/or a physical rotor model apparatus realized to model the behavior of a wind turbine rotor, and an exciter apparatus for exciting a physical model apparatus. Also provided is a method of testing a wind turbine nacelle, which method includes mounting the nacelle onto a physical tower model apparatus of a nacelle test apparatus, which physical tower model apparatus is realized to model the behavior of a wind turbine tower, and/or mounting a physical rotor model apparatus of the nacelle test apparatus to a hub of the nacelle, which physical rotor model apparatus is realized to model the behavior of a wind turbine rotor, and exciting the physical tower model apparatus and/or the physical rotor model apparatus. | 8 |
The present disclosure relates to technologies in the field of test response compaction.
BACKGROUND
Scan testing transforms the test of a sequential circuit into a combinatorial test problem. In conjunction with automated test pattern generation (ATPG) software, this allows to handle the ever increasing complexity of digital designs. However, test data volume continues to grow with the design's complexity. Moreover, new process technologies and materials which allow smaller feature sizes require more comprehensive tests covering a range of different fault models [1]. Today, test cost constitutes a significant part of the production cost, typically in the range of 10-20% [2].
To keep test time and automated test equipment's (ATE) memory requirements in check, test input stimuli as well as test response data are transferred in compressed form. The basic design of scan test with test compression is depicted in FIG. 1 . With test compression, the ATE transfers compressed test stimuli to the device-under-test (DUT), where it is deflated by a decompressor circuitry. The scan-out data is likewise compacted by an on-chip compactor. This setup allows to feed a large number of short internal scan chains with only a limited number of external ATE channels. This is advantageous as a large number of (relatively) short scan chains reduces the number of scan shift cycles per pattern, thus reducing test time and test cost.
A major obstacle to efficient test response compaction are unknown values (x-values) captured by scan cells during test. If test responses with x-values are compacted, some of the outputs of the compactor may also take unknown values and the correctness of the compactor inputs cannot be verified at the compactor outputs. The presence of x-values hence reduces observability of (non-x) scan cells which may lead to reduced test quality and/or limited compaction rates.
To overcome these problems a number of ideas have been proposed. Some compactors are designed to tolerate a limited number of x-values, e.g. [3], [4], [5], [6], [7], [8]. In general, however, these solutions are only applicable to designs with very low x-densities. A slightly different approach is taken in [9], [10], where scan out data is rearranged to reduce x-value impact before it is fed into the compactor.
A second approach is to mask the x-values before they enter the compactor [11], [12], [13], [14], [15]. These compactors require the transfer of additional masking data to the DUT. Furthermore, these concepts usually entail over-masking, i.e. the overall observability of scan cells is decreased. This may result in a lower probability to detect non-targeted faults.
Thirdly, output selection may be used to circumvent x-values [16], [17], [18]. Recently, the use of ATE timing flexibility to observe a subset of the output values of an accelerated compactor has been proposed [19], [20].
To further reduce test cost, circuits may be tested in parallel (multi-site testing). In that case, a number of DUTs shares the same input signals while transferring their test responses on separate channels each.
Furthermore, diagnosis data from volume testing is increasingly used for yield learning [21]. Hence, test compaction should also allow for efficient diagnosis. It has been demonstrated that test output data compacted into a single, 1-bit-wide output stream by an XOR-tree can be efficiently used for fault detection and diagnosis [22], [23]. However, these works considered x-free circuits only.
SUMMARY
A compaction solution is presented which allows an extreme response compaction (down to a single output) in presence of a high number of x-values. The solution is well suited for multi-site testing, can benefit from ATE timing flexibility, is design-independent and easily scales to an arbitrary number of scan chains.
According to one aspect of the invention, a circuit arrangement for controlling the masking of test and diagnosis data with X values of an electronic circuit with N scan paths is provided, wherein the test data are provided on insertion into the N scan paths by a decompressor with m inputs and N outputs, wherein m is <N and wherein the masked test data are compacted by a compactor with N data inputs and n data outputs and m<N applies, the arrangement comprising:
a first circuit component for masking the test data, which comprises N data inputs for input of N-digit binary unmasked test data, N control inputs for input of the binary control signals for masking the corresponding digits of the test data and N outputs for outputting the values of the masked test data bits corresponding to the control signals, a further circuit component with N binary inputs and N binary outputs for providing control signals, such that the N binary outputs are connected to the N control inputs of the first circuit component and wherein the first circuit component has a first serially loadable register with N memory elements, a second loadable register with likewise N memory elements for storing test pattern-dependent masking data and a third serially loadable register likewise with N memory elements for storing test-dependent masking data, wherein the following applies:
the input of the ith memory element of the second register is connected, for i=1, . . . , N, logically directly with the ith input terminal of the further circuit component, if a first binary value is stored in the ith memory element, the input of the ith memory element of the second register is connected, for i=2, . . . , N, with the output of the (i−1)th memory element of the second register, if a value is stored in the ith memory element of the first register which is different from the first binary value, the output of the jth memory element of the second register is connected, for j=1, . . . , N−1, logically directly with the input of the (j+k)th memory element of this register, if the binary values b, b, . . . , b, −b are stored in the jth, (j+1)th, . . . , (j+k−1)th memory element of the third register, and for k=1, . . . , N the output of the kth memory element of the second register is connected with the first input in each case of a kth logic gate with two inputs and one output, of which the second input is connected with the output of the kth memory element of the third register, wherein the output of the kth gate with two inputs and one output conveys the kth binary digit of the masking signal and is connected with the kth control input of the first circuit component, and wherein the logic gate with two inputs and one output in each case has a controlling value.
According to another aspect of the invention, a circuit arrangement for an electrical circuit to be tested is provided, the arrangement comprising:
a test input signal generator, which generates a test input signal of width N, wherein only g<N bits of the test input signal may be released per cycle, terminals for connection to inputs and outputs of an electronic circuit to be tested, wherein the electronic circuit to be tested has N digital test inputs and M digital test outputs and wherein the terminals for the test inputs are connected to the test input signal and wherein the electronic circuit to be tested is controlled such that it outputs test responses at its test outputs, a circuit component with M inputs and m outputs (M>m) is present for compacting data, a circuit component for masking X values, comprising the sub-components masking logic, mask register and loading circuit, wherein
as a function of the state of the mask register, the masking logic is configured to allow masking of a portion of the outputs of the circuit to be tested the mask register comprises one or more dynamically shortenable shift registers, whose state may be specified at least in part by way of the loading circuit the loading circuit specifies one or more inputs for the mask register data, such that a freely selectable portion of the M outputs of the circuit to be tested form the data inputs of the mask register.
According to a preferred embodiment of the invention, the loading circuit is connected directly to at least one output of the test input signal generator.
In a preferred embodiment, the dynamically shortenable mask register comprises memory elements, which at least in part provide the masking information for the masking logic and which are connected to from as a whole a shift register, each memory element is configured to store one mask bit, at least one memory element i is configured to be excluded from the shift chain, i.e. that the initial value of the preceding element i−1 is forwarded combinatorially to the input of the following memory element i+1, the loading circuit consists of a series of memory elements IR j and multiplexers MUX 1 j , the output of the memory element IR j is connected to the input of the memory element IR j+1 and the control input of the multiplexer MUX 1 j , and one data input of the multiplexer MUX 1 j is connected to the data output of a memory element k of the dynamically shortenable mask register and the other input is connected to a signal from the signal cluster and the output of the multiplexer MUX 1 j is connected to the data input of the subsequent memory element k+1 in the mask register.
In still a further embodiment, the loading circuit and the dynamically shortenable shift register jointly consist of modules, the modules comprises memory elements IR i , MR i , Cr i , multiplexers MUX 1 i , MUX 2 i , and an AND gate, and the components are connected as follows: the memory element with the data input controls with its data output the multiplexer, the multiplexer allows the data signal or the data signal to pass to its output, which is connected with the input of the memory element and one input of the multiplexer, the output of the memory element is connected to the second input of the multiplexer and one input of the AND gate, the output of the multiplexer is the line, the output of the memory element with the input is connected to the second input of the AND gate and control input of the multiplexer, the line is the output of the AND gate, and wherein the lines form the inputs of the module and the lines form the outputs of the module, and wherein the loading and mask register logic are formed by chaining these modules, wherein output of a module i is connected with in each case the input of the module i+1 and wherein the input is connected with a signal from the signal cluster and the output is connected with the X masking logic via signal cluster.
BRIEF DESCRIPTION
FIG. 1 depicts an embodiment of a design of scan test compression.
FIG. 2 depicts an embodiment of outputs of scan chains filtered through a novel x-masking logic and subsequently compacted into a single, one-bit wide bitstream by an XOR-tree.
FIG. 3 depicts an XHCMR cell for a single scan chain.
FIG. 4 depicts an embodiment of a 4-element XHCMR with a 3-bit virtual mask register.
FIG. 5 depicts an embodiment of a selection of strobe positions within a scan cycle.
FIG. 6 depicts an embodiment of multiple DUTs in parallel on a single ATE.
FIG. 7 depicts a compaction ratio r for design B (cf. Table 2) depending on the number of scan chains.
FIG. 8 depicts the resulting fault coverage for the considered number of scan chains.
FIG. 9 depicts an embodiment of IR cells with additional multiplexers between the inputs respective outputs connecting successive HCMR cells.
FIG. 10 depicts a flow chart in accordance with the present disclosure.
DETAILED DESCRIPTION
Following the invention will be described in further detail, by way of example, with reference to different embodiments.
The XHCMR-Compactor
In the proposed compactor the outputs of the scan chains are filtered through a novel x-masking logic and subsequently compacted into a single, 1-bit wide bitstream by an XOR-tree ( FIG. 2 ). The masking logic allows to define arbitrary, pattern-specific masks for filtering x-values and provides an efficient mechanism for the loading of x-masking information.
The x-masking is performed in the eXtended Hierarchically Configurable Mark Register (XHCMR). At the beginning of the test, the XHCMR is initialized once by loading two k-bit words (k denoting the number of scan chains) via IR in and C in (cf. Section II.1 and II.2).
During test, pattern-specific, reduced masking data can be loaded in parallel using the scan chains. An explicit mask-enable signal determines the clock cycles in which x-masking is to be performed. If ATE timing flexibility is used, the need for the mask control signal is eliminated (cf. Section 0). In the following three subsections we introduce the proposed XHCMR compactor in detail. Firstly, we illustrate advantages of using a hierarchical masking logic to reduce masking data volume, then we describe a novel approach to load the (reduced) masking data in parallel using the scan chains of the DUT. In the last subsection, we discuss options to utilize ATE timing flexibility.
Reducing Masking Data
The masking logic is employed to mask x-values captured by scan cells with arbitrary, pattern-specific masks. In known approaches [13], each mask defines for each scan chain whether this chain is to be masked, hence, the length of the x-mask is equal to the total number of scan chains. However, the majority of scan chains never capture any x-values. Therefore, masking data can be reduced if masking information is only loaded for those chains which are affected by x-values during one or more patterns.
For that reason, the XHCMR compactor employs a hierarchically configurable mask register (HCMR) [24], which configures the masks in two stages. At the beginning of the test, the subset of all the scan chains which potentially need to be masked is selected (first stage). Subsequently, to create a pattern-specific mask, only the masking information for the selected subset needs to be transferred.
To that end, a k bit word Zefining an arbitrary subset of l out of all k scan chains which can be masked during test is loaded into the HCMR via the input C in . Usually, this subset contains all scan chains which capture x-values in at least one pattern. The remaining scan chains cannot (and, by definition, need not to) be masked.
The choice of l maskable scan chains configures the HCMR to form a virtual mask register of length l. The virtual mask register VMR stores the pattern-specific x-masks which determine the scan chains to be masked in the respective test pattern. Consequently, for loading a new masking pattern, only l (instead of k) bits have to be loaded into the VMR.
A mask enable signal allows a per-clock activation of the mask. This control line is not necessary if ATE timing flexibility is used (cf. section II.3).
Parallel Loading of Mask Data
The architecture of the HCMR as presented in [24] provides only for serial loading of the mask information. This increases the test time if the length l of the x-masks exceeds the number n of flip-flops of the longest scan chain. In that case, additional l-n cycles are needed per test pattern to finish loading of the masking information. In this section, we present a new solution using parallel inputs to speed-up the loading of the mask information and eliminate the need for a separate input channel to transfer the x-mask data.
Ideally, the parallel loading mechanism should not require any additional data channels. For that reason, we propose to use the scan chains to feed the mask register. Even though there are k>l scan chains, these are usually fed by a decompressor (cf. FIG. 1 ). The decompressor limits the number of bits per slice whose values can be set independently of each other [25]. This number cannot exceed the number of decompressor inputs. To keep input bandwidth small, the number of decompressor inputs is usually only a fraction of the number of scan chains k, and also likely to be significantly smaller than the x-mask length l.
In the following, we assume that the values of g scan chains can be set independently of each other. Our solution uses g (g<<l) scan chains to load the mask information in parallel. This reduces the number of cycles required to load a mask to
⌈ i g ⌉
cycles.
To facilitate parallel loading, we divide the l-bit wide virtual mask register VMR into g segments s 1 , s 2 , . . . , s g of (nearly) equal length. Each of these segments forms a separate shift register. The segments s 1 , s 2 , . . . , s g are fed by a single scan chain each, which allows to feed them simultaneously. However, both the length and the flip-flops constituting the VMR depend on the subset of scan chains actually affected by x-values. Hence, the position and length of the segments s 1 , s 2 , . . . , s g are unknown at design time. Therefore, it we cannot use a fixed set of scan chains to form the intakes of s 1 , s 2 , . . . , s g .
In the following, we describe the internal structure of the XHCMR which enables the dynamic positioning of the g intakes. This allows to create sections of equal length and thus provides for efficient parallel loading.
FIG. 3 depicts an XHCMR cell for a single scan chain. The proposed structure consists of a standard HCMR cell [24] and an intake position register cell (IR cell) which defines the source for the input M in of the associated HCMR cell.
A HCMR cells stores all masking related information for a given scan chain. If the scan chain never captures x-values, the HCMR cell is configured to be transparent, i.e. its input M in is directly connected to its output M out and the corresponding scan chain is never masked (m i =0). If, on the other hand, the scan chain may capture x-values, the HCMR cell is activated and acts like a flip-flop with the input M in and output M out . Furthermore, value of the masking output m i is determined by the flip-flop's state. The HCMR (cf. FIG. 4 ) is made up by HCMR cells connected into a chain. It can thus be used to form a virtual mask register (VMR) by activating only a subset of its cells.
To split the VMR into g segments, the IR cells add additional multiplexers MUX, (0≦i≦k) between the inputs respective outputs connecting successive HCMR cells (cf. FIG. 3 and FIG. 9 ). Each MUX i is controlled by the corresponding flip-flop IR i and switches between the output M out of the preceding HCMR cell (equivalent to input int i ) and the external intake ext i . If the value of the flip-flop IR i is 1, then the (external) source ext i is the input of the HCMR cell i. Thus, the VMR is splitted at this position and a new segment with a new external intake is created. If, on the other hand, IR i equals 0, then the HCMR cell i is directly connected to its predecessor (as in a standard HCMR). In this way, the standard HCMR can be dynamically divided into a number of shorter segments s 1 , s 2 , . . . , s g . By feeding the input ext i with the i-th scan chain, the segments can be loaded simultaneously through the scan chains.
The IR cells form a shift register, the intake position register IR, with the global input IR in . The contents of the register IR thus defines the position of the intakes for parallel loading of the virtual mask register VMR. Like the subset of scan chains selected as maskable, the configuration of the IR remains unchanged during test.
FIG. 4 illustrates a 4-element XHCMR with a 3-bit virtual mask register VMR (formed by HCMR cells 1 , 3 and 4 ). The configuration of the intake-position register divides the VMR into two separate segments s 1 and s 2 with the two intakes ext 1 and ext 4 , respectively. Due to the selection of maskable scan chains and IR configuration, the first segment s 1 is made up of HCMR cell 1 and HCMR cell 3 , while the second segment s 2 is made up by HCMR cell 4 only. HCMR cell 2 is in neither section (dynamically disabled) as the corresponding scan chain is not in the subset of maskable chains. In this example setup, the 3-bit mask can be loaded in only two clock cycles using ext 1 and ext 4 .
Putting it all together, the overall test sequence using XHCMR can be summarized as follows:
(1) select virtual mask register elements (VMR) (k cycles) (2) initialize intake position register (k cycles) (3) load x-mask for patter P into VMR via scan chains (1/g cycles) (4) scan-shift for pattern P (n≧1 cycles) (5) if P<#pattern goto (3)
Compared to the basic HCMR architecture, reloading of the x-masks using XHCMR is reduced by the factor g.
The architecture from [24] and the XHCMR architecture were synthesized with the Synopsys Design Compiler (Version Z-2007.03-SP5) using the lsi — 10k library. Table 1 displays area consumption per scan chain in NAND-equivalents. Compared to the HCMR, the XHCMR architecture reduces load time overhead and eliminates the need for an additional mask load channel with comparable per-cell area consumption.
TABLE 1 Comparison of HCMR-architecture and XHCMR architecture area (in NAND-equivalents) HCMR cell (with shadow register (cf. [24])) XHCMR cell Combinational area 6.0 8.0 Non-combinational area 25.0 27.0 Total cell area 31.0 35.0
Eliminating Control Signals Using Timing Flexibility
Modern automated test equipment (ATE) supports placement of several strobe positions within a single test cycle for a given channel. A practical solution using timing flexibility in conjunction with an accelerated compactor to reduce the impact of x-values was presented in [19], [20]. In this work, we propose to use the timing flexibility to eliminate the need for an explicit mask control signal.
In the standard approach, the mask enable signal is used to decide whether the current x-mask should be applied at the current test cycle. If the ATE timing flexibility is used, both the masked and the non-masked test response are provided during each scan-out cycle. The decision whether to apply the mask can then be transformed into the decision about the time in which the test response is strobed by the ATE. Hence, the mask enable signal is eliminated while the volume of test data to be evaluated on the ATE remains constant, thus increasing the overall compaction ratio.
Please note that a strobe position is stored on the ATE for each clock cycle and each pin irrespective of whether the strobe position is always the same or not. Hence, using multiple different strobe positions does not affect the strobe position data volume.
To provide both a masked and a non-masked test response within a single cycle, an internal mask enable signal is used. This internal signal is alternating between 0 and 1 with a period equal to a single scan shift cycle, which effectively means that the signal is equal to the scan clock signal.
By programming the strobe positions for each scan cycle, either the masked or non-masked compactor output can be evaluated by the ATE. As only two different strobe positions are required, this technique can be used on all current ATE models.
FIG. 5 displays the selection of strobe positions within a scan cycle. The internal mask enable signal activates the masking logic during the second half of each clock cycle. Correspondingly, two strobe positions s 0 and s 1 have to be defined on the ATE. If the masked test response is to be evaluated, strobing has to be performed at time s 1 . If a masking of the test response is not desired, strobing should be performed at s 0 . In FIG. 5 , the test response in cycle i is evaluated without masking (strobed at s 0 ), while in cycle i+1 the masked test response is evaluated (strobed at s 1 ).
Improving Compaction Ratio Further
Multi-Site Testing
Multi-site testing aims at reducing test cost by testing multiple DUTs in parallel on a single ATE. The parallel testing increases the number of DUTs testable by a single ATE in a given time.
All DUTs can share the same input signals (shared driver [2]), while output signals have to be individually transferred to and processed by the ATE to allow identification of failing chips. The power of multi-site testing stems from the fact that the sharing of input stimuli makes both test stimuli memory and the number of output channels on ATE independent of the number of DUTs tested (cf. FIG. 6 ). The feasibility of testing up to 8 DUTs in parallel on a low pin count ATE in a production environment was demonstrated in [2].
As the number of output channels of the ATE is independent of the number of DUTs tested, parallelism is limited by the number of input channels required to process the test responses of individual DUTs. For that reason, a solution suited for multi-site testing requires a low output pin count on each DUT, while the number of required input pins is of much less importance.
The proposed compactor solution requires only a single 1-bit wide tester channel to transfer the test responses to the ATE. The input channels providing the mask information and test stimuli can be shared. Thus, in multi-site testing the overall compaction ratio of the proposed compactor scales well with the number of DUTs tested in parallel (see experimental results).
Determining an Optimal Scan Chain Configuration
The overall compaction ratio of the XHCMR compactor is the ratio between uncompacted scan-out data and XHCMR compactor input and output data. If the number of scan chains is increased, the amount of output data is reduced as a higher compaction is achieved by the XOR-tree. On the other hand, input data increases, as more scan chains likely cause a longer virtual mask register (VMR). In this section, we present a formula that can be used to compute the optimal number of scan chains in a standard test set-up.
The overall compaction ratio r of the XHCMR compactor for single-site testing without ATE-timing flexibility can be calculated as
r =( p·k·n )/( p·n+ 2 k+p·n+p·l )) (1)
where p is the number of test patterns, k is the number of scan chains, n is the number of flip-flops of the longest scan chain and l is the length of the virtual mask register VMR.
The number of scan chains k for which the maximum overall compaction ratio r is achieved can be computed based on (1). For the sake of simplicity we assume:
All scan chain have (almost) the same length. Thus, the number c of scan-flip flops in the design is approximately c=k·n. The length l of the VMR scales linearly with the total number of scan chains k, m·k, with 0≦m≦1. The reconfiguration of the scan chains does not affect the number of test patterns p. Transforming (1) using these assumptions we obtain
r
=
p
·
c
2
k
+
p
(
2
·
c
k
+
m
·
k
)
(
2
)
Since the values of p, c and m are known (and constant) for a specific design, the nominator is also a constant; therefore, the compression ratio r increases if the denominator of equation (2) decreases.
To find the minimum of the denominator of equation (2) depending on the value of k, we compute the first and second derivative of the denominator d(k), denoted as d(k)′ and d(k)″ in equation (3) and (4):
d
(
k
)
′
=
mp
-
2
cp
k
2
+
2
(
3
)
d
(
k
)
″
=
4
cp
k
3
(
4
)
Using the derivatives d(k)′ and d(k)″ it can be easily shown that equation (5) describes a minimum of d(k) if k>0. Thus, (5) can be used to calculate the number of scan chains for the proposed XHCMR compactor to maximize the compression ratio r.
k
=
2
cp
2
+
mp
(
5
)
In a similar way, formulas to compute the optimal scan chain configuration taking ATE timing flexibility and/or multi-site testing into account can be derived.
FIG. 7 illustrates the compaction ratio r for design B (cf. Table 2) depending on the number of scan chains. The solid line displays the compaction ratio for the standard test set-up with a maximum of 208x at k=833 scan chains. Thus, in this case an optimal scan chain configuration implements 833 scan chains of length ˜125. The curve indicates a wide range of nearly maximal compression. For design B, a compression ratio ≧200 can be achieved with scan chain configurations ranging from 620 to 1100 scan chains, providing considerable flexibility for the test engineer.
Using ATE timing flexibility as presented in section 0, the compression ratio can be further improved peaking at k=589 scan chains with r=294x.
Methodology
To assess the effectiveness of the proposed compactor, its performance on three different industrial designs is investigated. For production test, all three designs use on-chip decompression/compaction provided by a commercial test suite. For our experiments, we used the circuits' original scan chain configuration. Instead of the original compactor, all scan chain outputs are compacted into a 1-bit stream by a XHCMR compactor. Fault coverage was determined by performing a full (stuck-at) fault simulation using the existing stuck-at test set tuned to the commercial test suite.
Two masking approaches were studied: full masking, which masks all x-values, and a second, less restrictive masking method, which we called smart masking. The idea of smart masking is that over-masking of output care bits can be reduced by not masking all x-values.
As output care bit information was not readily accessible, we used the fault simulator's ability to define any given line to be a virtual output to directly observe the scan cells' inputs. The care bit positions were then computed using this information in conjunction with the scan chain configuration data.
Masking information for smart masking was computed using a simple heuristic algorithm. The algorithm processes the patterns sequentially. For each pattern, the mask is initially empty and all yet undetected faults causing errors within that pattern are listed in arbitrary order in the fault queue. The first fault is retrieved from the fault queue. If it is detectable with the current mask, processing continues with the next fault. Otherwise, the mask is extended to allow detection of the fault effect of the considered fault in at least one output slice and the next fault is processed. This is repeated for all faults in the fault queue. While the extension of the mask may cause a masking of faults considered earlier, this heuristic works remarkably well (see experimental results).
The fault coverage was determined by resimulating the test set with the computed masking information. By using the test set actually employed in production testing (albeit with another compactor), fault detection is limited to faults detected by the predefined test set. On the other hand, our results give a realistic impression of the compactor's performance without customized tooling support. It seems likely that a customized ATPG algorithm tailored to the XHCMR compactor would further improve the fault detection rate and/or reduce pattern count.
Experimental Results
In this section, we investigate the performance of the proposed compactor with respect to overall scan cell observability and fault coverage. Basic information for the considered designs is given in table 2. The designs A and B have been presented in [24].
TABLE 2
basic design information
design A
design B
design C
# scan flip-flops
139,597
104,509
33,296
# scan chains
515
1,360
171
longest scan chains
295
82
198
# test pattern
503
9,188
5,654
x-probability
0.43%
1.78%
2.75%
# chains affected by
256
409
5,654
x-values
Table 3 summarizes the resulting overall compaction ratio r (cf. equation (1)) for the given designs using their original scan chain configuration. In standard test set-up (first row) the XHCMR compactor achieves compaction ratios up to 194x (design B) for the given industrial designs. Even for design C, which implements only a small number of scan chains, a compaction ratio of more than 70x is achieved.
Compression ratios can be further increased by using ATE timing flexibility and/or multi-site testing. Testing four DUTs in parallel, compression of up to 544x (design B) can be realized. If ATE timing flexibility is used in combination with 4x multi-site test, compaction ratios ranging from 155x (design C) to 605x (design B) are achieved (last row).
TABLE 3
comp. ratio r for different test setups with XHCMR compactor
compaction ratio r
test setup
design A
design B
design C
standard setup
179.36x
194.57x
71.43x
ATE timing flexibility
275.21x
227.06x
122.66x
MST 4 DUTs
350.86x
544.57x
126.81x
MST4 DUTs + ATE timing
422.89x
605.14x
155.66x
flexibility
In the first experiment we investigated the fraction of observable non-x-cells if all x-values are masked (full masking) using the XHCMR masking logic. A high observability of the scan cells indicates a high fault coverage for a given test set, as (both targeted and non-targeted) errors are then likely to be observed at the compactor's output.
TABLE 4
observable non-x scan cells using full x-masking
design A
design B
design C
observable non-x cells
91.78%
93.30%
91.89%
For all three designs, the fraction of observable scan cells is high, ranging from 91.7% to 93.3% (cf. table 4), in spite of large compaction ratios (171-to-1 to 1360-to-1) and medium (1.78%) to high (2.75%) x-densities. Thus, x-masking has a low impact on the number of observable scan cells even if all x-values are masked during test.
In the second experiment, the fault coverage based on care bit information to investigate the test quality for design C was specifically measured. Using XHCMR with the original scan chain configuration, a compaction ratio of ˜71x is achieved. Two masking approaches were used: full masking masks all x-values during test while smart masking (cf. section IV) is less restrictive. Depending on the masking approach, 99.5% and 99.8% of all faults (100% is equal to all faults covered by original test set (cf. section IV)) are detectable at the compactor output for full masking and smart masking, respectively.
To assess the impact of further increases of the compaction ratio, we also investigated the fault coverage for a higher number of scan chains. To that end, we rearranged the scan chains of design C to get 2, 3, and 4 times as many scan chains as in the original configuration. FIG. 8 depicts the resulting fault coverage for the considered number of scan chains. For both masking methods the fault coverage is very high and independent of the number of scan chains. This indicates that a scan chain configuration which maximizes compression ratio can be chosen without compromising test quality.
An example how the invention is included in the test architecture is given in FIG. 10 .
A new compactor solution for very high compaction ratios (>200x) in presence of many x-values without compromising test quality was presented. This is accomplished by a highly effective x-masking register which only targets scan chains actually capturing x-values. The x-masking information can be loaded in parallel using the DUT's scan chains and built-in decompressor logic.
A novel technique uses ATE timing flexibility to eliminate the need for a mask control channel and increase the overall compaction ratio. The compactor architecture is design independent. Due to its regular structure, it can readily be implemented as a push-button solution.
The proposed single-output compactor is very well suited for multi-site testing, enabling compression ratios of ˜500x in 4-DUT multi-site testing setups.
The features disclosed in this specification, claims and/or the figures may be material for the realization of the invention in its various embodiments, taken in isolation or in various combinations thereof.
REFERENCES
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[6] Chen Wang and Reddy, S. M. and Pomeranz, I. and Rajski, J. and Tyszer, J., “On compacting test response data containing unknown values”, Computer Aided Design, International Conference, pp. 855-862,
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[10] A. Chandra, Y. Kanazwa and R. Kapur, “Proactive Management of X's in Scan Chains for Compression”, Proceedings of 10th Int'l Symposium on Quality Electronic Design, pp. 260-265, 2009
[11] J. Rajski, J. Tyszer, M. Kassab, et al., “Embedded deterministic test for low cost manufacturing test”, Proceedings ITC, pp. 301-310, 2002
[12] Huaxing Tang and Chen Wang and Rajski, J. and Reddy, S. M. and Tyszer, J. and Pomeranz, I., “On efficient X-handling using a selective compaction scheme to achieve high test response compaction ratios”, 18th International Conference on VLSI Design, pp. 59-64, 2005
[13] V. Chickermane, B. Foutz, B. Keller, “Channel masking synthesis for efficient on-chip test compression”, Proceedings ITC, pp. 452-461, 2004
[14] Wang, Seongmoon and Wei, Wenlong, “An Efficient Unknown Blocking Scheme for Low Control Data Volume and High Observability”, IEEE Transactions on Computer-Aided Design of Integrated Circuits and Systems, Vol. 27, pp. 2039-2052, 2008
[15] S. Wang, K. J. Balakrishnan, W. Wei, “X-Block: An Efficient LFSR Reseeding-Based Method to Block Unknowns for Temporal Compators”, IEEE Trans. on Computers, vol. 57, no. 7, pp. 978-989, 2008
[16] P. Wohl, J. A. Waicukauski, S. Patel, M. B. Amin, “X-tolerant compression and application of scan-atpg patterns in a BIST architecture”, Proceedings ITC, pp. 727-736, 2003
[17] P. Wohl, J. A. Waicukauski, S. Patel, “Scalable Selector Architecture for X-Tolerant Deterministic BIST”, Design Automation Conference, pp. 934-939, 2004
[18] E. Gizdarski, “Constructing Augmented Multimode Compactors”, Proceedings of VLSI Test Symposium, pp. 29-34, 2008
[19] Leininger, A. and Fischer, M. and Richter, M. and Goessel, M., “Using timing flexibility of automatic test equipment to complement X-tolerant test compression techniques”, Proc. IEEE International Test Conference, pp. 1-9, 2007
[20] Hilscher, M. and Braun, M. and Richter, M. and Leininger, A. and Gossel, M., “Accelerated Shift Registers for X-tolerant Test Data Compaction”, Conference Proceedings ETS, pp. 133-139, 2008
[21] Arnold, R. and Leininger, A., “Evaluating ATE-equipment for volume diagnosis”, Proceedings ITC, paper 41.1, 2005
[22] Holst, S. and Wunderlich, H.-J., “A diagnosis algorithm for extreme space compaction”, Proc. Design, Automation & Test in Europe Conference & Exhibition, pp. 1355-1360, 2009
[23] H. Vranken, S. K. Goel, A. Glowatz, J. Schloeffel, F. Hapke, “Fault Detection and Diagnosis with Parity Trees for Space Compaction of Test Responses”, Proc. oft the 43rd Design Automation Conference, DAC, pp. 1095-1098, 2006
[24] T. Rabenalt, M. Goessel, A. Leininger, “Masking X-values by Use of a Hierarchically Configurable Register”, Conference Proceedings ETS, pp. 149-154, 2009
[25] N. A. Touba, “Survey of Test Vector Compression Techniques”, IEEE Design & Test of Computers, Vol. 23, pp. 294-303, 2006 | A circuit arrangement for controlling the masking of test and diagnosis data with X values of an electronic circuit with N scan paths, wherein the test data are provided on insertion into the N scan paths by a decompressor with m inputs and N outputs (m<N) and wherein the masked test data are compacted by a compactor with N data inputs and n data outputs and m<N applies is provided. | 6 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates generally to carpenters' tools, and, more particularly, is directed to a carpenter's level having a means for quickly and accurately calibrating a bubble vial within the device.
2. Description of Related Art
The related art is described as follows:
Lemile, U.S. Pat. No. 676,330 describes improvements in the construction of spirit-levels, more especially the manner of mounting the level or glass or vial, and to enable the latter to be readily adjusted vertically from the exterior and to cushion the same.
James, U.S. Pat. No. 778,130 describes improvements in spirit levels, and the object is to provide an improved construction of spirit-level having simple and effective means for attaching the liquid-tube to the support and conveniently adjusting the same.
McCain, U.S. Pat. No. 808,862 relates to leveling and plumbing instruments, and it consists of a chambered bar provided with a pivoted spirit-level and a shaft and cam for adjusting the same to an extent indicated by a pointer on the shaft.
Oswald, U.S. Pat. No. 935,807 describes an improvement in the construction of spirit level attachments, and to provide a simple, inexpensive and efficient device of this character capable of ready adjustment to arrange the bubble tubes in proper position with relation to the instrument, and adapted to permit a bubble tube to be readily removed and replaced by a new tube, should the bubble tube be broken or otherwise impaired through rough handling of the instrument.
Lofberg, U.S. Pat. No. 1,012,668 describes improvements in levels and has for its object the provision of an improved level of simple construction and efficient operation.
Ellison, U.S. Pat. No. 1,298,024 describes a spirit level which may be easily and readily applied to or detached from a level-stock, so that bricklayers, masons, or other artisans who use such leveling instruments may carry the spirit level to and from their work and apply the same to any suitable level-stock.
Hubbard, U.S. Pat. No. 2,487,245 relates to a level of the type used by carpenters, bricklayers, and other workmen erecting buildings and other structures which must be kept perpendicularly and horizontally accurate. If such levels are not carefully handled the casings or rings holding bubble glasses are liable to move out of their proper positions and the level will not be accurate.
Scheyer, U.S. Pat. No. 4,774,767 describes a water level or spirit level having at least one water level member whose angular adjustment relative to the contact surface can be changed. The water level member is rotatably mounted on the level body or a structural part fixedly connected to the level body. The water level member is fixable in the desired angular position relative to the level body or the structural parts connected to the level body. The rotatable water level member has at least one circumferentially extending flange which engages under a clamping jaw. The clamping jaw can be pressed against the surface of the flange by means of a manually operated clamping member.
Dengler, U.S. Pat. No. 4,860,459 describes a bubble level with a hollow metal section that has a circular window, in which a cylindrical level tube for a vertical level can be inserted with a positive interlock in the axial direction and can be fastened with a material interlock. A level support is inserted into the hollow section in the axial direction. The support has a cylindrical seat aligned with the window, to receive a level holder that bears a level. An interlock device is disposed between the level support and the level holder. By means of this interlock device, the level holder is mounted axially fixed, but rotatable until it is fastened by the material interlock.
Bird et al, U.S. Pat. No. 4,999,921 describes an adjustable spirit level having a plurality of spirit levels therein. A first spirit level measures vertical orientation, a second adjustable spirit level is adjustable to a true horizontal position, and a third spirit level is adjustable to any desired position between vertical and horizontal. The second level may be adjusted with a rotatable cam-shaped end piece secured within the level body, while the third level is ratcheted to a predetermined angle. The third level may be held in place by a spring member biasing the level against the level body.
Tate, U.S. Pat. No. 5,111,589 describes an adjustable plumb level formed from an I beam with wood side panels. A circular hole is formed through the I beam and side panels, within which an indicating mechanism is disposed. The indicating mechanism is easily replaceable so that the present invention can be used as a plumb or a level.
Tate, U.S. Pat. No. 5,177,873 describes an adjustable plumb level having a first gear driven by a second gear. The second gear has a smaller external diameter than does said first gear. The second gear is operatively coupled to first gear so that when an external force causes the second gear to rotate, the first gear also rotates. The first gear includes a straight vial disposed in the center thereof.
The prior art teaches the use of an adjustable vial and of a means for adjustment of the vial position in order to calibrate the leveling device. However, the use of a spring loaded biasing means is not taught and the mounting of a vial so as to pivot about a third point of contact between the vial and the leveling frame appears to be novel in the art. There is a need for a general purpose leveling tool that is able to sustain the physical shocks encountered in normal use as well as the occasional severe shocks encountered under unusual circumstances such as when the tool is dropped. There is a need for a leveling tool that is able to be easily and quickly calibrated as required. The present invention fulfills these needs and provides further related advantages.
SUMMARY OF THE INVENTION
The present invention is a level and plumb indicating device, and more generally, one for indicating the orientation of a surface. The device provides a novel construction so as to be able to maintain alignment between a bubble vial and the leveling frame structure. A box cylindrical frame houses a bubble level held in a housing which is supported within the box frame at three points. First, the housing is supported rotationally on a cam pin so that the bubble may be positioned at will over a range of motion about the cam pin. Second, the housing is engaged by a biasing device to move in a preferred direction about the cam pin. Third, the housing provides a pivot point upon which the housing sits against the inside of the frame due to the pressure exerted by the biasing device. At any time the housing is therefore supported within the housing at three points; the cam pin, the bias device and the pivot point. When the bubble vial must be adjusted to align the vial with the leveling frame it is easily rotated by engaging the cam pin.
Therefore it is one capacity of the present invention to provide an accurate means for indicating level or plumb surfaces in that the frame of the device is aligned with a bubble vial so that with the frame in contact with a flat surface a bubble within the bubble vial is aligned between a pair of spaced apart alignment lines on the bubble vial in such manner as to enable a skilled craftsman to read when the flat surface is in a plumb or level condition.
It is another capacity of the present invention to provide such a means for indicating level or plumb surfaces where the alignment of the vial and the frame of the device is manually adjustable so as to eliminate any error in the device.
It is a further capacity of the present invention to provide such a means for indicating level or plumb surfaces where the alignment of the vial and the frame of the device is manually adjustable through the use of an eccentric rotating surface.
It is yet a further capacity of the present invention to provide such a means for indicating level or plumb surfaces where the vial is held within the frame of the device by three points of contact, a rotational cam pin, a pivot ridge on the vial housing, and a biasing means forcing the vial housing to press the pivot ridge against the frame. Because two of the three points are contacts only with no engagement, there are few surfaces to wear, no chance for parts to become loose in their sockets, etc. This provides a distinct advantage over the prior art in that the assembly is able to withstand greater mechanical shocks without becoming misaligned
Other features and advantages of the present invention will become apparent from the following more detailed description, taken in conjunction with the accompanying drawings, which illustrate, by way of example, the principles of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
The accompanying drawings illustrate the invention. In such drawings:
FIG. 1 is a plan view of the present invention showing a box frame of the invention with a leveling device within the frame;
FIG. 2 is a partial elevational view taken along line 2--2 of FIG. 1;
FIG. 3 is plan view taken in the direction shown by line 3--3 in FIG. 2;
FIG. 4 is a plan view according to FIG. 1 showing the leveling device with a top wall shown partially cut-away to view details of the leveling device within the frame in a nominal position of adjustment;
FIG. 5 is a plan view according to FIG. 4 showing the leveling device in a first extreme position of adjustment; and
FIG. 6 is a plan view according to FIG. 4 showing the leveling device in a second extreme position of adjustment.
DETAILED DESCRIPTION OF THE INVENTION
The present invention is a surface orientation sensing device as shown in FIG. 1. A leveling frame 10 is preferably constructed as an extruded structural box cylinder. The frame 10 provides a rigid plate means 11, preferably a pair of rigid plates 12 and 14 (FIG. 2) forming opposing sides of the box cylinder, the plates being in spaced-apart, fixed positions as the box cylinder is a rigid body.
The plate means 11 can alternately be a single plate or other possibilities which are in accordance with the meaning of the present structure. The plates 12 and 14, each have a cam hole 16A and 16B formed through the plates 12 and 14 respectively, the cam holes being mutually concentric in opposing positions as best seen in FIG. 2. Adjacent to the cam holes 16A, B is an aperture means 18 for viewing a leveling vial 20. The aperture means 18 comprises a single viewing hole in one of the plates as shown in FIG. 1, or a pair of such viewing holes, one in each of the plates in opposing positions so the vial 20 may be viewed from the top or from the bottom of the frame 10 as best seen in FIG. 2. In FIG. 1 the viewing hole is round, but such viewing holes may be any shape or size as may allow viewing of the leveling vial 20. The leveling vial 20 is shown in FIG. 1 in a position where the vial 20 might be used for determining if a surface of a vertical beam, for instance, is plumb. The leveling vial 20 may also be positioned, within the leveling frame 10, at 90 degrees with respect to the position shown in FIG. 1 so that the present device might be used to determine if a beam surface is in a horizontal or level condition. The leveling frame 10, may in general, have more than one vial 20 so as to be used alternately for either of these applications.
Within the leveling frame 10, a vial assembly 30 provides, a vial holder body 40 engaging the leveling vial 20 within it. The holder body 40 further has a pivoting means 50. The pivoting means 50 is preferably a single ridge 50A which is formed integrally with the vial holder body 40, or the pivoting means 50 may be a pair of side-by-side, parallel ridges 50A and 50B, integral with the vial holder body 40 as shown in FIGS. 4-6. In these figures, the ridges 50A and 50B are positioned on the side surface 40 S of the vial holder body 40 and extend linearly into the plane of FIGS. 4-6.
Please note that the vial holder body 40 is of such size and shape as to be easily and quickly inserted into the leveling frame 10 from one of the frame's open ends, without tools. Note also, that the vial holder body 40 is a symmetrical part so that it may be inserted into the body 40 with either of its two major side surfaces facing upwardly. A biasing means 60 communicates with the leveling frame 10 for directionally urging the pivoting means 50 into communication with the leveling frame 10, i.e., placing it in contact with the side wall 72. The biasing means 60 preferably comprises an elongate finger 62 integral with and extending from the vial holder body 40, the finger supporting a coil spring 64 as shown in FIGS. 4-6. In this embodiment, the spring 64 is always in a state of compression so that it urges the vial holder body 40 away from the side wall 70 and toward the side wall 72. In this way, one or both of the ridges 50A, 50B are always in contact with side wall 72. When pivoting means 50 includes two ridges as shown in FIGS. 4-6, it is clear that the ridges complement each other, in that each takes part of the load induced by the bias means 60 thereby reducing the effects of material creep, stress induced strain, elastic flow of the materials of construction and other effects. This enables the invention to have a longer life and maintain greater accuracy in alignment over that life.
An elongate cam pin 80 provides a rotational support means 80A and 80B for engaging the cam holes 16A and 16B respectively in plates 12 and 14. The rotational support means 80A,B preferably fit tightly into their respective cam holes 16A,B and are able to rotate but with a certain amount of frictional interference or drag so that the cam pin is not easily rotated unintentionally. In this way rotation by purposeful effort is achieved but not inadvertent rotation. A camming surface 80C is adapted by its size for frictional rotational engagement within a cam pin engagement hole 42 in the vial holder body 40. The camming surface 80C is eccentrically located with respect to the rotational support means 80A,B and therefore, also with respect to the cam holes 16A,B. This is best seen in FIG. 2. A tool engagement means 82, such as a hexagonal wrench socket, as shown in FIG. 1, is formed in the cam pin 80 for rotating the cam pin 80 in the cam holes 16A,B and therefore also in the cam pin engagement hole 42. As the cam pin 80 rotates, the vial holder body 40 moves eccentrically with it. The rotational support means 80B is shown in FIGS. 4-6 by a circle with hidden lines since it is below the cam pin 80 in these figures. Notice that the support means 80B takes different positions relative to the engagement hole 42 depending upon the rotational position of the cam pin 80. Notice also that the vial holder body 40, and so also the vial 20 itself takes various positions, i.e., changes position with rotation of the cam pin 80. In this way, the vial 20 is able to adjust for any loss of correspondence between the vial 20 and the leveling frame 10 due to temperature changes, strains set up from rough handling or other causes. Therefore with rotation of the cam pin 80, the vial assembly 30 is movable for aligning the leveling vial 10 with the leveling frame 10. In the figures it is seen that the axis of rotation of the cam pin 80 is aligned, that is, parallel, with the axis of the aperture means 18. Preferably, the cam pin 80 and the engagement hole 42 together provide a detent means 80D so as to enable the vial holder body 40 to sit within the leveling frame 10 in a preferred position, i.e. centrally. The detent means 80D, as shown in FIG. 2, is formed preferably as an annular groove in the cam pin 80 and a corresponding annular ridge in the vial holder body 40, but any other detent means serving the same purpose may be employed to the same advantage.
While the invention has been described with reference to a preferred embodiment, it is to be clearly understood by those skilled in the art that the invention is not limited thereto. Thus the scope of the invention is to be interpreted only in conjunction with the appended claims. | A carpenter's level provides a three point mounting for a vial housing within a level frame. The frame is a square cylinder, preferably an extruded part. The vial housing mounts within the frame on a pivot pin and is biased by a spring toward one side wall of the frame where the vial housing abuts the side wall on a pivot ridge extending from the housing. The pivot pin provides a camming surface so that the vial housing may be rocked slightly to a new position in order to re-align the vial housing within the frame. | 6 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] This disclosure relates to a sensor assembly and, more particularly, to an adjustable sensor assembly for determining the location of at least one edge of print media.
[0003] 2. Description of the Related Art
[0004] Printer sensors are typically used to determine the presence and location of the edge of the print media during operation. The printer requires a reference position in order to begin printing. This ensures that an appropriate location is available in the print area and that edge or over the edge printing does not occur. It is also desirable to be able to distinguish between labels, for example, on a continuous supply roll. The printer, therefore, can determine the appropriate start and finish locations on the print media in order to place a printed bar code, for example, on the appropriate label and advance the print media to the next location in a reliable and efficient manner.
[0005] Sensors are used to determine the position of a label within a print head, that is, the distance that the print media has advanced. Traditional optical means of detecting the position of labels, for example, include a “through beam” system wherein an emitter is placed on one side of the label and a detector is placed on the reverse side. There are two methods of using “through beam” technology. These include gap and stripe indication. In the gap indication method, light is passed through the print media and gaps between labels are sensed as a change in light intensity.
[0006] Stripe indication senses a black stripe printed on either side of the print media. When the indicator stripe is present, the light from the emitter does not pass through the labels and is not detected by the detectors. Stripe sensing can also be performed from one side of the media. A light source shines on the print media and the reflection is sensed to determine the position of the print media.
[0007] In order for the position sensor to work properly the black stripe must be in line with the sensor. When various print media sizes are used, printers are typically provided with an additional sensor at each location for each size of the print media. This increases the complexity and cost for the printer, however, since numerous sensors are needed to accommodate print media of different sizes. Some printers typically require that the single sensor be removed and remounted each time a different size media is used.
[0008] Printer versatility is desirable. Therefore, a need exists for a sensor, which can be easily adjusted to allow the use of various sized print media in the printer. A further need exits for such a sensor wherein the sensor is readily accessible and therefore does not require difficult disassembly steps in order to adjust the sensors position.
[0009] Prior to the present disclosure, significant advances have been made in the prior art. An example of these improvements is the subject of U.S. Pat. No. 6,396,070 to Christensen et al., the contents of which are hereby incorporated by reference in their entirety.
SUMMARY OF THE INVENTION
[0010] A print media sensor mounting assembly includes a housing having a sensor mounting element. The sensor mounting element has a sensor position movably mounted therein for movement of the sensor position to a plurality of predetermined positions corresponding to a width of a print media web.
[0011] In particularly preferred embodiments, the printer sensor assembly includes a base defining a slot. A slide, for mounting a sensor therein, is slidably mounted within the slot and has at least one bump. A plurality of detents have predetermined locations formed within the base adjacent to the slot such that the slide is adjustably positioned and releasably secured in a predetermined location when at least one bump engages the detents.
[0012] The sensor assembly may include a distal end portion of the slide having lateral extensions extending perpendicularly from a longitudinal axis and engaging a lower surface of the base. The lateral extensions may have at least one bump disposed thereon. The lateral extensions may be used to provide a force for holding bumps within a detent position, wherein the lateral extensions extend downward defining a bowed structure such that when the bowed structure is deflected a force is exerted. A cover plate may be used for attaching to the base such that the bowed structure is deflected to provide a preload force for holding bumps within a detent position. The sensor assembly can include a light sensor.
[0013] In another embodiment, the printer sensor assembly includes a sensor base that defines a recess for receiving the sensor, the cable assembly, and the sensor slide. The sensor slide is slidably mounted to the sensor base and is adapted to receive a sensor. The sensor slide includes at least one arm having a button at its distal end for releasably engaging the detents of the sensor base. By releasing the button from the detent and applying motive force along the longitudinal axis of the sensor base, an operator can reposition the sensor slide to sense print media of a different size. The sensor operates in the same manner as in the previous embodiment.
[0014] A further embodiment of the sensor assembly replaces the arm and detent structure of the previous embodiment with a threaded rod and wheel structure. The sensor slide is threadably engaged with the threaded rod and moves along the longitudinal axis of the sensor base as the threaded rod is rotated. The operator rotates the wheel that in turn rotates the threaded rod thereby transferring motive force to the sensor slide while the threaded rod is not movable in the longitudinal direction. In lieu of manual rotation of the threaded rod, an electric motor may be coupled to the threaded rod thereby allowing remote signals to control the motor and position the sensor slide in sensor assembly.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] The invention will be described in detail in the following description of embodiments with reference to the following figures wherein:
[0016] [0016]FIG. 1 is an exploded view showing the components of an adjustable sensor assembly;
[0017] [0017]FIG. 2 is an isometric view of a sensor base;
[0018] [0018]FIG. 3 is an isometric view of a sensor slide;
[0019] [0019]FIG. 4 is an isometric view of a lower surface of a first end portion of the sensor slide shown in FIG. 3;
[0020] [0020]FIG. 5 is a bottom view of the sensor base;
[0021] [0021]FIG. 6 is a sectional view of the sensor base sectioned along the line indicated in FIG. 5;
[0022] [0022]FIG. 7 is an isometric view of an assembled adjustable sensor assembly;
[0023] [0023]FIG. 8 is an end view of two sensor assemblies in placed in an operative position relative to one another;
[0024] [0024]FIG. 9 is an exploded view of two sensor assemblies being installed within a print media feed;
[0025] [0025]FIG. 10 is an isometric view of two sensor assemblies installed within a print media feed according to a first embodiment of the subject invention;
[0026] [0026]FIG. 11 is a perspective view of two sensor assemblies installed within a print media feed showing a second embodiment of the subject invention;
[0027] [0027]FIG. 12 is a perspective view of two sensor assemblies installed within a print media feed showing a third embodiment of the subject invention;
[0028] [0028]FIG. 13 is an exploded view showing the components of a first embodiment of an adjustable sensor assembly illustrating a first embodiment of the subject invention;
[0029] [0029]FIG. 13A is an exploded view showing the components of a second embodiment of an adjustable sensor assembly showing a second embodiment of the subject invention;
[0030] [0030]FIG. 14 is an isometric view of two sensor assemblies installed within a print media feed according to a second embodiment of the subject invention; and
[0031] [0031]FIG. 14A is a side cross-sectional view of first and second sensor assemblies according to a second embodiment of the subject invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0032] The present disclosure describes an adjustable sensor assembly for printers. In order to sense the boundaries between labels, for example, or the position of an indicator stripe, sensors are installed inside a printer in an area where a print head is located. The adjustable sensor provides a sensor slide, which adjusts the location of a sensor mounted thereto. A sensor base provides a plurality of preset locations and locks the slide and sensor in place when the desired location is set. The plurality of preset locations corresponds to standard size print media.
[0033] Referring now in specific detail to the drawings in which like reference numerals identify similar or identical elements throughout the several views, and initially to FIG. 1, one embodiment of an adjustable sensor assembly constructed in accordance with the present disclosure is shown generally as adjustable sensor assembly 10 . Adjustable sensor assembly 10 includes a sensor base 14 , a sensor slide 16 , a cover plate 12 , and a sensor 20 .
[0034] Referring to FIG. 2, sensor base 14 has a front face 22 , first end portion 24 , and a second end portion 26 . Front face 22 of sensor base 14 has a slot 28 on first end portion 24 with a plurality of opposing detent pairs 30 formed at a lateral boundary 27 of the slot 28 . Slot 28 is formed longitudinally through sensor base 14 . Front face 22 forms a recess 32 on second end portion 26 along the longitudinal axis of sensor base. Recess 32 extends below front face 22 and remains parallel thereto. Recess 32 forms an open end 34 and a closed end 36 . Closed end 36 is located on second end portion 26 . Open end 34 leads into slot 28 and communicates therewith. A pair of slots 38 is located adjacent to both side of recess 32 and extend substantially the length of recess 32 . The preferred material for sensor base 14 is a moldable polymer.
[0035] Referring to FIGS. 3 and 4, sensor slide 16 has a first end portion 50 , a second end portion 52 , an upper surface 54 , and a lower surface 56 . Second end portion 52 extends longitudinally from first end portion 50 . First end portion 50 has a center hole 60 therethrough and extended clips 62 extending from lower surface 56 for securing a sensor (not shown) adjacent to center hole 60 . Center hole 60 is provided to allow light signals to pass therethrough. Power and signals to the sensor are provided through a cable 18 . See FIG. 9. The sensor is mounted on lower surface 56 of first end portion between extended clips 62 during operation. Cable 18 is connected to the sensor and is routed longitudinally through the second end portion 52 and secured within sensor slide 16 by wire guides 80 . First end portion 50 has extensions 46 extending downward for slidably engaging slot 38 of sensor base 14 . Second end portion 52 has lateral sides 64 . Each lateral side 64 has a step 66 formed thereon. Second end portion 52 has a finger pad 68 disposed on upper surface 54 adjacent to an end 70 of sensor slide 16 . Two bumps 72 are formed on lateral sides 64 on a top surface 76 of steps 66 . End 70 also includes lateral extensions 74 disposed perpendicularly from the longitudinal axis and remaining below top surface 76 of steps 66 . The preferred material for sensor slide 16 is a moldable polymer.
[0036] Referring again to FIG. 1, sensor slide 16 fits into recess 32 and slot 28 such that lateral extensions 74 and top surface 76 of steps 66 engage a lower surface 58 of sensor base 14 . See FIG. 5. Extensions 46 clip into slots 38 , which act as guides for sensor slide 16 and secure slide 16 to sensor base 14 . Sensor base 14 supports sensor slide 16 and allows longitudinal translation between detent pairs 30 of sensor base 14 . Opposing pairs of detents 30 are formed to receive two bumps 72 in order to set a location for sensor slide 16 and sensor 20 . When cover plate 12 is installed on sensor base 14 , lateral extensions 74 engage the surface of cover plate 12 . Lateral extensions 74 elastically deflect placing an upward force on second end portion 52 of sensor slide 16 . This force maintains bumps 72 in pair of detents 30 locking sensor slide 16 in a fixed location. If adjustment of sensor slide 16 is desired, finger pad 68 is depressed releasing two bumps 72 from pair of opposing detents 30 . Sensor slide 16 can now be repositioned and locked in place by releasing finger pad 68 at a new detent position.
[0037] In a preferred embodiment, eight pairs of detents 30 are positioned along slot 28 . The detents 30 are spaced from a predetermined reference location to allow adjustment of sensor 20 for standard sized print media, for example, bar coded labels. It is contemplated that slot may have more detents 30 to allow more versatility of the printer. Detents 30 are marked to identify each location to provide the user with a set of reference labels 29 , for example, letters, to more easily determine the appropriate setting for the print media being used. It is further contemplated that sensor slide 16 can be locked in place at preset positions in a variety of ways. For example, sensor slide can have tabs laterally disposed for locking tabs into recesses within the slot.
[0038] Referring now to FIGS. 5 and 6, cover plate 12 (FIG. 1) is installed onto lower surface 58 of sensor base 14 . Lower surface 58 of sensor base 14 is equipped with clips 82 and a pin 84 in order to secure cover plate 12 to sensor base 14 . Cover plate 12 defines an opening 86 on one end to allow cable 18 to pass. Sensor base 14 may be mounted to a surface adapted to receive clips 82 and pin 84 without the use of cover plate 12 . The surface functions as cover plate 12 providing engagement to lateral extensions 74 to maintain bumps 72 within pair of detents 30 .
[0039] Referring to FIG. 7, an adjustable sensor assembly 10 is assembled showing sensor slide 16 mounted within slot 28 and recess of 32 of sensor base 14 . Cover plate 12 is shown mounted to sensor base 14 .
[0040] Referring to FIG. 8, a working configuration is shown. A first sensor assembly 10 a is installed above print media 90 and a second sensor assembly 10 b is placed below print media 90 . Sensor base 14 has rounded edges 94 to aid in passing print media 90 therebetween. First sensor assembly 10 a transmits a light impulse from sensor source (shown as part of sensor 16 a ) through print media 90 to second sensor assembly 10 b where the signal is received by a detector (shown as part of sensor slide 16 b ). Sensors can be used to determine if print media is present, to read a position indicating stripe, to determine the location of the print media edge or to measure the presence of gaps for labels. When print media is changed, for example, a 4 inch wide label is replaced in printer by a 3.5 inch label. Sensor slides 16 a and 16 b are repositioned to corresponding detent positions to accommodate the new size of print media 90 .
[0041] Power and signals to the sensor source and detector are provided through cable 18 . Cable 18 is connected to the sensor source or detector and secured within sensor slide 16 by wire guides 80 . See FIG. 3. Cable 18 passes around recess 32 to a second end 42 of sensor base 14 . Second end 42 defines an opening 44 to allow cable 18 to pass therethrough. Opening 86 in cover plate 12 corresponds to opening 44 and provides additional clearance for cable 18 . Slack must be stored within cable 18 to allow adjustment of sensor slide 16 within sensor base 14 . This is accomplished by routing cable 18 around recess 32 . Cable 18 is similarly routed in second sensor assembly 10 b.
[0042] It is also contemplated that sensor assembly 10 can be used with a reflected light sensor, in which case, the sensor is both a source and a detector of light, requiring only one sensor assembly 10 . In this case, print media 90 passes over sensor assembly 10 reflecting light back to sensor assembly, which is read and processed.
[0043] Referring now to FIG. 9, a first sensor assembly 10 a is installed above a print media feed 92 and a second sensor assembly 10 b is placed below print media feed 92 . Sensor assembly 10 a and 10 b each have a pair of threaded holes 96 at each end for securing to print media feed 92 by screws 98 . First sensor assembly 10 a mounts to a top 100 of print media feed 92 and second sensor assembly 10 b mounts to a bottom 102 of print media feed 92 .
[0044] Referring to FIG. 10, top 100 rotates up to allow access to easily adjust sensor assemblies 10 a and 10 b . During operation, top 100 is rotated down so that the sensor source of sensor assembly 10 a can communicate with the sensor detector of sensor assembly 10 b as shown in FIG. 8. In preferred embodiments, a light emitting diode or laser acts as a sensor source.
[0045] [0045]FIGS. 11 and 13 illustrate an additional embodiment of the adjustable sensor assembly 210 . Referring to FIG. 11, the sensor assembly, or adjustable sensor assembly, 210 is shown installed in a print media feed. Under normal circumstances, a pair of sensor assemblies 210 a , 21 b will be installed in a print media feed as shown. Each sensor assembly 210 a , 210 b includes an elongated sensor base 214 having its longitudinal axis positioned perpendicular to the path of the print media. The sensor base 214 includes a front wall 222 and sidewalls 224 , 226 that further define a recess 232 . The recess 232 is dimensioned to receive the sensor slide 216 . A pair of spaced apart channels 212 is disposed along the longitudinal axis of the sensor base 214 with each channel 212 extending from side wall 226 towards side wall 224 and forming part of the uppermost perimeter of recess 232 . A plurality of detents 230 is disposed along interior wall 228 below channel 212 .
[0046] The sensor 220 and cable assembly 218 are slidably received by the recess 232 for motion along the longitudinal axis of the sensor base 214 . Preferably, cable assembly 218 includes flex cable 219 to avoid bunching up of the cable as the sensor 220 moves relative to the sensor base 214 . Directly above the sensor 220 is a sensor slide 216 that includes a centrally located grille 244 . The grille 244 is centrally located on the sensor slide 216 and has a plurality of slots that permit the transmission of light signals to and from the sensor 220 . The operation of the sensors 220 is the same as in the previous embodiment with the data being sent and received along cable 218 . In addition, the sensor slide 216 has a number of feet 242 that are slidably engaged in the channels 212 to maintain the relative orientation and position of the system components. A stud 234 and receptacle 236 are disposed on side walls 224 , 226 for ensuring the correct physical alignment of the sensor assembly 210 a , 210 b when it is installed in a print media feed. Each sensor assembly 210 a , 210 b is constructed and installed such that the stud 234 of the first sensor assembly will positively align with the receptacle 236 of the second sensor assembly 210 b , 210 a thereby properly aligning the sensors 220 of the respective sensor assemblies 210 a , 210 b . It is envisioned that other complementary structural combinations could accomplish this as well without departing from the scope of the invention. For example, a complementary arrangement of posts and holes or interleaving arms disposed along the top surface of each sidewall would achieve the same goal.
[0047] As in the previous embodiments, the sensor 220 is movable along the longitudinal axis of the recess 232 with a predetermined discrete stop occurring at each detent's 230 position. Along one side of the sensor slide 216 is an arm 238 having a button 240 at its distal end. The arm 238 is flexible and, in its rest position, is sufficiently tensioned such that it moves towards interior wall 228 to ensure positive engagement with each detent 230 . To reposition the sensor slide 216 , the operator moves the arm 238 so that it deflects away from the interior wall 228 and the button 240 is disengaged from the detent 230 . Applying force along the longitudinal axis of the sensor base 214 , the operator slides the sensor slide 216 to the desired position and releases the arm 238 . The natural tension of the arm 238 causes the button 240 to move towards interior wall 228 and positively engage with the detent 230 for securely positioning the sensor slide 216 .
[0048] Detection of the print media in this embodiment of the subject invention is identical to that of the first embodiment. Briefly, first and second sensor assemblies 210 a , 210 b are disposed in the print media feed as shown in FIG. 11. Thusly, the sensor 220 of the first sensor assembly 210 a faces the sensor 220 of the second sensor assembly 210 b . Sensors can be used to determine if print media is present, to read a position indicating stripe, to determine the location of the print media edge, or to measure the presence of gaps for labels. When print media is changed, sensor slides 216 are repositioned to corresponding detents to accommodate the new size of print media.
[0049] Power and signals to the sensor source and detector are provided through flex cable 219 . Cable assembly 218 is connected to the sensor source or detector and secured within sensor slide 216 . Slack must be stored within cable assembly 218 to allow adjustment of sensor slide 216 within sensor base 214 . This is accomplished by routing cable assembly 218 around recess 232 . Cable assembly 218 is similarly routed in second sensor assembly 210 b.
[0050] Referring now to FIGS. 12 and 13A, a further embodiment of the sensor assembly is shown. In lieu of the predetermined positions of the detent style structure, this embodiment utilizes a threaded rod 318 that extends along the length of the sensor assembly 310 and protrudes through sidewall 324 . Furthermore, for this embodiment, the flexible arm attached to the sensor slide has been removed and so have the detents along the interior wall. Attached to the threaded rod 318 is a wheel 320 for adjusting the position of the sensor slide 316 . In this embodiment, the sensor slide 316 is threadably engaged to the threaded rod 318 . As the wheel 320 rotates, the threaded rod 318 rotates and transfers the rotational motion of the threaded rod 318 to the sensor slide 316 and moves it along the longitudinal axis of the sensor assembly 310 . This is advantageous because it allows the operator to precisely position the sensor in the recess 232 of the sensor base 314 instead of relying on predetermined detent locations. It is envisioned that the wheel 320 is normally disengaged from the threaded rod 318 and a positive action by the operator is required to engage the threaded rod 318 . This arrangement prevents inadvertent motion of the sensor slide 316 . For example, the wheel 320 may be spring loaded requiring the operator to push or pull the wheel 320 prior to rotating the threaded rod 318 . Alternately, the wheel 320 may be removable and only attached to the end of the threaded rod 318 when repositioning of the sensor slide is necessary. In this instance, the wheel 320 is attached to the end of the threaded rod 318 using a setscrew, cotter pin or other similar structures that positively engage the wheel 320 to the threaded rod 318 .
[0051] In addition, a gear 330 is disposed in each sensor assembly 310 a , 310 b and is operatively coupled to each threaded rod 318 . As illustrated in FIGS. 12, 13A, and 14 A, each gear 330 is configured and adapted to extend vertically through a slot 348 in a top surface 346 . Preferably, each gear 330 is disposed substantially adjacent to sidewall 224 and substantially perpendicular to the threaded rod 318 . Configured thusly, when the sensor assemblies 310 a and 310 b are moved towards each other, studs 234 engage recesses 236 to align the sensor assemblies 310 a and 310 b . Further still, gears 330 a , 330 b of the first and second sensor assemblies 310 a , and 310 b releasably engage each other. During operation, rotation of threaded rod 318 a in first sensor assembly 310 a rotates gear 330 a . Since gears 330 a and 330 b are engaged, as shown in FIG. 14A, rotational motion of gear 330 a imparts rotational motion to gear 330 b thereby providing rotational motion to threaded rod 318 b . Due to the advantageous arrangement of gears 330 a , 330 b and threaded rods 318 a , 318 b , sensor slides 316 are moved along the longitudinal axis of the sensor base 314 in unison, thereby maintaining their alignment to each other as they move relative to the sensor base 314 .
[0052] Except for the alternate means of positioning the sensor slide, the remaining aspects of the sensor assembly operation are as in the previous embodiment. The upper and lower sensor assemblies 310 a , 310 b are preferably of the type utilizing the threaded rod 318 and wheel 320 arrangements. In addition, the structure employing the threaded rod 318 and wheel 320 assembly is easily adaptable for motorized operation by the optional incorporation of a small electric motor 350 , as illustrated in FIG. 14A. Further still, the addition of an electric motor 350 provides the foundation for remotely moving the sensors. By interfacing the electric motor 350 with the associated circuitry of the print media feed and/or the control wiring of the printer, remote signals can reposition the sensor assemblies 310 a , 310 b individually or in unison.
[0053] Referring now to FIG. 14, a first sensor assembly 310 a is installed above a print media feed 392 and a second sensor assembly 310 b is placed below print media feed 392 . First sensor assembly 310 a mounts to a top 300 of print media feed 392 and second sensor assembly 310 b mounts to a bottom 302 of print media feed 392 . During operation, top 300 is moved generally downward so that the sensor source of sensor assembly 310 a can communicate with the sensor detector of sensor assembly 310 b . In preferred embodiments, a light emitting diode or laser acts as a sensor source.
[0054] Having described preferred embodiments of a novel sensor assembly (which are intended to be illustrative and not limiting), it is noted that modifications and variations can be made by persons skilled in the art in light of the above teachings. For example, it is contemplated that the sensor assembly can have remote adjustment capability. It is therefore to be understood that changes may be made in the particular embodiments of the invention disclosed which are within the scope and spirit of the invention. | A print media sensor mounting assembly includes a housing having a sensor mounting element. The sensor mounting element has a sensor position movably mounted therein for movement of the sensor position amongst a plurality of positions corresponding to a width of a print media web. | 7 |
BACKGROUND OF THE DISCLOSURE
This disclosure is directed to a sensor for converting certain measurements into a signal suitable for laser transmission, and further sets forth a laser which appropriately encodes the sensed variable, transmits the encoded variable, and enables the transmitted signal to be received. It is particularly adapted for use in systems involving high impact e.g., in using a steam powered pile driver or hammer to drive a piling. In this particular example, a piling of any length and substantial size is subjected to severe impact or shock loading. In a typical situation, assume that a steam powered hammer is positioned to drive a long pile through a pile jacket into the mud bottom beneath a body of water with mud of any depth and water of typical depth. The piling is subjected to severe impact or shock loading which can peak at many g's. With each stroke of the hammer, the hammer falls at instantaneous high velocity, delivers impact to the piling. Several variables are important. One variable is the rate of movement of the gauge position on the piling. Another important factor may be the velocity of the hammer that strikes the piling. There is some energy loss between hammer and piling so that the motion of the hammer and motion of the piling are different. Another important factor is the stress wave which propagates along the piling. This normally has the form of strain which can be observed in the piling.
In the latter instance, the strain is typically measured by a strain gauge on the piling. The present invention enables strain gauge measurements to be obtained away from the piling through wireless communication. More specifically, the present apparatus utilizes a laser telemetry system to encode by means of the laser any data of interest in the laser signal. This arrangement conveys the strain or other data to a remote location where a receiver can be located, thereby enabling the strain or other information to be received, amplified, demodulated as appropriate and converted into data for subsequent analysis and processing.
The strain gauge function is accomplished by means of changing the length of the laser resulting in a change of frequency output of the laser. One application of this concept is to an apparatus comprised of an injection laser diode (ILD). It is supported on a substrate. The substrate is affixed to the piling. The substrate is then subjected to the strain of the piling and thereby applies strain to the ILD. The strain of the laser cavity, a change in length per unit length, causes a shift in the lasing frequency. The unstrained laser has a nominal lasing frequency. As strain occurs, the lasing frequency shifts to thereby encode the strain in the frequency. The strain in the piling is directly proportional to the change in frequency divided by the nominal frequency. This variable is transmitted as a function of frequency and hence is an FM system where the strain is encoded in frequency change, not amplitude. The shift in frequency is discerned from the laser beam. A receiver located remote from the laser transducer picks up the beam for data retrieval.
In addition to this, the laser can be used to determine movement of the piling to which it is attached. It also can be used to measure hammer velocity. One lob in the field pattern transmitted from the laser can be used to measure the distance from the laser to the remote receiver to thereby provide an indication of movement of the laser position on the piling. The particle velocity in the piling, with respect to the position of the remote receiver, is then determined by means of a Doppler effect. A different lob in the field pattern transmitted from the laser can be used so that hammer velocity is determined by means of a Doppler effect. To this end, the laser transmits the signal to a reflector mounted on the hammer which is reflected to a receiving system, encoding hammer velocity in a Doppler shift.
Another important application of the present apparatus is in the measurement of stresses and vibration occurring in rotating machinery. A typical rotating machine might be a motor, generator, compressor or turbine. Another type machine might be a centrifugal pump. In this context, a machine typically has an external fixed cabinet or housing which encloses the rotating parts. The rotating parts are subjected to stress and vibration. Heretofore, it has been possible to obtain such data and send it out of the machine either by means of commutated conductors or perhaps through an FM telemetry system. The present apparatus however overcomes the limitations of such apparatus and provides a system combining the sensor with the telemetry linking equipment. The sensor is preferably a laser which responds by forming modulated laser output data and is thereby able to transmit free of commutator for reception adjacent to the rotating machinery. For instance, assume that the rotating machinery is susceptible of significant damage and harm in the event that the bearings of the shaft of the rotating machinery were to fail. Partial bearing failure is typically indicated by vibrations coupled through the shaft to the rotating components of the machinery. Other variables of interest can be coupled through the laser for reception remote from the rotating components free of commutated connection.
As will be understood, the foregoing describes different settings in which the apparatus of the present disclosure can be installed and used to provide data indicative of strain, vibration, movement or velocity. It takes advantage of the sensitivity of a laser to the direct mounting of the laser on the equipment to be monitored and therefore is able to convert the monitored data into a laser beam modulation and therefore is successful in delivery of the variable of interest without commutation. A quality linkage is achieved free of the difficulties and maintenance associated with commutators, FM telemetry systems, and the like.
DETAILED DESCRIPTION OF THE DRAWINGS
So that the manner in which the above recited features, advantages and objectives of the present invention are attained and can be understood in detail, more particular description of the invention, briefly summarized above, may be had by reference to the appended embodiment thereof which are illustrated in the appended drawings.
It is to be noted, however, that the appended drawings illustrate only typical embodiments of this invention and are therefore not to be considered limiting of its scope, for the invention may admit to other equally effective embodiments.
FIG. 1 shows in sectional view a semiconductor laser adhered to a supportive substrate and installed for providing strain measurements;
FIG. 2 is a schematic block diagram of components for operating an integrated circuit laser;
FIG. 3 is a side view of the radiation pattern of an IC laser;
FIG. 4 shows an IC laser telemetry system of the present disclosure installed on a piling for transmitting data regarding the piling strain, piling movement, piling particle velocity and hammer velocity to a remote location;
FIG. 5 is a view of an alternative mounting apparatus installing an IC laser on a piling to obtain a multiple of strain input for transmission;
FIG. 6 is an enlarged detailed view of the apparatus shown in FIG. 5 including details of construction of the laser and support equipment therefor;
FIG. 7 shows a laser telemetry system installed on a rotating device; and
FIG. 8 shows a pressure measurement system using the present apparatus.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Attention is first directed to FIG. 1 of the drawings where an IC laser telemetry system of the present disclosure is identified by the numeral 10. FIG. 1 shows the preferred embodiment, an IC laser telemetry device, but other forms of laser can be used including gas lasers. It will be described in the context of measuring strain as a first example of the mode of operation of the device. Other examples, including different types of measurements, will be given also.
In FIG. 1, a specimen 11 to be measured is subjected to strain by means not shown, and the strain changes the length of the member 11. The member 11 is drilled and suitable bolts 12 attach a substrate 13 to the specimen 11. An adhesive 14 is used to attach a semiconductor laser 15. The substrate 13 is any suitable base member which can be used for supporting a semiconductor. An isolation layer such as an adhesive 14 can be placed on it. Alternatively, the substrate might be nonconductive material (doped silicon dioxide) wherein the semiconductor is deposited thereabove. In that instance, the substrate 13 can be a typical MOS layer with the layer 14 placed on it by conventional deposition techniques. The layer 14 can be conductive or insulative, but in the preferred embodiment, it is made of an insulative material such as appropriately doped silicon compound such as silicon nitride. The measure of doping determines the measure of electrical insulation.
The semiconductor 15 forms an IC laser. Lasers are generally three different types. One type of laser is formed of a solid body having mirrored parallel end faces at a specified length. It is not uncommon to make such devices of various materials including ruby. More recent material include YAG. An alternative form of laser is a gas laser, one typical form being CO 2 gas. It is contained within a housing having ends where the laser beam is emitted from the ends. The preferred embodiment is directed to an IC laser wherein the IC chip 15 forms the laser beam emitted from the ends at 16 and 17. The device is symmetrical and emits laser beams from the two ends. In contrast with other types of lasers which define a very narrow beam having almost no divergence, the IC laser 15 forms beams from the ends 16 and 17 which have some divergence. Other lasing devices can be used also. More will be noted regarding beam divergence on describing FIG. 3.
The IC laser 15 requires supportive circuitry. FIG. 2 shows a power supply 18 which provides power switched by a pulse circuit 19 timed by a clock. In turn, the pulsed power is supplied to the laser 15 to trigger its operation. More regarding operation of the laser will be described in detail.
Going back to FIG. 1 of the drawings, the IC laser 15 has a specified length between the ends faces 16 and 17. The IC laser is mounted so that it strains with the metal member 11. When such strain occurs, the length of the IC laser is changed, thereby changing the spacing of the end faces 16 and 17. When the spacing changes, the frequency of the monochromatic light emitted as a coherent light beam is changed. If the length is left unchanged, the frequency of the IC laser is fixed. When strain occurs, the strain is coupled from the specimen 11 into the substrate 13. In turn, that strain is coupled into the IC laser 15. This causes the lasing action to change frequency emitted from the laser. It is possible that there will be amplitude changes, but they are less important than the changes in frequency for reasons to be described.
Attention is now directed to FIG. 3 where the IC laser 15 is shown in side view. There is a radiation pattern for the beam. Moreover, the beam tends to spread to define off axis sensitivity. This sensitivity at an off axis location is valuable as will be described below. Alternately, the beam can be deflected, reflected or refracted by a mirror, prism, grating or other light responsive device.
Attention is now directed to FIG. 4 of the drawings. A pile 20 is being driven through a jacket 21 and is embedded in the mud 22 beneath a body of water 23. It is driven by a reciprocating hammer 24, typically a steam powered hammer. The jacket 21 serves as a fixed platform during installation of the pile 20. The IC laser 10 is installed on the pile 20 at a suitable location. A reflector 25 is installed on the hammer, and it is positioned to reflect the laser beam along the specified path. Two receiving dishes are indicated at 26 and 27. In turn, they connect with a laser receiver and amplifier 28. This converts the laser signal by extracting the encoded information and delivers the encoded data to a data processor 30. That processes the data and delivers the data to a recorder 31.
Going again to the reflector 25, the ray path from the IC laser to the reflector 25 is identified by the numeral 32. On reflection, the same beam then travels along the path 33. There is another pathway which is separate from the reflected path 33. It is identified by the numeral 34. It will be described as the direct pathway from the IC laser to the receiver. The term "receiver" will thus refer to the receiver system as well as the receiver, antenna, and amplifier indicated at 28.
Assume for the moment that the IC laser 10 is stationary. When the hammer 24 moves, it creates a Doppler shift in frequency. The shift is related to the velocity of the hammer during hammer movement. The hammer travels in a reciprocating fashion. Its movement can be traced along the reciprocating path for the hammer. The signal on the pathway 32 from the reflector 25 is used to encode hammer movement. Hammer velocity can be obtained and that data can be integrated and differentiated to thereby obtain hammer position and hammer acceleration. Thus, the first specific form of data from the system shown in FIG. 4 is recovery of hammer position, velocity and acceleration. This can be obtained by providing a continuous wave (CW) signal from the IC laser system 10 or it can be obtained through a pulsed system. In either case, the data is indicative of hammer data.
After the hammer strikes the piling 20, strain developed in the piling from the impact loading propagates along the piling to form a strain in the piling in the vicinity of the IC laser system 10. This is coupled as shown in FIG. 1 into the IC laser and thereby shortens the spacing between the ends faces 16 and 17. This creates a frequency shift in operation of the IC laser. The beam path 34 from the IC laser delivers this encoded information. Thus, strain is converted into a frequency shift. The shift from a specified or nominal frequency is proportionate to changes in length of the apparatus shown in FIG. 1 with strain. This provides another type of data along the signal path 34.
A third type of data which is obtained from the system is the relative distance between the IC laser 10 and the receiver. Assume, as an example, that the pulse circuit 19 shown in FIG. 2 is pulsed periodically, say with a spacing of one pulse precisely timed every ten milliseconds. An example of this is shown in the pulse train 40 in FIG. 4. The receiver forms a receiver pulse train 42. The pulse train 42 is shifted from the pulse train 40 by a specified time. The initial time shift is really not important other than to know that there is an initial time delay required for propagation of the light transmitted from the IC laser 10 the receiver. This defines an initial time shift. When the piling is driven into the subsurface at 22, it moves closer, thereby shortening the propagation path. As it moves, the time shift between pulses in the two trains 40 and 42 changes, indicating the shortening of the propagation path 34. FIG. 4 has shown the path 34 to be slightly at an angle with respect to the axis of the piling. In actuality, the propagation path 34 is conveniently parallel to the center line axis of the piling. In other words, the propagation path is substantially parallel to the axis of the piling. On or off axis data linking is readily available; if the laser and receiver are positioned to create laser beam coupling problems, the problems can be overcome by means of light beam reflectors, etc., such as prisms, mirrors and the like. In this event, the change in time delay is indicative of the movement of a point of the piling. This represents another type of data obtained from this system, namely, movement (hence, rate of movement) of a selected point on the piling, or particle velocity. When the laser on the piling moves with respect to the receiver, movement creates a Doppler shift related to particle velocity.
Attention is now directed to FIGS. 5 and 6 which shown an alternate mounting mechanism. Assume that the piling 20 supports a pair of spaced and aligned eyelets 44 as shown in FIG. 5. They are connected to a pair of arms 46 joined at hinges 45 with a strut 48. The arms 46 are relatively hinged and rotate towards one another when an axially compressive load is placed on the piling during hammering. When the strain is released, the arms 46 rotate away from one another. The arms 46 in turn connect at some mid point with a bar 47. The bar is shown in better detail in FIG. 6 where the IC laser is mounted on the bar.
The electronic equipment for operation of the IC laser shown in FIG. 2 is placed in a housing 50 which is mounted next to or in the vicinity of the IC laser. Ideally, the electronic equipment for operation of the IC laser, and the IC laser are contained in the same integrated circuit chip. The bar 47 can be transparent or at least translucent, permitting the coherent laser light beam to pass through the translucent member upwardly and downardly from the IC laser. Again, sufficient beam spread and reflection can be obtained with prisms so that the bar 48 need not be translucent.
This arrangement shown in FIGS. 5 and 6 provides a multiple of the strain between points 44 of the piling 20. The purpose of this apparatus is to scale (increase or decrease) the strain actually measured by the IC laser 15 from the strain sensed at the attachment points 44. While strain is a function of gauge length, by increasing or decreasing the distance between points 44, the strain can be amplified or attenuated as desired. Since stress is a function of strain, and is measured across a cross sectional area, the strain in section 49 can be amplified or attenuated by altering the cross sectional area of the bar 47 as desired.
Attention is now directed to FIG. 7 of the drawings. There, the numeral 55 identifies the surrounding shell or housing of rotating machinery. One example of rotating machinery is a motor or generator, and other examples include devices which rotate at higher speeds such as turbines. The central rotatable shaft 56 supports a hub 57 which in turn supports rotating components at 58. In the event of a motor or generator, that is the rotating magnetic cage while in the case of a turbine, that would describe the buckets. The hub 57 is aligned with a port 59 which is open through the shell 55. A window 60 is placed in that port. The window provides an interior view toward the hub. The window 60 opens into a housing 61 which supports a receiver antenna system 62 for laser transmission. Alternatively, the receiver can be housed inside the machinery housing.
A first IC laser is identified at 63 and is conveniently mounted to align with the port 59 to thereby project a beam out through the port. The beam passes through the port and is observed by the receiver antenna system 62. The IC laser mounted at 63 is positioned in a slot formed in the shaft 56. The beam is located to enable the data to be laser coupled from the rotating shaft.
An alternate location for the IC laser is shown at 64 where it is mounted on the hub 57. It is offset to the side of the axis of rotation. It is aligned so that the beam sweeps over the port 59. Recall that the beam has a measure of divergence. This permits the beam to fall on the chamber window 60 and pass to the receiver antenna system 62. Moreover, beam projection from both locations can be observed at the receiver 62. Accordingly, this arrangement utilizes two different IC's which are synchronously observed by the receiver system 62.
The IC laser 64 can be affixed to the hub in the fashion illustrated in FIG. 1. This enables stresses in the hub which cause strain or vibration to be converted into a laser signal. Alternatively, the IC laser 63 responds in frequency to shaft vibrations and thereby convert the vibrations to laser encoded data. This technique enables the information to be coupled out of the rotating machinery without commutating the signals. Moreover, the laser beam can pass through steam or gases in the chamber. The steam would otherwise obscrue the transmission path for veisible light transmission. The laser frequency is selected so that the steam is not able to block signal transmission. In similar fashion, if the turbine is gas fired, there will be a cloud of incandescent gases in the near vicinity of the turbine but again, the laser frequency can be selected so that it is not obscured by the hot gasses being combusted in the turbine. In the latter event, the temperature increase in the vicinity of the IC laser may require that the laser be cooled as for example, by conducting a flow of coolant in the near vicinity. If the IC laser 63 is exposed to lubricating oil, the laser beam can penetrate a significant thickness of this. This is especially true in view of the fact oil is centrifugally forced outwardly. The port 59 is preferably located at the top so that lubricant does not settle in the port and thereby block laser transmission.
Another variable of interest is temperature. By selection of materials and dopants in the laser, it can be made to operate at selected temperature (including high temperatures) with and without cooling. The lasing frequency varies with temperature; hence, the laser frequency can be calibrated as a function of temperature to enable encoding of temperature as a variable.
In the arrangement of FIG. 8, an IC laser is fastened to a pressure vessel 70. The vessel is typically constructed of metal of specified thickness, and expands with pressure. When the pressure is reduced, it will contract to an unstressed size. The pressure in the vessel 70 creates stress in the metal member, causing strain in the metal acting on the IC laser. The strain causes the lasing frequency to shift and thereby encodes pressure as a frequency shift. The shift is measured and yields a value proportional to pressure. This value can be calibrated directly as pressure if desired.
The precise laser frequency choice can be varied widely. This is achieved by appropriate doping of the materials in the IC laser. The dopant is selected to obtain the desired frequency by relationships that are belived to be well known.
While the foreoing is directed to the preferred embodiment, the scope is determined by the claims which follow. | A transducer defined by a laser is set forth. Strain, movement, velocity, temperature, pressure, and vibration coupled to the laser change the lasing frequency or form a Doppler shift. The laser is thus installed at a specified location to couple a measured phenomenon and thereby enable transmission of the encoded variable in the laser beam. A receiver located remote from the laser picks up the beam for data retrieval. | 6 |
BACKGROUND
The present invention relates to methods for processing images and for generating chain code representations of images.
A configuration of pixels in an image may be represented as a series of vectors. Each vector represents a unit displacement in a predetermined direction and is referred to as a chain element. The series of vectors is called an "indexed sequence" or "chain code." The coordinates of each connected point are called chain coordinates.
The process of expressing an image as a series of vectors is generally called "chain coding." Chain coding is useful for representing images using a minimum amount of storage.
FIG. 1 illustrates a conventional method for generating a chain code representation of a configuration in an image. A pixel representation is scanned in a raster scan order. The first configuration pixel encountered during scanning, designated as pixel A, serves as the starting point for the chain code representation. The chain code representation will be a series of vectors tracing the boundary of the configuration in a clockwise or anti-clockwise direction. A method for tracing the boundary in an anti-clockwise direction is described as a series of steps as follows.
(a) Pixels around A are searched to locate another pixel of the configuration. Searching begins with the pixel below and to the left of pixel A and advances in an anti-clockwise direction. Since a line above A was previously scanned, no pixels of the configuration exist above A. Since a line is scanned from left to right, no pixels of the configuration exist to the left of A. In the example of FIG. 1, the pixel below and to the left of pixel A (in the direction labeled al) is evaluated first, but is not a pixel of the configuration. Advancing in an anti-clockwise direction, the pixel below pixel A (in a direction labeled a2) is evaluated second. This second pixel is part of the configuration, and is labeled as pixel B.
(b) Pixels around B are searched to locate another pixel of the configuration. Searching begins with the pixel to the left of B when the direction from pixel A to pixel B is downward. (The upward pixel A need not be searched, and the location to the left of A was evaluated before locating A as a starting point.) Searching advances in an anti-clockwise direction. In the illustration of FIG. 1, a pixel of the configuration below and to the left of B would be found. That pixel is labeled as pixel C.
(c) After each new pixel is located, searching continues around the new pixel. When the new pixel is located in a horizontal or vertical direction from the previous pixel, searching begins from a pixel which is located two pixels around from previous pixel in the anti-clockwise direction. When the new pixel is located in a diagonal direction from the previous pixel, searching begins from a pixel which is located three pixels around from the previous pixel in the anti-clockwise direction. The chain code is completed when the process returns to pixel A.
(d) After completing a chain code representation for the configuration, the method resumes scanning the image in raster scan order beginning with pixel X (in search of a new configuration).
As can be recognized from the process described above, an image stored as raw pixel values is an inconvenient form from which to generate a chain code representation.
SUMMARY
The present invention relates to methods for generating chain code representations of configurations of pixels in an image. The boundary of a configuration can be represented as a series of chain code, each code connecting one boundary pixel to an adjacent boundary pixel. In one aspect of the invention, each boundary pixel of the configuration is given an eight bit sequence (referred to a convolution information). In a second aspect of the invention, chain codes are obtained from the eight bit sequences.
A hardware circuit generates an eight bit sequence for boundary pixels of the image. For any such pixel (referred to as an object pixel), the eight bits provide information about eight pixels adjacent to the object pixel. The value of each bit indicates whether the adjacent pixel is (or is not) part of the same configuration as the object pixel. For example, a value "1" in a bit position indicates that the pixel located in a certain direction is part of the same configuration as the object pixel.
A chain code for an object pixel is obtained based on its eight bit sequence and the prior code in the chain. The eight bit sequence is examined beginning at a selected bit position. The beginning bit position is determined from the prior code in the chain. The eight bit sequence is examined in a selected order until a bit is found which has a value indicating that a pixel located in a certain direction is part of the same configuration. The chain code for the object pixel is the bit position identified in this manner.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 illustrates a portion of a configuration of pixels illustrating a method for generating chain codes.
FIG. 2 illustrates an image containing two configurations suitable for representation by chain codes.
FIG. 3 illustrates labels of pixels of FIG. 2.
FIG. 4 illustrates eight directions from an object pixel to locations of adjacent pixels and numeric identifiers for each direction.
FIG. 5 illustrates a circuit for generating convolution information.
FIG. 6 illustrates a logic network from FIG. 5.
FIG. 7 is a flow diagram illustrating steps of a first method for obtaining a chain code from convolution information.
FIG. 8 is a flow diagram illustrating steps of a second method for obtaining a chain code from convolution information.
DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 2 illustrates pixels in an image having two configurations. Pixels of the first configuration are designated with a labeling number "1", pixels of the second configuration are designated with a labeling number "2" and pixels which are not part of either configuration are designated with a labeling number "0".
Boundary pixels define the contours of each configuration. In order to judge whether a pixel is (or is not) a boundary pixel it is necessary to compare the pixel being judged (referred to here as the object pixel) with neighboring pixels. For example, A "4-neighborhood," includes pixels immediately above, below, to the right and to the left of an object pixel. The object pixel is compared to neighborhood pixels to determine whether the densities of each neighborhood pixel are different from or the same as the object pixel.
When generating chain codes, it is necessary to determine connectivity of an object pixel with up to eight adjacent pixels ("8-neighborhood").
FIG. 3 illustrates a labeling arrangement for pixels in the image of FIG. 2. Each pixel is designated with a unique label. Pixels of the first configuration are designated with the letter A followed by a number. The number sequence is the order in which a raster scan would encounter the pixels Similarly, pixels of the second configuration are designated with the letter B followed by a number. Background pixels are designated by the letter C followed by a number.
FIG. 4 shows numeral designations of eight directions. For example, numeral 1 designates a direction to the right, numeral 2 designates a direction up and to the right, and numerals 3-8 designate directions advancing in an anti-clockwise rotation. It may be noted that chain codes traditionally use numerals 0 through 7 with 0 indicating a direction directly to the right, numeral 1 indicating a direction up and to the right, and numerals 2-7 advancing in an anti-clockwise rotation.
Table 1 records information about the coincidence of each pixel in the first configuration and pixels in each respective neighborhood. Columns labeled as 1 to 8 correspond to the eight directions of FIG. 4. Rows labeled as A1 to A19 corresponds to pixels in the first configuration. An entry of "1" in a row/column intersection indicates that a neighboring pixel has the same density as the object pixel. An entry of "0" indicates that a neighboring pixel has a different density. For example, Row A1 has "1" entries in columns 6, 7 and 8. These "1" entries indicate that pixels in directions 6, 7 and 8 from pixel A1 have the same density as pixel A1. An inspection of FIG. 3 verifies that pixels A3, A4 and A5 are part of the first configuration as A1 (indicating that they have the same densities).
Table 2 records information about the coincidence of pixels in the second configuration. Table 3 records information about the coincidence of pixels which are neither part of the first nor the second configurations. An entry "--" indicates that the row-pixel is on the image edge (and does not have a complete neighborhood). It is also possible to define edge pixels in other ways.
"Convolution information" refers to information which indicates the difference (or coincidence) between object pixels and pixels of their neighborhoods. Convolution information may be defined for 8-neighborhoods or 4-neighborhoods. Tables 1, 2 and 3 are examples of "convolution information" for an 8-neighborhood.
Circuits shown in FIGS. 5 and 6 rapidly generate convolution information. The circuit of FIG. 5 includes two line memories 5,6 connected in series. Each line memory has capacity for holding one scan line from an image. As an image is scanned (or as a frame memory holding a pixel representation of an image is scanned), a first scan line of pixel values is input to the first line memory 5 through a signal line 7A. As a second scan line is input to the first line memory, pixels from the first line memory 5 are input to the second line memory 6 through signal line 8A. That is to say, pixels of the of the first scan line advance to the second line memory 6. As a third scan line is input to the first line memory, pixels from the first memory advance to the second line memory, and pixels of the second line memory are output on a signal line 9A. Thus, as third line of the image is scanned, pixels from the prior two scan lines are output from the first and second line memories 5,6.
The circuit of FIG. 5 also includes three delay networks 7,89. Pixel values on signal lines 7A are input into delay network 7. Delay network 7 includes two D-type flip flops 7B,7C. A pixel value is input into the first flip flop 7A on a first clock cycle. As a second pixel value is input into the first flip flop 7B, the first pixel value advances into the second flip flop 7C. Similarly, pixel values output from the first line memory 5 and the second line memory 6 are input into a second delay network 8 and a third delay network 9 respectively. The second and third delay networks 8,9 include D-type flip flops 8B,8C and 9A,9B which operate in the same manner as flip flops 7B,7C of the first delay network 7.
A center pixel may be designated as Pi,j where i and j are coordinates. The index j designates the scan line in which the pixel is located and the index i designates position along the scan line. A 3×3 convolution includes pixels to the left and right of a center pixel P(i-1),j, Pi,j and P(i+1),j. The convolution also includes three pixels on the previous scan line P(i-1)(j-1), Pi,(j-1) and P(i-1,j-1), as well as three pixels on the following scan line P(i+1),(j+1), P(i+1),j, P(i+1),(j+1).
Delay networks 7,8,9 and line memories 5,6 are clocked such that their outputs present nine pixels of a 3×3 array (convolution) of the image to a logic network 10. For example, after a first and second scan line of pixels have been input to the first line memory 5 (and the first scan line has advanced to the second line memory 6) a third scan line will be processed. As the first pixel of the third scan line is input to the first line memory 5, it is also clocked into the first flip flop 7B of the first delay network 7. At the same time, the first pixels of the first and second scan lines are clocked into the third and second delay networks 9,8 respectively. As a second pixel of the third scan line is input into the first line memory 5, it is clocked into the first flip flop 7B and the first pixel of third scan line advances from the first flip flop 7B to the second flip flop 7C. Similarly, first and second pixels of the first and second scan lines advance through their respective delay networks. As a third pixel of the third scan line is placed on signal line 7A, line memories 5,6 place the third pixels of the first and second scan lines on signal lines 8A and 8B. At this time, nine pixel values of a 3×3 convolution are presented to logic network 10 as shown in FIG. 5.
Logic network 10 performs a logical comparison of the center pixel Pi,j with other pixels of the convolution and places convolution information for Pi,j on signal lines BT1 -BT8. The logical formulas for each line are as follows:
BT1=Pi,j×P(i+1),j
BT2=Pi,j×P(i+1)(j-1)
BT3=Pi,j×Pi,(j-1)
BT4=Pi,j×P(i-1),(j-1)
BT5=Pi,j×P(i-1),j
BT6=Pi,j×P(i-1),(j+1)
BT7=Pi,j×Pi,(j+1)
BT8=Pi,j×P(i+1),(j+1).
FIG. 6 shows a logic network 10 made of AND gates which is suitable for performing logic on object pixels having a value of 1. Exclusive NOR gates can be used for comparisons which are independent of the object pixel value.
Convolution information can be stored in a frame memory. That is to say, the address of the memory corresponds to the pixel coordinates, and the address contents are the convolution information for the corresponding pixel. This organization allows immediate reading of convolution information.
In the method of the present invention, a chain code for an object pixel is determined from a prior chain code and from convolution information. Convolution information and the prior chain code are each eight bit expressions (or less). This contrasts with conventional methods which compare an eight bit object pixel value with each of up to five o six other eight bit pixel values. Thus a process using the present invention is simplified. Several processing methods are individually discussed.
Method 1
A chain code for an object pixel is determined by searching the convolution information from selected starting bit position. An eight bit expression of convolution information may be designates as Ni. The direction of the previous pixel may be designated as k (a value between 1 and 8 as shown in FIG. 4). If k is odd, Ni is examined beginning at the k+ 2nd digit N(k+2). If k is even, Ni is examined beginning at the k+ 3rd digit N(k+3). Digits are examined in increasing order until a value "1" is found. The digit so found corresponds to the chain code.
FIG. 7 is a flow chart diagraming steps of this method with BASIC expressions. In a decision step 21, k is tested to determine whether it is odd (where K is the direction code of the object pixel from the previous pixel in the chain). If so, a process step 23 sets J to K+1. If K is not odd, a process step 25 sets J to K+ 2. After setting J, a process step 27 defines X as a logical AND between Ni (all eight bits) and the value 2 J . (The value 2 J has a "1" in the Jth position). A decision step 29 test the value of X. If X=1 (indicating that Ni had a "1" in the Jth position), then a process step 31 equates the chain code for the object pixel with the value J and the process is complete for that object pixel. If X is not "1", then a process step 33 increments J and examination of Ni repeats with the incremented value of J.
Method 2
The location of a "1" digit in convolution information is determined by shifting the eight bit convolution information expression. The convolution information Ni for an object pixel is first shifted to a start position. If the direction code k from the object pixel to the previous pixel in the chain is odd, Ni is shifted K+ 1 digits to the right. If is even, Ni is shifted k+2 digits to the right. Shifting continues until a "1" is detected in the least significant bit of the shifted expression. FIG. 8 is a flow chart diagraming steps of this method with C-language expressions.
Method 3
The chain code of an object pixel can be determined from a table look-up procedure based on the convolution information and the direction code of the previous pixel in the chain.
Coding speed of methods of the present invention can be increased by limiting the methods to boundary pixels. That is to say, background pixels and pixels in the interior of a configuration need not be processed. Boundary pixels can be readily identified from the locations of "0" digits in the convolution information. The presence of a "0" in digits of the 4-neighborhood (digits 1,3,5 or 6) indicates that the object pixel is a boundary. If data is otherwise compressed, only data for boundary pixels need be extracted.
Convolution information is also useful for identifying characteristics of a chain code sequence. For example, information of the pixels in a 4-neighborhood around an object pixel gives information about whether the object pixel forms part of a vertical or horizontal line across a configuration. For example Table 4 includes rows for different convolution information expressions. The second column (headed "7 5 3 1") has "0" and "1 " entries which are possible combinations of convolution information. The first column is a decimal numeric corresponding to each convolution information expression. The third column has entries indicating whether a object pixel having the corresponding convolution information is a start point, an end point or a middle point of a horizontal segment. The fourth column has entries indicating whether a center point having the corresponding convolution information is a start point, an end point or a middle point of a vertical segment.
For example, an object pixel having convolution information "1 0 1 0" (10 decimal) has pixels directly above (direction 3) and below (direction 7). If this object pixel is part of a horizontal segment, it would be a start or end point as indicated in the third column. If this object pixel is part of a vertical segment, it would be a middle point as indicated in the fourth column.
Convolution information may be generated for sets of directions. For example, convolution information limited to directions 1, 2 and 8 can be used for chain coding a right edge.
It can be seen that convolution information in an 8-neighborhood is sufficient for generating a chain code representation.
Storing pixel density data in a first frame memory and convolution information in a second frame memory allows immediate access to both sets of information. | A method for processing images is useful for generating a chain code representation of a configuration of pixels in an image. The method stores a pixel representation in first frame memory. For each pixel, "convolution information" is stored in a second frame memory. Convolution information indicates whether neighborhood pixels are part of the configuration. In one embodiment, convolution information for an object pixel is a bit string. The location of a bit in the string corresponds to a direction of displacement from the object pixel. The value of a bit in the string indicates whether a neighborhood pixel located in the corresponding direction is part of the configuration. A first method for generating a chain code expression examines the convolution information for a bit which identifies an adjacent configuration pixel. Examination begins from a bit location determined from a prior code in the chain. The position of the identified bit is then the next code in the chain. An alternate method uses a look-up table. The address of the look-up tab is the convolution information expression, and the content of the table is a chain code. | 6 |
TECHNICAL FIELD
The invention relates generally to devices that are capable of operating in a reduced power consumption mode and, more particularly, for providing such devices with a noncontact sensor for use in causing the device to transition from the reduced power consumption mode to full power mode.
BACKGROUND OF THE INVENTION
Over the years, many attempts have been made to reduce the power consumption of battery powered electronic devices, thereby yielding longer battery operation. For obvious reasons, many of these attempts have focused on reducing the amount of power consumed by such devices while the device is on, but not in use. Hence, a reduction in power consumption has been achieved by slowing or stopping certain components of the device after the device or devices have been inactive for a predetermined period of time, which may or may not be set by the user. Clearly, therefore, it is critical to maintaining proper device performance accurately to determine when to slow or power down the device without disrupting the user's work, until further operation is needed.
For example, in the field of portable personal computers, when a computer's disk drive has not been accessed for a predetermined amount of time, for example, two minutes, the drive is powered down or caused to operate in a reduced power consumption mode, often referred to as “standby mode,” such that the drive consumes less power, thereby reducing the overall power consumption of the computer. Thereafter, when a drive access is attempted, full power is reapplied to the drive and the drive spins up and is ready to be accessed.
Another example of a device capable of operation in a reduced power consumption mode is a device known as a radio mouse. Typically, after expiration of a predetermined amount of time in which the mouse has not been used, a microcontroller included in the mouse causes the mouse to operate in a reduced power consumption mode. This may be accomplished, for example, by writing the contents of a volatile memory device within the microcontroller, which is accessed by the microcontroller during operation of the mouse, to a nonvolatile memory device, which is slower than the microcontroller's volatile memory device. Power is then removed from the volatile memory device and is removed from or reduced to other components of the mouse. When the user is again ready to use the mouse, the user must move the mouse or click a mouse button provided thereon, at which point a signal is sent to wake up the mouse.
Although the above-described methods accomplish their primary goal, that is, to reduce in the amount of power consumed by the device, they suffer certain deficiencies, the most obvious of which is the time delay experienced by the user in waiting for the device to return to full power mode so that it can be used for its intended purpose. Referring to the disk drive example, the user must wait for power to be reapplied to the drive and the drive to spin up before access can be made thereto. With regard to the radio mouse, because the wake up signal is not sent until the user actually attempts to use the mouse to input data, the user may experience a delay of up to several seconds in inputting the data while the necessary operations for awakening the mouse are performed.
Hence, although it is possible for a user to wait for a device to return to full power state when he or she is again ready to use the device, it is not particularly desirable to require him or her to do so. On the other hand, there are inherent limits on the speed with which a device can be transitioned from a reduced power consumption to a full power mode.
Therefore, what is needed is a means for causing a device operating in a reduced power consumption mode to return to a full power mode immediately before the user is ready to use the device, such that the device has already returned to the full power mode by the time the user attempts to operate the device.
SUMMARY OF THE INVENTION
The foregoing problems are solved and a technical advance is achieved by a method and apparatus for transitioning an electronic device operable in a reduced power consumption mode from the reduced power consumption mode to a full power mode immediately before a user attempts to operate the device. In a departure from the art, a hand held intelligent data entry unit (IDEU) is provided with a noncontact sensor for detecting the presence of a user's hand within an actuation region of the IDEU during operation of the IDEU in the reduced power consumption mode and for sending a signal responsive to such detection for causing the IDEU to operate in full power mode.
In a preferred embodiment, the IDEU of the present invention comprises a microcontroller connected to one or more input devices, a nonvolatile memory device, a power supply comprising one or more batteries and a noncontact sensor, such as a capacitive sensor. In accordance with a feature of the present invention, the IDEU is operable in a full power, or active mode, in which all of the IDEU components are operating at normal levels, and in a reduced power consumption mode, in which the IDEU consumes significantly less power than it does during operation in the active mode. Accordingly, the microcontroller further includes a timeout timer, which, in the preferred embodiment, is a count-down timer that is initially set to expire after a predetermined amount of time, for example, 5 minutes, has elapsed and is reset responsive to input received by the microcontroller from one of the input devices. Upon the expiration of the predetermined amount of time without receipt of input from the devices, the timeout timer generates a “timeout” signal, causing the microcontroller to perform the operations necessary to place the IDEU in the reduced power consumption mode.
The capacitive sensor is arranged to detect the presence of a user's hand within a predefined “actuation region” of the IDEU and generate a “wake up” signal to the microcontroller responsive to the detection. The actuation region is ideally defined based on the amount of time required to wake up the computer, such that the IDEU can be caused to be ready to accept data via the input devices 22 as soon as the user picks up the IDEU.
A technical advantage achieved with the present invention is that it prevents the user from experiencing time delays typically associated with transitioning a device from a low power consumption mode to a full power mode.
A further technical advantage achieved with the present invention is that it can be used in connection with any number of different types of portable hand held electronic devices, such as intelligent remotes, radio mouses and the like.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a block diagram of a host system and associated hand held intelligent data entry unit (IDEU) embodying features of the present invention.
FIG. 2 is a state diagram of the operation of the IDEU of FIG. 1 .
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to FIG. 1, a hand held intelligent data entry unit (IDEU) embodying features of the present invention is designated by reference numeral 10 . The IDEU 10 is connected to a host system 12 , via a data communications link 14 and first and second interfaces 16 and 18 , respectively, for receiving data from and transmitting data to the host system 12 . In one embodiment, the data communications link 14 is a wireless link, such as a radio frequency (RF) or infrared (IR) link. In an alternative embodiment, the data communications link 14 is a physical link, such as a coaxial cable or other wiring means. In either case, it should be understood that the interfaces 16 and 18 will be of a type known in the art for enabling the selected mode of data transmission.
The IDEU 10 comprises a microcontroller 20 connected to one or more input devices, designated collectively by reference numeral 22 , nonvolatile memory device 24 , a power supply 26 comprising one or more batteries (not shown) and a capacitive sensor 28 . The host system 12 comprises at least a microprocessor 30 connected to a plurality of I/O devices, designated collectively by reference numeral 32 , and memory 34 .
In accordance with a feature of the present invention, the WDEU 10 is operable in a full power, or active, mode, in which all of the IDEU 10 components are operating at normal levels, and in a reduced power consumption mode, in which the IDEU 10 consumes significantly less power than it does during operation in the active mode. Accordingly, the microcontroller 20 further includes a timeout timer 36 and volatile memory, such as a static random access memory (SRAM) 38 . It should be understood that dynamic random access memory (DRAM) may also be used without departing from the scope of the present invention. In a preferred embodiment, the timeout timer 36 is a count-down timer that is initially set to expire after a predetermined amount of time, for example, 5 minutes, has elapsed and is reset responsive to input received by the microcontroller 20 from one of the input devices 22 via a line 40 . As is typically the case with devices that are operable in a low power consumption mode, upon expiration of the predetermined amount of time without receipt of input from the devices 22 , the timeout timer 36 generates a “timeout” signal. Responsive to the timeout signal, the microcontroller 20 performs the operations necessary to place the IDEU 10 in a reduced power consumption mode.
It should be understood that there are many methods known in the art for operating a device, such as the IDEU 10 , in a reduced power consumption mode; however, in an illustrative embodiment, this may be at least partially accomplished by the microcontroller's 20 writing the contents of the SRAM 38 to the nonvolatile memory device 24 and then removing power from the SRAM 38 , as well as other devices, if desired. The IDEU 10 remains in the reduced power consumption state until a “wake up” signal is received by the microcontroller 20 from the capacitive sensor 28 on a line 42 , as will be described below.
In a preferred embodiment, the capacitive sensor 28 is configured to sense an increase in the voltage drop across a reference capacitor (not shown) resulting from the presence of a user's hand within a predefined “actuation region” of the IDEU 10 and generate a “wake up” signal to the microcontroller 20 when the sensed voltage drop exceeds a preset threshold voltage. The threshold voltage is selected based on the amount of time needed to perform the operations necessary to return the IDEU 10 to full power mode, such that the more time required to awaken the IDEU 20 , which in the illustrative embodiment described above comprises at least reapplying power to the SRAM 38 and writing the contents of the nonvolatile memory device 24 back to the SRAM 38 , the lower the threshold voltage should be set, thereby to allow more time to awaken the IDEU 20 . In this manner, the IDEU 10 can be made ready to accept data via the input devices 22 as soon as the user picks up the IDEU 10 .
In one embodiment, the IDEU 10 is a radio mouse, in which case the input devices 22 include a trackball and mouse keys. In alternative embodiments, the IDEU 10 is an intelligent remote control unit, in which case the input devices 22 comprise a plurality of keys or toggle switches, or a joystick or other known pointing device.
In an extension of the present invention, the wake up signal generated by the capacitive sensor 28 on the line 42 may also be transmitted to the microprocessor 30 of the host system 12 (via the interface 16 , the data communications link 14 and the interface 18 to return the host system 12 to a full power mode from a reduced power consumption mode.
FIG. 2 is a state diagram of the operation of the IDEU 10 (FIG. 1 ). The IDEU 10 is operable in three states, including a reduced power consumption state 200 , an active, or full power, state 202 , and an inactive state 204 , which corresponds to a condition of the IDEU 10 in which batteries (not shown) comprising the power supply 26 (FIG. 1) have been removed or are depleted.
In the preferred embodiment, the IDEU 10 powers up in and is reset to the reduced power consumption state 200 , it being understood that this is a design choice only, and that the IDEU 10 could just as feasibly power up in and/or reset to the active state 202 . When the IDEU 10 is in the reduced power consumption state 200 and the capacitive sensor 28 (FIG. 1) generates a wake up signal to the microcontroller 20 (FIG. 1 ), the IDEU 10 transitions to the active state 202 , as indicated by an arrow 208 . When the IDEU 10 is in the active state 202 and the timeout timer 36 (FIG. 1) generates a timeout signal, the IDEU 10 transitions to the reduced power consumption state 200 , as indicated by an arrow 210 . When the IDEU 10 is in either the reduced power consumption state 200 or the active state 202 and the batteries (not shown) comprising the power supply 26 are removed or depleted, the IDEU 10 transitions to inactive state 204 , as indicated by arrows 212 and 214 , respectively. When the IDEU 10 is in the inactive state 204 and fresh batteries are inserted, the IDEU 10 transitions to the reduced power consumption state 200 , as indicated by an arrow 216 .
It is understood that the present invention can take many forms and embodiments. The embodiments shown herein are intended to illustrate rather than to limit the invention, it being appreciated that variations may be made without departing from the spirit or the scope of the invention. For example, any number of different types of “noncontact sensors,” including optical sensors, ultrasonic sensors, and passive infrared intrusion sensors, may be used in place of the capacitive sensor for sensing the approach of a user's hand toward the IDEU 10 . In addition, the wake up signal generated by the capacitive sensor 28 may also be provided to the microprocessor 30 for transitioning the host system 12 from a reduced power consumption mode to a full power mode.
Although illustrative embodiments of the invention have been shown and described, a wide range of modification, change, and substitution is intended in the foregoing disclosure and in some instances, some features of the present invention may be employed without a corresponding use of the other features. Accordingly, it is appropriate that the appended claims be construed broadly and in a manner consistent with the scope of the invention. | Method and apparatus for transitioning an electronic device operable in a reduced power consumption mode from the reduced power consumption mode to a full power mode immediately before a user attempts to operate the device is disclosed. A hand held intelligent data entry unit (IDEU) of the present invention is provided with a noncontact sensor for detecting the prepense of a user's hand within an predefined actuation region of the IDEU while the IDEU is operating in a low power consumption mode. Responsive such detection, the sensor generates a wake up signal to a microprocessor of the IDEU for causing the IDEU to transition from the low power consumption mode to a full power mode. | 8 |
CROSS REFERENCE TO RELATED APPLICATIONS
This application claims priority under 35 U.S.C. §119 to German Application No. 102 15 181.4 filed in Germany on 5 Apr. 2002, and as a continuation application under 35 U.S.C. §120 to PCT/CH03/00123 filed as an International Application on 19 Feb. 2003 designating the U.S., the entire contents of which are hereby incorporated by reference in their entireties.
BACKGROUND
The invention relates to a sealing arrangement for sheet-like elements or wall elements, in particular for dryers of pasta and the like.
It is known to seal sheet-like elements, for example sheet-like wall elements, against the transmission of gaseous or liquid or else solid substances. This may be performed by sealing compounds or adhesives, which however lead to soiling or permanent connection of the wall elements. Furthermore, it is known for example from EP-A-685255 to seal the outlet flaps of a mixing container in the operating state by means of a pressure roller and a sealing tube. In this case, after swinging in a bar, the pressure roller presses against the location where the flaps overlap. An inflatable sealing tube seals off the side of the flaps respectively lying opposite. Before opening the flaps, the sealing tube must be evacuated.
Further sealing arrangements are known from the documents DE-A-3734818, DE-A-1804043 and U.S. Pat. No. 3,175,652.
In the case of the arrangement of DE-A-3734818, however, no positional compensation is possible parallel to the plane of the separating gap between two neighboring wall elements, because there is a rigid connection between the clamping elements of the sealing elements and the rigid frame of the dryer.
The arrangement of DE-A-1804043 and U.S. Pat. No. 3,175,652 uses sealing elements arranged in the separating gap, the end faces of adjacent wall elements on both sides of the separating gap having to have specially shaped formations complementing the sealing elements arranged in the separating gap.
SUMMARY
A sealing arrangement is disclosed for sheet-like elements or wall elements, for example of pasta dryers, which permit simple connection of such elements while at the same time the location where they are connected is sealed off.
One exemplary feature is that the connection takes place without overlapping of the elements, and consequently assembly and disassembly can also take place with simple means. Moreover, compensation of positional or dimensional deviations is possible, in particular temperature-induced positional or dimensional deviations.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention is described in more detail below by referring to two examples on the basis of a drawing, in which:
FIG. 1 shows a sealing arrangement in the form of top plate seal; and
FIG. 2 shows a further embodiment of a sealing joint.
DETAILED DESCRIPTION
A multilevel dryer for pasta, as described for example in WO 85/00090 or the applicant's DE 10158446.6, not published before the priority date, the disclosures of which are hereby incorporated by reference in their entireties, has individual dryer sections, which in turn have an outer casing. The casing comprises individual, shaped plates.
In the example, a top plate 1 is connected to a further top plate 2 ( FIG. 1 ). The connection takes place by a butt joint at the end faces 3 and 3 ′. In this case, neither a sealing abutment of the end faces 3 and 3 ′ against each other nor particularly fine working of the end faces 3 , 3 ′ is required, so that the separating gap 4 does not have to meet any special requirements.
Parallel to the end face 3 , 3 ′, the plates 1 and 2 respectively have through-bores or blind-bores 5 . Placed on the inner side of the separating gap 4 is a top crosshead 6 with a planar supporting surface and through-bores analogous to the through-bores 5 of the plates 1 , 2 and, on the outer side, a planar sealing strip 7 with analogous through-bores. A further crosshead 8 may be placed on the sealing plate. The positionally fixed fastening of the individual elements takes place as depicted by means of screw connections 9 .
The outer regions of the sealing strip 7 are L-shaped parallel to the path of the sealing gap 4 , so that a flexible sealing element, here a silicone tube 10 , can be additionally placed between the sealing strip 7 and the plates 1 , 2 .
As a result of the screw connections 9 , adequate sealing of the separating gap 4 against vapor or gases is consequently obtained. If need be, however, a further sealing plate 11 may be provided, as depicted, between the separating gap 4 and the sealing strip 7 or the top crosshead 6 .
Positional compensation perpendicular to the plane of the separating gap 4 is possible.
In the case of a sealing joint according to FIG. 2 , two casing parts 20 , 21 of a multilevel dryer are connected to each other in a sealed manner, forming a separating gap 4 , positional compensation parallel to the separating gap 4 being possible.
Both on the inner side and on the outer side of the separating gap 4 , a sealing strip 7 ′ is in turn arranged over the entire length thereof, containing a silicone tube 10 to the right and left of the separating gap 4 . On the outer side of the sealing joint there is additionally a cover plate 22 (analogous to the top plate 11 ) between the sealing strip 7 ′ and the casing parts 20 , 21 . As in the first example, the two sealing strips 7 ′ are clamped against each other by means of a screw connection 9 and reliably seal off the separating gap.
The invention is not restricted to these exemplary embodiments. It will be appreciated by those skilled in the art that the present invention can be embodied in other specific forms without departing from the spirit or essential characteristics thereof. The presently disclosed embodiments are therefore considered in all respects to be illustrative and not restricted. The scope of the invention is indicated by the appended claims rather than the foregoing description and all changes that come within the meaning and range and equivalence thereof are intended to be embraced therein. | A sealing arrangement is disclosed for sheet-like elements such as flat wall elements (e.g., pasta dryers). A separation joint can be sealed against penetration gases or steam by placing level sealing elements on both sides of the separation joint, the sealing elements being braced against each other by connections, such as screw connection. | 5 |
RELATED APPLICATIONS
Priority is claimed based on a Provisional Application, Ser. No. 60/025,506, filed on Sep. 5, 1996.
BACKGROUND
1. Technical Field
This invention is in the field of radiant energy sensitive photocell circuits. More particularly, the invention provides a means for automatically compensating for quiescent current produced by a photodetector while amplifying the signal current.
2. Background and Description of the Prior Art
Photodetectors are made using a variety of mechanisms and materials. Chief classes of these are photoemissive devices, such as phototubes and photomultipliers, photoconductive resistors made from, e.g., cadmium sulfide, amorphous silicon, lead salts, etc., photovoltaic devices made from, e.g., silicon, indium arsenide, etc. and phototransistors, usually made from silicon. Photovoltaic devices are unique in that they will produce a signal current without the aid of an external power source (e.g., silicon solar cells). All others require an external bias voltage. As a result, even in the absence of radiation, a so-called dark current will flow. Since some background radiation is always present, the term quiescent current is more accurate but the terms are often used interchangeably. Sometimes it is desirable to measure the background radiation. Herein, the term quiescent current means that caused by sources which are not desired to be measured directly as opposed to signal currents.
The quiescent current for photoemissive and photovoltaic devices is, in general, smaller than for photoconductive devices and also, as a general rule, devices using materials which are sensitive to longer wavelength radiation have higher quiescent currents. In fact, for photoconductors used to detect infrared radiation, the quiescent current is orders of magnitude larger than the usually obtained signal current. Thus, circuits which are suitable for other classes of photocells are usually inadequate for photoconductors. Nonetheless, assuming suitable circuitry, infrared photoconductors such as PbS and PbSe possess several advantages in the detection of infrared radiation. Among these are high sensitivity, room temperature operation, low cost, and ease of fabrication as high density arrays.
Photoconductors produce a signal by a variation in conductance roughly proportional to the intensity of infrared radiation. As mentioned, this conductance change is very small compared to the conductance when no radiation is incident. When a fixed external voltage is applied across the photoconductor the resulting current may be described as having two components, the quiescent current due to the quiescent conductance and the much smaller photo current due to the infrared radiation induced conductance change. Amplifying a small signal current in the presence of a large fixed current is difficult and with photoconductors it is even more so because the quiescent conductance varies with the temperature of the detector and there may be a significant component due to variations in any background radiation. Thus, photoconductors require carefully conceived signal processing techniques to maintain their advantages in a commercially viable system.
For photoconductors, if the optical signal is constant or varies at a slow rate, the most favored method for separating the photo current from the quiescent current is to modulate the optical signal, usually with a mechanical chopper. This modulation translates the information in the optical signal to the chopping frequency. The photo current may then be separated from the quiescent current by some form of high pass filtering, wherein signals at frequencies below the chopping frequency are attenuated while signals at or above the chopping frequency are amplified.
In systems using a small number of detectors, high pass filtering is usually accomplished using discrete capacitors and resistors. A simple well-known basic circuit is illustrated in FIG. 1. The photoconductor is biased with voltages, E+ and E-, through a bias resistor, Rb. The bias voltages may be of any polarity as long as there is a difference between them. When the resistance of the photodetector changes, the voltage at the junction with Rb changes and is transmitted by the coupling capacitor Cc to the amplifier A with input resistance Rin. If Rin is large compared to Rd or Rb, the high pass filter cut on frequency is determined by the inverse of the product of Cc and Rin.
For lead salt detectors, the desirable gain of the amplifier is typically on the order of as much as one million. However, with one or two operational amplifiers, it is easy to achieve such high gains as well as large input resistances. Since lead salt detectors work best with chopping frequencies below about one kilohertz, a high input resistance reduces the need for large value coupling capacitors. Even so, if they were required, in discrete circuits, capacitor size is not a major problem.
However, there are a number of applications such as spectroscopic instruments and imaging devices which require a large numbers of detectors. An emerging standard for low cost infrared spectroscopic instruments is a 128 detector linear array. For scanned imaging systems, 512 or more is preferable and there are applications where two dimensional arrays with thousands of detectors are desired. In these applications, integrated circuits with a large number of detector amplifier channels per chip are preferred. However, operational amplifiers and large value capacitors would take up too much chip area. A typical instrumentation op amp might be 0.01 sq. in. and 32 channels of these would require 0.32 sq. in. for these alone. This is too large to be economical enough for most applications. Thus, different approaches are required.
Referring back to FIG. 1, one possibility is to make the bias voltages equal and opposite and the bias resistor the same value as the quiescent resistance of the photodetector. In this case, the DC voltage at the junction is zero and the coupling capacitor can be eliminated. However, this is not a workable solution. As noted, the amplifier gain is so large that, in practice, changes in photodetector resistance due to temperature changes or background radiation quickly unbalance the circuit so the output of the amplifier saturates. For lead salt detectors, the temperature coefficient of resisitance is about -2%/°C. so that small temperature changes are troublesome. Using a bridge circuit with a matched photodetector and a differential amplifier is a well-known improvement. Unfortunately, this reduces the signal to noise and roughly doubles the number of components.
One step known in the prior art which has been taken toward solving the problem of providing amplifier gain using small amounts of chip area is to integrate the current from the photodetector as illustrated in FIG. 2. In this circuit, the MOSFET transistor Q serves as an impedance transformer where the resistance presented to the detector is low (hundreds of kΩ) relative to the resistance presented to the capacitor Ci (thousands of MΩ). Also, if the amplifier a has a MOSFET input, Rin will be large enough to be ignored. Thus, Ci is fed by a current source with value I net =I det -I b . In operation, the switch, S, is closed until the integrating capacitor is discharged (reset) and then opened under the control of RST. The voltage on Ci is simply V i =(1/Ci)∫I net (t) dt. For the purposes of illustration, assume that I net is constant so that V i =I net ×T i /Ci. With typical values of integration time T i =1 ms and Ci=10 pf (which takes up little chip area), T i /Ci=100 MΩ. In the circuit of FIG. 1, with typical values of Rdet=Rb=10 MΩ, the parallel resistance R p =5 MΩ so that a relative voltage gain of 20 is obtained by the circuit of FIG. 2. Higher gains can be obtained by reducing Ci or increasing T i .
An initial gain of 20 or more is enough to overcome the effects of any noise that might be introduced by later signal processing. In particular, the amplifier following Ci can be a simple buffer and it becomes possible to delay further amplification until the multiple signals have been sampled and held, passed through a multiplexor, and all channels amplified in sequence by a single additional amplifier residing off the chip.
Unfortunately, the drawback to using a reset current integrator is that it amplifies the, often much larger, DC quiescent current as well and can result in saturation of the following amplifier. Besides chip area, selecting a value for Ci always results in a tradeoff between having enough signal gain and avoiding saturation. For each application, the signal frequency will determine T i and the detector characteristics will determine the net DC current I net into Ci. For detectors with large quiescent currents, to avoid saturation, the bias current I b must still be matched to the quiescent current I det with a precision which is roughly better than the inverse of the gain (5% in the example). As noted above, this is hard to accomplish and/or maintain as ambient conditions change, especially for a large number of channels. An attempt to solve this problem for lead salt detectors, hopefully allowing for use without any intentional chopping, which is commercially available is believed to be illustrated in FIG. 3.
This differs from the previous prior art example in that, instead of a fixed bias resistor acting as a balancing current sink, MOSFET transistor M3 in conjunction with an on-chip digital-to-analog convertor D/A act as a variable current sink. Transistors M1 and M2 are voltage level translators, but have no intentional effect on the currents charging the integration capacitor CW. The amount of current required from the D/A is determined by a calibration step in which the detectors are exposed to a DC radiation source, the detector current is integrated by CW, sampled and held by S/H, and converted to a digital value by the off-chip analog-to-digital convertor A/D CONVERTOR. Off-chip DIGITAL PROCESSING then calculates a digital value which is sent to the on-chip digital STORAGE REGISTER which drives the D/A.
This approach works under some conditions but has several disadvantages. The major one is that the temperature coefficient of resistance of the photodetectors is so large that the quiescent current will drift large amounts even with reasonable temperature control. Thus, signal measurements must be interrupted and the calibration step preformed from time to time. Even so, temperature controllers are expensive, bulky, and consume many times the power of an integrated circuit. Second, every photodetector must have its own associated on-chip digital-to-analog convertor. This requires a large amount of chip area unless the resolution of the convertor is very low. If the resolution is low, then it will be difficult to match the photodetector quiescent current and, therefore, the gain at the integration capacitor must be reduced to avoid saturation. Lastly, in some situations it may not be convenient or cost effective to require an external analog-to-digital converter and digital processor.
SUMMARY
Accordingly, an object of the present invention is to suppress the effects of variations in the quiescent current of a photodetector with precision and minimal delay while providing a high gain for signal currents. A further object is to use electronic components which are both small in number and would require small amounts of integrated circuit chip area. Still further objects are to provide such suppression on the fly without interrupting normal operation nor requiring significant apparatus external to the integrated circuit. Although the need is greatest for photoconductors, the object of the invention is not limited to them and may be used with other classes of detectors. Another object of the invention is to provide the capability of changing the average output signal and time constant of the quiescent current suppression by means external to the circuit. All of these and additional benefits are described below.
In a photodetector amplifier scheme, the invention compensates for variations in photodetector quiescent current by sampling the amplifier output and subtracting a controllable current from the input to the amplifier. When a chopper or other modulator is used on the optical signal, the samples are taken periodically during the chopping cycle. This sampled signal is processed by a combination of gain and low pass filtering. The result of this processing controls a current source which subtracts a significant fraction of the average quiescent current from the total detector current. In a typical application, the amplifier is of the resettable current integrator type. In this case, the invention makes it possible to use smaller integration capacitors resulting in larger signals than if the quiescent current were not reduced by the operation of the invention. Larger voltage signals are desirable because the noise and drift of succeeding stages are relatively less significant. In addition to the suppression of quiescent current, the circuit provides other beneficial features. Among these features are: simplicity and small size permitting economical incorporation into an integrated circuit, the ability to modify the frequency response and gain of the circuit by adjustment of timing signals generated external to the circuit, operation in at least the two modes most commonly used in the processing of photoconductor signals, and suitability for fabrication as a CMOS integrated circuit without any special manufacturing techniques.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic of a basic photoconductor front end.
FIG. 2 is a schematic of reset type integrating amplifier.
FIG. 3 is a schematic of a commercially available quiescent current suppression scheme.
FIG. 4 is a schematic diagram of a typical embodiment of the invention.
FIG. 5 is a timing diagram showing signals at various points in the circuit as a function of time.
FIG. 6 is a schematic diagram of a linear model.
FIG. 7 is a frequency response plot of the circuit based on the linear model.
FIG. 8 is an open loop gain-phase plot that includes the effects of sampling delay.
FIG. 9 is a schematic diagram used to manufacture an integrated circuit with 32 channels.
DETAILED DESCRIPTION OF THE INVENTION
1. Description of a Typical Embodiment
The invention may be made in a number of ways and used in a number of applications. However, it can be understood most readily by reference to an embodiment utilized in a typical application as illustrated in FIG. 4. In this version, the invention is employed with an integrated circuit chip 30 which is capable of servicing a large number of detector channels (here, 32). The chip contains signal processing known in the prior art and additional circuitry. Off the chip is illustrated one of the number of detectors 15 receiving a modulated optical signal and circuitry for generating timing signals required by the on-chip circuitry.
In a typical application, an optical modulator 12, for example a mechanical chopper, is used. The optical signal 13 is made to pass through it before impinging on a photodetector 15 which, for illustration, is a photoconductive type. The topmost waveform in FIG. 5, Chopped Detector Signal, illustrates the optical radiation intensity on the detector. There are two regions identified. Chopper Closed indicates a period of time when the optical modulator is blocking the optical signal from reaching the detector. This time period may also be thought of as a reference period because during this time the detector is viewing the chopper blades or some other optical reference surface which remains at a fixed optical intensity. The other region identified as Chopper Open is a period of time when the optical signal (shown much exaggerated) is allowed to pass completely through the modulator and reach the detector. In between, the modulator is in the process of making a transition between open or closed and the optical signal is rising or falling. Typically, this period is shorter than the relatively long times shown for illustration.
Also, usually, as shown in FIG. 4, it will be possible to employ a modulator pickup 11 which by optical, mechanical, or other means senses and outputs a synchronizing signal indicating the state of the modulator, open or closed. Timing circuits 16 receive the pickup output and generate signals RST, SW2, and SW3 whose function will be explained. The timing circuits can be easily made with simple digital logic circuits and so construction details will not be set out.
FIG. 4 illustrates only one of the identical detector/electronics channels. A multiplexor 32 sequentially accesses the signals from all of them and makes these available at the chip output. The input signal to one channel is a current I det flowing through its associated detector 15 which is caused by the voltage Eb at 14. This voltage must be larger than the chip power supply voltage but is typically ten or more volts versus six volts for the chip. The I det current flows through a common gate connected MOSFET Q1 the drain of which is connected to a current node 21. At the current node, I det is divided into two components, I Q3 and I sig . I Q3 is a current which is determined by the gate-to-source voltage on common source connected MOSFET Q3 which is in turn determined by the remainder of the circuitry. I sig is that portion of I det left after subtraction of the I Q3 current, i.e., I sig =I det -I Q3 . I sig flows through the common gate connected MOSFET Q3 and into the node at 22.
Neither Q1 nor Q2 are required for the invention to work. However, they are desirable in a typical application because, as is well known, they isolate the source side of the circuit from voltage variations on the drain side. The voltage bias on the gate of Q1 should be as high as possible but cannot be higher than one threshold voltage, V TH , (about one volt for silicon CMOS) below the chip power supply, 5 volts for a 6-volt supply. The voltage bias on the gate of Q2 cannot be higher than about one threshold below the bias at Q1, about 4 volts. The maximum of the voltage V C1 at 22 on C1 before Q2 would saturate V sat is three threshold drops below the chip power supply. This is only about 3 volts, but this is not a major limitation if I Q3 subtracts the large quiescent current from I det . Even if Q1 and Q2 are not used, a high enough voltage, e.g., about 6 volts, on C1 would saturate some other circuitry connected to it. (When the voltage on C1 is limited to 3 volts, the point A1 in the figure indicates where an additional amplifier with a gain approaching 2 could be inserted to boost the signal to a maximum approaching 6 volts.)
The integration of the signal I sig by C1 proceeds as follows. During the transition period, RST is made positive enough to turn on the MOSFET switch S1 and clamp C1 to a ground reference level. When the chopper is open or closed, RST is made low enough to turn off S1 and C1 is charged by I sig for the time T r as shown by the waveform V C1 in FIG. 5. The sample and hold 31 samples V C1 at the end of the integration periods and holds the value for later signal processing such as multiplexing as shown in FIG. 4.
FIG. 5 illustrates V C1 as ramps which indicates that I sig was essentially constant and there was a small difference between Chopper Open and Chopper Closed. For a photoconductor, as noted in the background discussion, by far the largest component of the current is the quiescent current which varies slowly over a chopper period. In fact for a typical photoconductor with a resistance of 10 MΩ, a detector bias of Eb=10 volts and using a chopping frequency of 500 Hz so that T r =1 ms, V C1 would attempt to rise to 100 volts and would certainly saturate some device in the circuit. This can be prevented by increasing C1 if space permits, but this results in less signal gain. The alternative is to use the circuitry to subtract so much of the quiescent current that V C1 never rises above a few volts.
Quiescent current compensation signal processing proceeds by also taking a sample of V C1 . However, as shown in the curve labeled S2 in FIG. 5, it need not occur at the end of the integration periods T r but may occur at a shorter time T i . At this time, signal SW2 turns on S2 momentarily to take a sample of V C1 . A short time later, as shown by curve SW3, S3 turns on momentarily to take a sample of the voltage on C2 which is transferred to C3. As is well known, the size of C2 should be small compared to the size of C1 in order to avoid transferring much of the charge on C1 to C2. If not, the value of V C1 seen by the later sample and hold 31 and further processed will be reduced. Alternately, the point A2 indicates where a buffer amplifier could be inserted so that C1 is not discharged by C2.
C3, on the other hand, is preferably larger than C2. This sampling with the combination S2, C2, S3, C3 is well known in the art to be equivalent to an R-C low pass filter where S2, C2, and S3 form a switched-capacitor resistor and C3 is the filter capacitor. The equivalent resistance is given simply by
Req=T.sub.a /C2
where T a is the average time between samples. The RC time constant, T c , is therefore
T.sub.c =(C3/C2)T.sub.a
If, for example, C3/C2=300 and since, here, T a is one chopper cycle, then the circuit averages V C1 over 300 chopper cycles.
The voltage on C3 is connected to the gate of common source connected MOSFET Q3. When this voltage rises above the threshold voltage, V TH , of Q3, it turns on and the current I Q3 is subtracted from I det at the node. The circuit creates a feedback loop which, to the extent that the transconductance G m of Q3 is large, forces V C1 at the time T i to be slightly above the threshold voltage of Q3, i.e., V C1 (T i )≅V TH . (Point A3 indicates another point where an amplifier could be inserted to, in this case, increase the gain either alone or in conjunction with current source linearizing circuitry.)
The waveforms SW2 and SW3 in FIG. 5 illustrate two sampling modes which emulate the two most common photoconductor signal processing techniques. In a DC Restore mode, samples are taken only during the Chopper Closed period. In this mode the circuitry will keep V C1 (T i ) during the Chopper Closed period at a level representing the Optical Reference Level. In an AC Mode, a sample is taken at the same time T i in both the Chopper Open and Chopper Closed periods. In this mode, the circuitry will keep V C1 at a level representing the average of the Optical Reference Level and the Optical Signal Level. The resultant signal V out is effectively AC coupled, swinging equally around a fixed level. The DC Restore is useful if, during the Chopper Closed period, a stable optical reference signal impinges on the detector. If so, then the off-chip electronics may be able to ignore the Chopper Closed and simply display the Chopper Open results without taking any differences. The AC Mode is more useful when either the signal during the Chopper Open period is large compared to the quiescent current and it is necessary to keep this ramp from saturating or the Chopper Closed reference radiation is not stable.
Additional flexibility may be obtained by adjusting the position of the samples within the periods. In the DC Mode, for instance, if T i is delayed until the end of the period, then the Chopper Open ramp is minimized allowing the largest positive values for I sig . If T i occurs sooner, the values for Isig can be pushed more and more negative (see below). This ability to adjust the level of the output signal by simple external time delays increases the utility of the circuit by allowing the user to set the level at a value most suitable to their application.
Moreover, sampling is not limited to once per period. One can skip periods or sample many times within a period, even at irregular intervals. The result would produce a voltage on Q3 which is the average of all these samples. For example, if high frequency noise were present to such an extent that integration by C1 did not reduce it adequately, one could sample many times in a period.
If no synchronizing signal is available to determine RST, then typically it and the circuitry would be operated at some fixed frequency designed to capture optical signals which might be present. However, the circuit doesn't require an optical signal to operate. In all cases, it simply forces the average V C1 (T i ) toward the V TH of Q3.
2. Linear Model of the Circuitry
The gain and frequency response of the circuit can be understood by analyzing a linear model as illustrated in FIG. 6. The following substitutions are made for the elements in FIG. 4.
Q1 and the detector 15 are replaced by an ideal current source, I det .
Q3 is replaced by an ideal controllable current source with transconductance=G m .
Q2 is not needed because I det and I Q3 are ideal current sources.
C1 and S1 are replaced by resistor Rc, where Rc=T i /C1.
S2, C2, and S3 are replaced by Req=T a /C2.
If A1, A2, or A3 are used, they replaced by pure gains G1, G2, and G3.
For this linear model, the amplifier and MOSFET offsets and the delay are set to zero. The circuit equations for the linear model yield: ##EQU1## where T c =ReqC3=(C3/C2)T a and s=the complex frequency, jω+σ. Using typical values from above:
C1=10 pf., C2=0.1 pf., C3=30 pf.
G1=G2=G3=1
T i =0.5 mS for a Chopping Cycle Time=2 ms
Gm=2 μS
so that
Rc=50 MΩ and T c =300 T a
The value of G m has not been discussed because it requires special consideration. Usually, G m would be selected to be as high as possible to the point where the circuit becomes unstable. However, for use with photodetectors, it must be high enough for the circuit to have enough gain, but not too high. The current noise from a MOSFET which, in the case of Q3, feeds directly into the signal path, is proportional to the square root of G m . As a compromise, a MOSFET with an unusually low G m , on the order of a μS, is preferable for this typical application. In other cases, G m should be selected so that the noise from Q3 is preferably less than the noise from the detector. It should be noted that for all FETs, G m is not constant but varies linearly with drain currents at low values and as the square root at higher ones. Thus, the required Gm is a function of the expected quiescent current to be compensated by Q3. The circuit may be stable at low I Q3 but unstable at higher ones. Fortunately, as the working example below shows, a broad range of I Q3 can be accommodated.
FIG. 7 shows a plot of the gain versus frequency response for two values of T a . With T a =1 ms, the signal is sampled twice per cycle and with T a =4 ms, once every other cycle. The curves for the two cases of T a show the ability to adjust the overall circuit frequency response by external timing means.
The gain (V C1 /I det ) at high frequencies (>100 Hz) is set by R c , here 0.5×10 8 , or 100 times the gain at low frequencies (<0.1 Hz) set by 1/(G1G2G3G m ). The dotted lines show Ideal AC Coupling, as would be obtained with an AC coupling capacitor, in which the gain approaches zero as the frequency approaches zero. This could be approached with this invention by adding amplifiers with gain at the points previously indicated. Even so, while the low frequency gain of the circuit does not approach zero, it is small enough to accommodate variations in quiescent resistance typically found in photoconductive arrays. For instance, if the bias current were 1 μA, a typical value, and the quiescent resistance were to drift 10%, the output of the circuit would change only 0.05 volts. (10% of 1 uA=0.1 μA, and 0.1 μA×0.5×10 6 =0.05 V). If, on the other hand, the 500 Hz modulated photocurrent, were to change the same 0.1 μA, the output would change 5V (0.1 μA×0.5×10 8 =5). Thus, the circuit fulfills its purpose of reducing the effects of slow quiescent current variations while maintaining high gain at the chopping frequency.
As noted, to reduce noise, G m should be low but if it is, then V C1 (T i ) will have to be above V TH in order to produce a large enough I Q3 . However, as long as V C1 (T i ) is less than V sat , signals can be integrated. The maximum range of I sig , assuming a constant signal, is C1V sat /T r . If G m were very large, then I sig would range from -C1V TH /T r to +C1(V sat -V TH )/T r . As G m is reduced, the range would shift more negative. Another way to cause a negative shift in range is to sample at less than the full Chopper Off period. In this case, V C1 (T i ) approaches V th but V C1 (T r ) will be larger and, if T i is small enough, reach V sat before the end of the Chopper Off period. However, if I sig is negative enough during the Chopper On period, it will cause the voltage on C1 to remain below V sat . This mode of operation is useful if the radiation on the detector when the chopper is on is less than when the chopper is off. This would occur, for example, when viewing the upper atmosphere or the night sky from a heated airplane. For use in such conditions, those skilled in the art could easily construct circuits to monitor the output of one or more channels and on detecting zero or saturated signals, vary T i to find an optimum setting for it. Of course, an intentionally hot choper could be used and compensated in all situations. It should be noted that this mode cannot be obtained if feedback were perfect in the sense of infinite G m and zero V TH .
3. Loop Stability
Since the circuit is a closed loop system, the issue of loop stability needs consideration. In general, a feedback loop will be unstable if the phase lag exceeds 180 degrees while the magnitude of the open loop gain is greater than unity. In the analysis of the linear model frequency response, the delay due to sampling was assumed to be zero. In that case, the loop will be stable for all conditions because the maximum phase lag is limited to the 90 degree contribution from the R eq C 3 time constant.
In a system that uses periodic sampling with a time between samples of T d , the phase lag in degrees as a function of frequency f is 360×T d ×f. (This is a close but adequate approximation in the case of the reset integrator C1-S1 used in the invention.)
In terms of times and capacitor values, the total phase lag becomes
Φ=tan.sup.-1 (2πfT.sub.a (C.sub.3 /C.sub.2))+2πfT.sub.d
and the magnitude of the gain is ##EQU2## where, as before, T i is the time delay into the reset integration before a sample is taken. The times T a , T d , and T i can all be independently varied so that a complete discussion is tedious. However, a simple case is presented by the DC Mode which also turns out to be a worst case in terms of stability. In this mode, even though the reset integrator is run twice per cycle, a sample is taken only once every full chopping cycle so that T a =T d =1/F chop where F chop is the chopping frequency. The case is made still simpler and worse (because the gain is increased) if the chopper is assumed to be ideal with no transition period and the sample is taken at the end of the Chopper Closed period so that T i =2/F chop . F chop now becomes a single parameter characterizing the loop.
Φ and M are shown in FIG. 8 as a function of frequency f for two different chopper frequencies, F chop =100 and 500 Hz. While the gain magnitude at DC for a 100 Hz chopper is higher than for the 500 Hz chopper by a factor of five because T i is five times larger, by about one Hz the gains are the same and dominated by the low pass filter. However, the phase lags differ. For the 500 Hz chopper, the phase lag when the magnitude crosses unity is about 107 degrees so that there is a stability margin of about 73 degrees. On the other hand, the 100 Hz chopper shows a phase lag slightly greater than 180 degrees, which means that the loop would be unstable. (A limit cycle analysis shows that the oscillation frequency is close to F chop /2 and not the 26 Hz suggested in the figure.)
This seems to indicate that quiescent current compensation employing the circuit component values, i.e., capacitor and G m values, cannot be used with a 100 Hz or slower chopper. However, the value for T d can be decreased. First, the AC Mode (sampling twice per cycle) could be used which would cut T d and T a in half (T i can remain unchanged) as well as the lowest stable F chop . Further, by over sampling, all three, T d , T a , and T i can be reduced. A reduction in T i means that the gain magnitude is also reduced which provides even more phase margin.
Of course, stability without gain is not useful. It could be regained if C1 is decreased but this requires a new chip or one with selectable capacitors. Decreasing C1 may also require a buffer amplifier at A2 in order not to load it with C2. C2 is already too small to be satisfactorily reduced further. If C2 is changed, C3 should be changed proportionately to maintain the same ratio which seems to be optimum from a noise and stability standpoint.
Although, for many detectors and systems, chopping frequencies between about 100 Hz and 1 Khz are preferred, higher ones can be accommodated if C1 is reduced. A lower practical limit is about 0.1 pf., 100 times smaller than the 10 pf used in the example, with the same considerations on C2 just noted. The CMOS circuitry can easily run above the 50 kHz level that this implies. At the other extreme, the circuitry can be operated without any chopper or signal modulation. Its primary purpose is to subtract the quiescent current for which it only needs a sample often enough to be stable.
4. Working Example
An integrated circuit that could handle 32 detectors was constructed based on the schematic shown in FIG. 9. Those skilled in the silicon foundry art were able to produce integrated circuits from this schematic without any more instructions than those contained therein. (Note that the notation 10/200 for N3 means a gate width of 10 μm and length of 200 μm and similarly for the other MOSFETs.) It is similar to the typical embodiment discussed above with a few differences. First, it uses P-wells instead of N-wells. This means that all polarities are reversed, i.e., all supply voltages are negative and, in some cases, N channel and P channel MOSFETS are interchanged. Thus, Q1 becomes P1, Q2 becomes P2, but Q3 becomes N3. S1 is shown as N1. Also, an additional MOSFET N2 was provided in case it was useful to subtract a fixed current from I det in addition to I Q3 . However, in practice this proved unnecessary.
The circuit was constructed using a very conservative 0.6 μm feature size process but, even so, the chip measured a relatively small 0.026 sq. in., less than about three instrumentation op amps in area. The circuit was run with chopping frequencies from 200 to 500 Hz and with photodetector quiescent currents ranging from 50 na to 5 μA. Over these ranges the processed V out was substantially linear with optical signal and followed the frequency response of the linear model. Channel to channel variations in gain and frequency response were about 5%. The noise was equivalent to the noise from a 10 MΩ lead sulphide detector when it was operated with a 2.5 μa quiescent current. For many commercial applications this performance is adequate.
If the economics permits a larger chip, better performance could be achieved with the following improvements. The 0.1 pf. value for C2 is so small that nearby parasitic capacitances cause its value to increase from the nominal by varying amounts. A larger value and/or MOSFET isolation would help. However, this requires a larger C3 which at 30 pf takes up about 10% of the existing chip area. If larger chips were affordable, a larger C3 would reduce the kT/C current noise that feeds Q3 in proportion to the square root of the increase in area and a larger ratio of C3/C2 would provide more stability at low frequencies. Lastly, a longer Q3 gate would reduce its G m and therefore its noise. Alternatively, an IC process using a thicker gate oxide (a drawback in most applications) would also reduce G m .
5. Other Applications
Those skilled in the art will appreciate that many tradeoffs are made in designing systems where this invention could be used. Consideration must be given to the signal characteristics, modulators available, background and detector characteristics. However, using the teachings herein it should be obvious how to modify the invention to handle a wide variety of applications.
For example, the invention is not limited to photoconductor applications. Since these have been made into and modeled as current sources, all other classes of detectors that require quiescent current suppression may benefit. As an example, InSb and InAs photovoltaic detectors have rather large quiescent currents, especially if they are reversed biased to reduce capacitance. Even silicon photodiodes have large quiescent currents if they are hot or reverse biased and have a large area. At low frequencies, even detectors with small quiescent currents could benefit. | In a photodetector amplifier scheme, the invention compensates for variations in photodetector quiescent current by sampling the amplifier output and subtracting a controllable current from the input to the amplifier. When a chopper or other modulator is used on the optical signal, the samples are taken periodically during the chopping cycle. This sampled signal is processed by a combination of gain and low pass filtering. The result of this processing controls a current source which subtracts a significant fraction of the average quiescent current from the total detector current. In a typical application, the amplifier is of the resettable current integrator type. In this case, the invention makes it possible to use smaller integration capacitors resulting in larger signals than if the quiescent current were not reduced by the operation of the invention. The gain, frequency response, and range of compensated quiescent currents and can be altered by changing timing signals. Implementation is directed toward using components which take up little area when fabricated as an integrated circuit. | 7 |
RELATED APPLICATIONS
[0001] This application is a continuation-in-part of application Ser. No. 09/479,694 filed Jan. 7, 2000, which in turn claims the benefit of U.S. Provisional Application No. 60/115,172 filed Jan. 8, 1999, all of which are incorporated herein by reference.
FIELD OF THE INVENTION
[0002] The present invention relates to nonwoven webs. More particularly, the invention is directed to nonwoven polyolefin webs which have durable hydrophilic properties and to articles formed from such webs.
BACKGROUND OF THE INVENTION
[0003] Polyolefin fibers have been widely used in the nonwovens industry in the manufacture of nonwoven webs, fabrics, and composites. Olefin polymers, such as polyethylene, polypropylene, polybutene, polypentene, and copolymers of ethylene or propylene with other olefinic monomers, are known for their hydrophobic properties. Thus, nonwoven webs of polyolefin fibers are frequently used in applications where their hydrophobic properties are advantageous. For example, polyolefin nonwovens are often used in diapers, other hygiene products and medical applications where it is desired to keep moisture away from a wearer's skin.
[0004] However, there are numerous other nonwoven fabric applications where the hydrophobic nature of polyolefin fibers is not required and where hydrophilic properties are desired. If a nonwoven fabric formed of polyolefin fibers is to be used, the fibers must be treated in some way to alter the normally hydrophobic properties of the fibers to impart hydrophilic properties. One well-known practice involves the topical application of compositions, such as surfactants, to render the fabric more hydrophilic. However, topical chemical applications are not entirely satisfactory for some applications, since they are not durable. The hydrophilic property is lost after washing or after extended use. The extra processing steps required for topical chemical treatments or other fiber surface modification treatments also undesirably increase the cost of the fabric. The few processes known to render the polyolefins wettable are environmentally unfriendly, relatively slow and have limited durability.
[0005] An alternative to chemical surface modification is to directly melt blend a hydrophilic additive into the thermoplastic polymer rendering the fibers themselves hydrophilic. Published PCT Patent Specification WO99/00447 discloses a product and process for making wettable fibers prepared from an olefin polymer, polyester or polyamide including a wetting agent consisting essentially of a monoglyceride or a combination of a monoglyceride and a mixed glyceride with the monoglyceride amounting to at least 85% by weight in the case of the combination.
[0006] The monoglyceride corresponds to the formula
[0007] wherein —OR 1 , OR 2 , and —OR 3 are hydroxyl or a fatty acid ester group, but only one of them is a fatty acid ester group (C 12-22 ). The mixed glyceride (di- or tri-) corresponds to the formula
[0008] wherein —OR 4 , OR 5 , and —OR 6 are hydroxyl or a fatty acid ester group (C 12-22 ). The combination of this di- or tri-glyceride with the monoglyceride constitutes the wetting agent in accordance with one embodiment.
[0009] However, the use of hydrophilic melt additives can add significantly to the cost of the nonwoven webs. Also, the addition of a hydrophilic melt additive to the polyolefin polymer can alter the properties of the fibers or filaments, resulting in unacceptable changes to important physical or aesthetic properties of the nonwoven web, such as strength, softness or hand, for example.
SUMMARY OF THE INVENTION
[0010] The present invention overcomes the foregoing limitations and provides a polyolefin nonwoven web which has durable hydrophilic properties, while achieving a highly desirable combination of cost, physical properties and aesthetics.
[0011] Nonwoven webs in accordance with the present invention include multicomponent fibers bonded by a multiplicity of bond sites to form a coherent web. The multicomponent fibers include a first component formed of a hydrophobic polypropylene and a second component formed of a blend of a hydrophobic polyolefin and a hydrophilic melt additive. This second component is disposed at the surface of the fibers. The hydrophilic melt additive-modified polyolefin component can be arranged in various configurations in the cross-section of the fiber and the fibers can have various cross sections. For example, the hydrophilic component can occupy a portion of the surface of the fiber, as would occur for example with a side-by-side or segmented pie multicomponent fiber configuration. Alternatively, the modified hydrophilic polyolefin can occupy substantially the entire surface of fiber, as for example by producing the fibers in a sheath-core configuration with the hydrophilic modified component forming the sheath. A particularly preferred configuration is a sheath-core bicomponent fiber where the hydrophobic polypropylene forms the core and the modified hydrophilic polyolefin forms the sheath. Other configurations include non-concentric sheath-core, multi-lobal or tipped cross sections, and islands-in-the-sea cross sections.
[0012] The multicomponent fibers may be formed into a nonwoven web using various processing techniques known in the nonwovens industry. For example, the multicomponent fibers may comprise an air-laid web of staple fibers, a carded web of staple fibers, a wet-laid web staple fibers, a web of meltblown fibers or a spunbonded web of substantially continuous filaments or a combination of two or more of these techniques.
[0013] There are various melt additives available which can be melt blended with a hydrophobic polyolefin composition to impart durable hydrophilic properties to the polyolefin. Melt additives suitable for the present invention must not undesirably alter the melt-spinability of the multicomponent fibers and should be relatively compatible with the polyolefin composition such that the additive will not prematurely leach out and lose the hydrophilic properties. Certain suitable melt additives useful in the present invention will be at least partially immiscible with the polyolefin polymer composition and will tend to bloom to the fiber surface over time or with application of heat to impart a prolonged hydrophilic surface modification. Particularly suitable are compounds with a molecular structure which includes at least one functional group which is tethered to the olefin polymer structure, with other functional groups which provide reactive hydrophilic sites.
[0014] Suitable hydrophilic melt additives for use in the present invention include monomer or dimer fatty acids, hydroxy phenols, polyethylene glycol, fluorohydrocarbons, polyvinyl alcohol and polyvinyl formal.
[0015] One particularly suitable class of melt additives is an admixture of hydroxy phenols and polyethylene glycols. The hydroxy phenol is characterized in that it contains the functional group HOC 6 H 4 —.
[0016] Another particularly suitable class of melt additives are monomer and dimer fatty acids having a carbon chain length in the range of 6 to 50, preferably 18 to 36.
[0017] According to one embodiment of the invention, the nonwoven web is fabricated employing wet laid and/or carded thermal bonding processes. It is possible to use combinations of hydrophobic and hydrophilic fibers in the web. In other words, all fibers in the web need not be permanently wettable.
[0018] In one specific preferred embodiment, the web includes bicomponent fibers in which the melt additive is incorporated into the sheath constituent of the fiber. Use of bicomponent fibers, as well as combinations of hydrophobic and hydrophilic fibers, reduces costs and permits optimization of the web for diverse applications.
[0019] Thus, a broad aspect of the present invention is to provide a nonwoven web that has the wettability and strength for use in various end uses (such as rechargeable alkaline batteries, hygiene products, medical products, or filtration products) by directly incorporating hydrophilic melt additives into one or more normally hydrophobic polyolefin components of a multicomponent fiber during melt processing. This fiber can be meltblown, spunbonded or made into staple fibers to form a wettable web. Alternatively the wettable fiber can be mixed with binder fibers that are wettable or non-wettable or mixtures of both which are then made into a nonwoven web.
[0020] Another aspect of the invention is to provide a nonwoven web with increased wettability and strength for use as battery separator material. Another broad aspect of the invention is a nonwoven that is durable and wettable in harsh environments.
[0021] A further aspect of the invention is a nonwoven web that has both hydrophilic and hydrophobic regions.
[0022] Still another aspect of the invention is to provide a method for producing products that can be designed to have varied wettablility and strength properties depending on the desired end use applications.
[0023] One specific embodiment of the invention is the provision of a lower cost battery separator material including sheath-core bicomponent fibers, wherein melt additives are incorporated in the sheath of the bicomponent fiber and not the core.
[0024] Another specific embodiment of the invention is the provision of an economical battery separator material made of both wettable and non-wettable polymeric fibers.
[0025] A still further embodiment of the invention is a nonwoven web that can be used for other applications such as diapers and feminine care products, and medical applications which would require durable wettability.
[0026] Another aspect of the invention is to provide a nonwoven web that can be used in clothing applications, wherein products produced remain durable and hydrophilic after multiple machine washings.
[0027] Another aspect of the invention is to provide a nonwoven that can be used in filtration applications, wherein durable and wettable properties are required.
[0028] The thermoplastic polymeric multicomponent fibers are preferably staple fibers or continuous filaments with a hydrophobic polypropylene component and another component formed of a hydrophobic polyolefin, such as polyethylene or polypropylene, containing a hydrophilic melt additive.
[0029] In one of the embodiments of the present invention, the wettable fibers are blended with non-wettable binder fibers. Preferably these binder fibers are polyethylene/polypropylene bicomponent fibers having a polyethylene sheath and a polypropylene core.
[0030] In another embodiment of the invention, the nonwoven web includes both non-wettable binder fibers and wettable binder fibers. The wettable binder fibers are preferably polyethylene/polypropylene bicomponent fibers where the hydrophilic melt additive is incorporated into the polyethylene sheath of the bicomponent fiber. The non-wettable binder fibers may comprise polyethylene/polypropylene bicomponent fibers.
[0031] In yet another embodiment, the nonwoven web is formed substantially entirely of wettable binder fibers of the type described.
[0032] In one suitable embodiment the nonwoven web is 30-90 weight percent of the wettable binder fibers; and 10-70 weight percent of the non-wettable binder fibers. In a more specific embodiment the nonwoven web is 50% wettable binder fiber and 50% non-wettable binder fibers.
[0033] In another suitable embodiment the nonwoven web comprises up to 40 weight percent of a wettable fiber matrix; up to 40 weight percent of non-wettable binder fibers; and up to 30 weight percent of the wettable binder fibers. Although specific exemplary ranges are described, any combination of wettable fiber matrix, non-wettable binder fibers and wettable binder fibers are encompassed by the invention with the amounts of each component depending on the desired wettability and strength properties of the resulting web.
[0034] In general, battery separator materials formed from nonwoven webs of the invention have enhanced wettability and strength and provide good permeability to gases.
[0035] The invention also includes the related process for making nonwoven webs which can be used as battery separators and in other applications which require durability and wettability. In general, wettable multicomponent fibers with at least one hydrophilic melt additive are produced and formed into a nonwoven web by meltblowing, spunbonding other nonwoven formation methods. In one embodiment the fibers are further mixed with binder fibers which are then laid on a papermaking machine to form a wet-laid web. The water is removed from the wet-laid web, thermal bonded and calendered to form the nonwoven.
[0036] The nonwoven mats produced, in addition to use as battery separators, can be used in other applications such as absorbent and hygiene products, medical products, clothing and filtration products which require durable wettability and strength.
[0037] Other objects, features and advantages of the present invention will become apparent from the following detailed description of the best mode of practicing the invention as follows:
DETAILED DESCRIPTION OF THE INVENTION
[0038] The hydrophilic melt additives are incorporated into the thermoplastic olefin polymer and are converted into a nonwoven using any of various forming technologies available for the production of nonwoven webs. The material can be converted directly from the polymer into a nonwoven by spunbonding or meltblowing or a combination of the two. Alternatively, the material may be first formed into fibers and the fibers may thereafter be converted into a nonwoven web by techniques such as wet-laying, air-laying or carding. By combining the melt additives and the nonwoven process, a durably hydrophilic nonwoven web is produced.
[0039] In one embodiment of the invention, the hydrophilic melt additives are blended with polypropylene and formed into multicomponent staple fibers to form a wettable fiber matrix. This matrix is then further combined with non-wettable binder fibers and wet-laid to form the nonwoven material of the invention. The non-wettable binder fibers used may also include a bicomponent fiber comprising a polyethylene sheath and a polypropylene core, available as Chisso fibers from Chisso, Japan. The nonwoven material formed has both discrete hydrophobic and hydrophilic regions due to the different types of fibers used in making the web.
[0040] In an alternate embodiment the hydrophilic melt additives are blended with bicomponent fibers comprising a polypropylene sheath and a polypropylene core to form the wettable fiber matrix. The bicomponent sheath/core fiber proportions used in the invention may vary over a wide range, with from 50/50 sheath/core to 60/40 sheath/core being exemplary. Essentially the melt additives are incorporated into the outer polypropylene sheath of the fibers. Use of bicomponent fibers having 60/40 sheath/core permit higher incorporation of the melt additive into the sheath portion. The wettable fibers may be then further combined with non-wettable binder fibers to form the nonwoven web.
[0041] In all embodiments, the durable hydrophilic web is manufactured by blending a concentrate of hydrophilic melt additives with the thermoplastic polymer and converting the polymer into multicomponent fibers, and a nonwoven fabric directly or through an intermediate fiber formation process. The chemistry and physical properties of the additives, its compatibility with the thermoplastic resin, as well as the process conditions and constructional features of the nonwoven separator are necessary to yield the desired performance. The type of melt additive and proportion are important to the durable wettability of the nonwoven fabric.
[0042] In one embodiment, the melt additives used in the invention are selected from the group consisting of monomer and dimer fatty acids having a carbon chain length in the range of 6 to 50, preferably 36. In a preferred composition of this embodiment, the blend contains 2 to 15% Acintol® tall oil fatty acid, Acintol® distilled tall oils (monomer acids) and Sylvadym® dimer acids, which are all commercially available from Arizona Chemical Company, Panama City, Fla. and are fully described in the Technical Data Sheets for these materials, which are incorporated herein by reference. These are polar liquid materials which migrate to the surface of the polyolefin and remain as liquid on the surface thereof. Uniform mixing of the components is important to achieve effective hydrophilic properties.
[0043] In another embodiment, the hydrophilic melt additives are fluorohydrocarbons, such as 3M FC 1296. In another embodiment, the melt additives used in the invention are an admixture of hydroxy phenols and polyethylene glycols. Examples of melt additives used are commercially available from Techmer PM, California under the product designations PPM 11211, PPM 11249, PPM 11212, PPM 11267 and PPM 11268. The technical brochures of each of these materials are incorporated herein by reference.
[0044] A variety of different melt additive formulations can be used to form the wettable fiber matrix. Specific formulations are illustrated in Examples 1 to 5 herein. In general, the formulas include an active chemical which is an admixture of hydroxy phenols and polyethylene glycols. This active or functional chemical is provided in a carrier resin, preferably polypropylene, of a given melt flow rate (MFR) suitable for meltblowing, spunbonding or staple fiber manufacture. Accordingly, the formulations have different melt flow rates depending on the end use applications. The MFR listed in the formulations below were measured at 230° C., 2.16 kg. Melt blown grade polypropylene resins typically have a much higher melt flow rate (MFR 800-1200), whereas spunbond and staple fiber grade polypropylene resins have a lower melt flow rate (MFR 7-35). The base chemicals in the formulations include durable hydrophilic materials or non-durable hydrophilic materials depending on the desired wettability properties and end use applications.
[0045] The non-durable hydrophilic materials provide initial wetting of the fibers to enhance and maximize incorporation of the durable hydrophilic materials. The durable hydrophilic materials impart the wettability and strength properties to the fiber materials. In particular, in battery separator applications, the more durable chemical loaded, absorbency and wicking increase and the longer the life of the battery.
[0046] Melt Additive formulations 1 to 5 are illustrative of the types of melt additive formulations used in the invention and shown in Examples 1 to 5.
[0047] Melt Additive 1 contains approximately 30% of the active chemical and includes the same durable hydrophilic materials as in Melt Additive formulation 4 but a different melt flow rate. This additive is commercially available as PPM 11211 from Techmer PM, California.
[0048] Melt Additive 2 contains approximately 30% of the active chemical and includes the same non-durable hydrophilic materials as in Melt Additive formulation 5 but a different melt flow rate. This additive is commercially available as PPM 11212 from Techmer PM, California.
[0049] Melt Additive 3 contains approximately 20% of the active chemical and includes non-durable hydrophilic materials. This additive is commercially available as PPM 11249 from Techmer PM, California.
[0050] Melt Additive 4 contains approximately 25% of the active chemical and includes the same durable hydrophilic materials as in Melt Additive formulation 1. This additive has a MFR of 54 grams/10 minutes and is commercially available as PPM 11267 from Techmer PM, California.
[0051] Melt Additive 5 contains approximately 20% of the active chemical and includes the same non-durable hydrophilic materials as in Melt Additive formulation 2. This additive has a MFR of 109 grams/10 minutes and is commercially available as PPM 11268 from Techmer PM, California.
[0052] For melt blown nonwoven structures, in illustrative applications, Melt Additive formulations 1, 2 and 3 are used. Preferred proportions for melt blown structures include use of 15-35% of Melt Additive 1 formulation, i.e., 4-10% of the active chemical or up to 10% of Melt Additive 2 formulation, i.e., up to 3% of the active chemical. Most preferred proportions for melt blown structures include 30% of Melt Additive formulation 1, i.e. 9% of the active chemical and 5% of Melt Additive 2 formulation, i.e. 1.5% of the active chemical.
[0053] For spunbond and nonwoven mats containing staple fibers, in illustrative applications, Melt Additive formulations 4 and 5 are used. Suitable proportions for such structures include use of 15-30% of Melt Additive 4 formulation, i.e., 4-8% of the active chemical or up to 10% of Melt Additive 5 formulation, i.e., up to 2% of the active chemical. More specific exemplary proportions for these structures include 25% of Melt Additive formulation 4, i.e. 6% of the active chemical and 5% of Melt Additive 5 formulation, i.e. 1% of the active chemical. For staple fibers, a preferred proportion includes 20 weight percent of Melt Additive 4 and 2½ weight percent of Melt Additive 5.
[0054] The hydrophilic melt additives can be used in the following exemplary forms of nonwovens, namely meltblown, spunbond, SMS (spunbond/meltblown/spunbond), wet-laid, dry-laid or a combination of these forms. Fiber deniers for melt blown structures typically range from 0.1 to 2.0 deniers, with less than 1.0 most preferred. In the case of staple fiber and spunbond filaments deniers, fiber deniers of less than 3.0 are used, but less than 2.0 are most preferred. For spunbond and staple fiber nonwoven structures, in preferred applications Melt Additive formulations 4 and 5 are used.
[0055] To understand the present invention more fully, the following examples of the invention are described below. These examples are for purposes of illustration only and this invention should not be considered to be limited by any recitation used therein. The examples demonstrate the preparation of various battery separator materials in accordance with the process of the invention.
[0056] As in the examples below, unless otherwise specified, the test procedures for testing electrolyte initial wet out time, retention (absorbency %) and wicking in battery separator fabric are as follows:
[0057] Preparation of 31% KOH Solution:
[0058] Ingredients:
[0059] Distilled water and potassium hydroxide pellets (KOH).
[0060] Procedure:
[0061] The distilled water is freed of dissolved carbon dioxide by boiling and covering with a watch glass. The boiled water is allowed to cool to room temperature. The solution should be 31% KOH by weight. Since solid KOH contains approximately 10% water, 34.5 g of solid KOH is used for every 100 g of solution required. The solution is made by slowly adding the 34.5 g of KOH to 65.5 g of water.
[0062] Wet Out Time
[0063] 10 ml of 31% potassium hydroxide (KOH) was placed in a five inch watch glass. One {fraction (5/8)}″ diameter disc sample was placed on the surface of the KOH. The time in seconds was recorded for initial wet out time up to 120 secs. These measurements were taken of the sample “as is” (WET OUT BEFORE) and of the sample after 7 days aging in the 31% KOH (WET OUT AFTER). The average time in seconds was reported for the samples. In some examples, the samples were only aged for 5 days.
[0064] Electrolyte Retentively (Absorbency %)
[0065] Retentively refers to the amount of potassium hydroxide solution that will be retained by a specimen. Values are obtained by determining the amount of solution of KOH that is retained by a specimen soaked in the solution.
[0066] specifically, three (3) specimens from each sample are cut (such that the “V” shaped portion of the die runs in the MD direction). The specimens are conditioned by drying in an oven at 70° C. (158° F.) for 1 minute, removed from the oven, and conditioned to the lab environment for 15 minutes prior to testing.
[0067] Each specimen of the fabric is weighed (“dry weight”) and then is soaked in a 31% solution of KOH. The amount of solution retained by the specimen is measured after 1 hour. The specimen is removed, allowed to drip for 10 minutes, and weighed and recorded as “wet weight”. The percent retention is calculated using the following formula:
( Weight weight - Dry weight ) ( Dry weight × 100 ) = % Retention
[0068] Electrolyte Absorbing (Wicking)
[0069] Wicking refers to the ability of a fabric to absorb a liquid through capillary action. Wicking values are obtained by determining the distance a solution of potassium hydroxide (KOH) is absorbed (wick) by a fabric specimen held vertically.
[0070] Specifically, three (3) specimens from each sample are cut 1″ CD×7″ MD. The specimens are conditioned by drying in an oven at 70% (158° F.) for 1 minute, removed from the oven, and conditioned to the lab environment for 15 minutes prior to testing. Each specimen of the fabric is suspended vertically in a 31% solution of KOH and the distance the liquid is absorbed by the specimen is measured after 30 minutes.
[0071] Alkali Proof Character
[0072] A pre-weighed specimen of the fabric is soaked in a 31% solution of potassium hydroxide (KOH) for 7 days at a temperature of 70° C. (158° F.) and then re-weighed to determine weight loss. This method is used to determine the effects on the fabric when subjected to a long term exposure in a solution of KOH, at an elevated temperature.
[0073] Specifically, three (3) specimens from each sample are cut 2″ CD×8″ MD. The specimens are conditioned by drying in an oven at 70° C. (158° F.) for 1 minute, removed from the oven, and conditioned to the lab environment for 15 minutes prior to testing. Each specimen of the fabric is weighed and then submerged in the KOH solution and soaked for 7 days. After 7 days the samples are removed and rinsed thoroughly with distilled water to remove all the KOH solution (6 or 7 times in a beaker with distilled water). The specimens are dried and re-weighed to determine weight loss.
EXAMPLE 1
[0074] A wettable battery separator material was prepared from a mixture of a wettable fiber matrix and non-wettable binder fibers.
[0075] In Samples 1, 2 and 3 the wettable fiber matrix used is a bicomponent fiber comprised of a polypropylene sheath and a polypropylene core. Combinations of Melt Additive formulations 4 and 5 were incorporated into the polypropylene sheath with essentially none of the additives migrating to the fiber core. The bicomponent fibers are 1.5 denier×{fraction (1/2)} inch and are obtainable from Fiber Inovation Technologies, Johnson City, Tenn.
[0076] Specifically in Samples 1, 2 and 3, 20% of the melt additive (30% active material) was incorporated into the polypropylene sheath (6% active material). The proportion of sheath/core in the bicomponent fiber is 50/50, thus the amount of active material in the total fiber was 3%.
[0077] The non-wettable binder fibers comprised a bicomponent fiber having a polyethylene sheath and a polypropylene core. The binder fibers are 2.0 denier×5 mm and are available as Chisso fibers from Chisso, Japan.
[0078] In each sample 50% of the wettable fiber matrix was mixed with 50% of the non-wettable binder fibers. The fiber mixture was dispersed and wet-laid to form the nonwoven substrates. The substrates were evaluated after calendering for absorbency, wicking and wet-out to KOH. The tests were also done after 7 days exposure to KOH at 70° F. The results are summarized in Table I below.
TABLE I ABSORB. WICKING WET-OUT BASIS % mm sec WT. THICKNESS BEFORE/ BEFORE/ BEFORE/ WT. LOSS SAMPLE gsy mils AFTER AFTER AFTER % 1 27.09 4.52 230.8/ 13 3 50.18/ 0.123 247.6 6 min 58 sec 2 26.26 3.6 193.6/ 19 3 55/ 0.862 213.7 4 min 29 sec 3 44.24 6.12 237.8/ 13 4 Lmin 40 sec/ 0.333 261.1 8 min 4 sec
EXAMPLE 2
[0079] A wettable battery separator material was prepared from a mixture of a wettable fiber matrix and non-wettable binder fibers.
[0080] In Samples 4, 5 and 6 the wettable fiber matrix used is a bicomponent fiber comprised of a polypropylene sheath and a polypropylene core. The proportion of sheath/core in the bicomponent fiber is 60/40. Combinations of Melt Additive formulations 4 and 5 were incorporated into the polypropylene sheath. The bicomponent fibers are 1.5 denier ×{fraction (1/2)} inch and are produced by Fiber Innovations Technologies, Johnson City, Tenn. In particular the samples were as follows.
[0081] Sample 4 the fiber sheaths are 77.5% 12 mfr polypropylene, 20% Melt Additive 4 and 2.5% Melt Additive 5. The fiber core is 18 mfr polyproylene.
[0082] Sample 5 the fiber sheaths are 73.55% 12 mfr polypropylene, 24%. Melt Additive 4 and 2.5% Melt Additive 5. The fiber core is 18 mfr polyproylene.
[0083] Sample 6 the fiber sheaths are 71.50% 12 mfr polypropylene, 26% Melt Additive 4 and 2.5% Melt Additive 5. The fiber core is 18 mfr polypropylene.
[0084] In Samples 4, 5 and 6, 50% of the wettable fiber matrix were combined with 50% of non-wettable binder fibers comprised of a bicomponent fiber having a polyethylene sheath and a polypropylene core. The binder fibers are 2.0 denier×5 mm available as Chisso fibers from Chisso, Japan.
[0085] Sample 7 was prepared from a mixture of a wettable fiber matrix and a wettable binder fiber. The wettable fiber matrix used is a polypropylene staple fiber containing combinations of Melt Additive formulations 4 and 5. The polypropylene staple fibers are 1.8 denier×12 mm and are available from American Extrusion. The wettable binder fiber is a bicomponent fiber wherein the fiber sheath is 77.5% low density polyethylene, 20% Melt Additive 4 and 2.5% Melt Additive 5. The fiber core is 18 mfr polypropylene. The binder bicomponent fibers are 1.5 denier×{fraction (1/2)} inch and are obtainable from Fiber Innovation Technologies, Johnson City, Tenn.
[0086] As a positive control, 50% of the non-wettable bicomponent binder fibers having a polyethylene sheath and a polypropylene core (Chisso fibers) were mixed with 50% of a polypropylene fiber matrix (American Extrusion fibers) without melt additives. The fiber furnish mixtures in each sample was dispersed and wet-laid to form the nonwoven substrates.
[0087] The handsheets were evaluated after calendering for absorbency, wicking and wet-out to KOH. The tests were also done after 5 days exposure to KOH at 70° F. The results are summarized in Table II below.
TABLE II STRIP Initial Initial 5 days 5 days TENSILE WICK ABSORB. WICK ABSORB. SAMPLE lbs/1″ mm % mm % CONTROL 3.58 70 257 75 237 4 4.06 84 338 82 370 5 4.07 73 283 80 308 6 3.95 72 305 91 357 7 1.43 68 302 78 378
[0088] As illustrated in Table II the tensile and absorbency of the handsheet samples increased. The strength and wettability of the nonwovens remained even after aging. These results indicate that the separate properties of tensile and absorbency can be provided in a nonwoven. In addition, nonwovens are produced that have both increased tensile and absorbency.
EXAMPLE 3
[0089] A wettable battery separator material was prepared from a mixture of a wettable fiber matrix, non-wettable binder fibers and wettable binder fibers.
[0090] In Samples 8 and 9 the wettable fiber matrix used is a bicomponent fiber comprised of a polypropylene sheath and a polypropylene core. The proportion of sheath/core in the bicomponent fiber is 60/40. Combinations of Melt Additive formulations 4 and 5 were incorporated into the polypropylene sheath. The bicomponent fibers are 1.8 denier ×{fraction (1/2)} inch and are obtainable from Fiber Innovation Technologies, Johnson City, Tenn.
[0091] The non-wettable binder fibers are bicomponent fibers having a polyethylene sheath and a polypropylene core. The binder fibers are 2.0 denier×5 mm and are commercially available as Chisso fibers from Chisso, Japan.
[0092] The wettable binder fibers used are bicomponent fibers comprised of a polyethylene sheath and a polypropylene core.
[0093] Combinations of Melt Additive formulations 4 and 5 were incorporated into the polyethylene sheath. The bicomponent fibers are 1.6 denier×{fraction (1/2)} inch and are obtainable from Fiber Innovation Technologies, Johnson City, Tenn.
[0094] The fiber furnish in each of the samples were as follows.
Sample 8 40% wettable fiber matrix; 40% non-wettable binder fiber; and 20% wettable binder fiber Sample 9 30% wettable fiber matrix; 30% non-wettable binder fiber; and 40% wettable binder fiber
[0095] The fiber furnish mixtures in each sample was dispersed and wet-laid to form the nonwoven substrates. The substrates were evaluated after calendering for absorbency, wicking and wet-out to KOH. The tests were also done after 7 days exposure to KOH at 70° F. The results are summarized in Tables III and IV below.
TABLE III AIR AIR BASIS MD CD PERME- PERME- WT. TENSILE TENSILE ABILITY ABILITY SAMPLE gsm kg/50 mm kg/50 mm cfm CM3/cm3/s 8 59.4 11.2 6.3 84.2 42.4 9 57.4 9.7 5.6 134.8 68.9
[0096] [0096] TABLE IV WETTABILITY BEFORE AND AFTER AGING BEFORE AFTER WICK- WICK- ALKALI ABSORB ING ABSORB ING PROOF SAMPLE % mm % mm % loss 8 226.8 85.3 237.9 93 0.67 9 297.2 79.3 333.9 100.7 0.5
[0097] In still another embodiment of the present invention, nonwoven webs are produced by wet-laying a blend of lower denier non-wettable binder fibers and higher denier wettable binder fibers. For example, 10 to 90 weight percent of the wettable binder fibers described in EXAMPLE 3 may blended with 90 to 10 weight percent of 0.7 one-half inch long non-wettable polyethylene/polypropylene sheath-core binder fibers. The lower denier fibers provide enhanced uniformity to the web. For a higher basis weight sheet on the order of 55 gsm, about 20 weight percent of the non-wettable fibers is preferred. For a sheet on the order of about 30 gsm, about 30 weight percent of the non-wettable binder fibers is preferred. These sheets are suitable for use as battery separators or for other applications, such as an ink-receptive inkjet printing substrate.
[0098] It is known that current nylon based battery separators degrade in the presence of the potassium hydroxide electrolyte. The nonwoven mats of the present invention present a replacement for the nylon based battery separators by providing separator materials that have been made permanently wettable, or if desired only partially wettable. Polypropylene is naturally hydrophobic. Known methods to make polypropylene wettable involves surface grafting of acrylic acid by ultraviolet radiation or by other surface modification methods such as plasma which are slow and expensive.
[0099] For fibrous battery separator applications the polypropylene needs to be resistant to the KOH and exhibit permanent wettability throughout the life of the product. Wettability is quantified by contact angle measurements in the case of a film and additionally by the rate of wicking and % absorbency in the case of a fibrous web used as the battery separator.
[0100] The process of the present invention provides advantages over prior practice by providing a nonwoven having both hydrophilic and hydrophobic regions as opposed to hydrophilic topical treatments. Additional wettability is achieved with incorporation of the surfactant that has more resistance to KOH solution than surfactants used in the prior art. Increased wettability is achieved simultaneously with an increase in strength. The wettability claimed in the invention is permanent and durable in a KOH solution as opposed to the prior art.
[0101] Finally, variations from the examples given herein are possible in view of the above disclosure. Therefore, although the invention has been described with reference to certain preferred embodiments, it will be appreciated that other processes may be devised, which are nevertheless within the scope and spirit of the invention as defined in the claims appended hereto.
[0102] The foregoing description of various and preferred embodiments of the present invention has been provided for purposes of illustration only, and it is understood that numerous modifications, variations and alterations may be made without departing from the scope and spirit of the invention as set forth in the following claims. | Nonwoven webs in accordance with the present invention include multicomponent fibers bonded by a multiplicity of bond sites to form a coherent web. The multicomponent fibers include a first component formed of a hydrophobic polypropylene and a second component formed of a blend of a hydrophobic polyolefin and a hydrophilic melt additive. This second component is disposed at the surface of the fibers. The hydrophilic melt additive-modified polyolefin component can be arranged in various configurations in the cross-section of the fiber and the fibers can have various cross sections. For example, the hydrophilic component can occupy a portion of the surface of the fiber, as would occur for example with a side-by-side or segmented pie multicomponent fiber configuration. Alternatively, the modified hydrophilic polyolefin can occupy substantially the entire surface of fiber, as for example by producing the fibers in a sheath core configuration with the hydrophilic modified component forming the sheath. A particularly preferred configuration is a sheath-core bicomponent fiber where the hydrophobic polypropylene forms the core and the modified hydrophilic polyolefin forms the sheath. | 3 |
FIELD OF THE INVENTION
[0001] This invention relates generally to hammermills.
BACKGROUND OF THE PRESENT INVENTION
[0002] Hammermills have long been used for grinding or comminution of materials. Typically hammermills consist of a rotor mounted on a solid through rotor shaft inside a housing. A material inlet is generally located at the top of the housing with one or more material outlets located near the bottom of the housing. The rotor includes a solid through drive shaft and rows of hammers which are normally flat steel blades or bars. A steel rod or pin pivotably connects the hammer to the rotor. The rotor is mounted inside a typically teardrop shaped enclosure, commonly known as a grinding or working chamber, which is comprised of a cutting plate mounted on either side of the material inlet for reversible hammermills. Reversible hammermills are capable of rotation in either direction, a feature which provides for increased life for the hammers, cutting plates and screen plates. The known cutting plates are comprised of a upper linear section connected with a convex radiused section and do not allow particles to escape.
[0003] Downstream of the cutting plate, the interior of the working chamber is defined by curved screen plates. The screen opening diameter is selected to match the desired particle size. Generally, material at or below an intended size limit exit the chamber through the screens while material above the size limit continue to be reduced by the rotating hammers.
[0004] Current hammermill rotor designs consist of a solid through rotor shaft which supports a number of cylindrical head disks. The head disks are keyed to the shaft and are spaced along the shaft with ring type spacers, often squeeze collars or the equivalent are employed. The head disks and spacers are held together on the rotor shaft by using bearing locknuts which are positioned on the threaded ends of the rotor shaft. These nuts are then tightened to take the clearance out between the disks and the spacers.
[0005] The disks structurally support a number of hammer pins radially around the solid rotor shaft. The swinging hammers are mounted on the hammer pins. The disks structurally support the hammer pins from the centrifugal forces generated by the rotation of the rotor which typically rotates over a range of 1500 to 3600 rpm. The disks also transmit the torque from the rotor shaft to the hammer pins; required to power the hammers through their impact against the product being processed in the hammermill.
[0006] In operation, the material to be reduced is fed into the material inlet and is directed toward the rotating hammers. The material is initially impacted by the hammers, which may cause some material reduction. The material is then flung from the hammer face against the cutting plates resulting in a primary reduction of material. After the material impacts the cutting plate, from which there is typically no outlet, the material is either flung back toward the rotating hammers or continues downstream between the hammer tip and the cutting plate until the screen plates are reached.
[0007] Ultimately, the particles encounter the openings of the screen plates. Here, the particles that are small enough begin to exit through the screen openings. The remaining particles impact the leading edge of the screen openings and are deflected up into the hammers' path. The rotating hammers continue to pulverize the material downstream of the cutting plate, moving it along the surface of the screens which define the circumference of the working chamber, causing gradual diminution of the material. Ultimately, the material is ground finely enough to permit it to flow out through the screens.
[0008] While the solid rotor shaft hammermill design as described above has been generally accepted and is widely used, there is a constant need and desire to increase the efficiency of the devices. Increasing efficiency will allow operation of the hammermill with decreased power consumption while increasing the capacity of the machine.
[0009] The present invention accomplishes these goals.
SUMMARY OF THE INVENTION
[0010] An improved rotor design for hammermills. The invention eliminates the solid rotor shaft and replaces it with a tubular structure comprised of two stub rotor shafts with plate flanges and grooved spacer rings therebetween. End head disks, attached to the plate flanges, and intermediate disks are concentrically positioned with the axis of rotation of the assembly. The intermediate disks are held in alignment by the pilot groove located in the spacer rings. The flanges, stub shafts, spacer rings and intermediate disks are supported and held in proper alignment by tension rod compression. The resulting tubular rotor shaft assembly is less massive, more stiff, less susceptible to vibration, has a reduced bending stress, is less expensive to startup and operate and less expensive and more flexible in terms of component inventory than known solid through-shaft rotors.
[0011] An object and advantage of the invention is to provide a hammermill with a more efficient structural design by eliminating the solid rotor shaft.
[0012] Another object and advantage of the invention is to provide a hammermill with a reduced maximum bending stress in the rotor shaft.
[0013] Another object and advantage of the invention is to provide a hammermill with an increased stiffness in the rotor shaft.
[0014] Another object and advantage of the invention is to provide a hammermill that is less sensitive to vibration.
[0015] Yet another object and advantage of the invention is to provide a hammermill that is less massive with a lighter inertial load than current hammermills, making start-up and reversal of rotational direction easier and less expensive.
[0016] Another object and advantage of the invention is to provide an improved method of manufacturing whereby common components may be combined to reduce the variety of parts required, resulting in reduced inventory carrying costs and improved economies of scale in the manufacturing process.
[0017] The foregoing objects and advantages of the invention will become apparent to those skilled in the art when the following detailed description of the invention is read in conjunction with the accompanying drawings and claims. Throughout the drawings, like numerals refer to similar or identical parts.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] [0018]FIG. 1 is a broken away view of a hammermill.
[0019] [0019]FIG. 2 is a side view of the rotor assembly.
[0020] [0020]FIG. 3 is a cross sectional view of the rotor assembly.
DETAILED DESCRIPTION OF THE INVENTION
[0021] With reference to the accompanying Figures, which provide one embodiment of the invention, there is provided a hammermill ( 10 ) for comminuting material, having a housing ( 12 ), material inlet ( 14 ), and particle discharge ( 16 ). FIG. 2 shows the rotor shaft assembly ( 17 ). The inventive tubular rotor shaft assembly ( 17 ) has an axis of rotation and comprises a driven stub rotor shaft ( 18 ), a support stub rotor shaft ( 20 ), a first flange plate ( 22 ) and a second flange plate ( 24 ), spacer rings ( 32 ), tie rods ( 40 ) and tie rod nuts ( 42 ).
[0022] Turning specifically to FIG. 3, the invention comprises a driven rotor stub shaft ( 18 ) that is drivingly connected to an engine or known other means for rotating the shaft, and a support rotor stub shaft ( 20 ) that is mounted to a bearing or similar structure that is not shown in the Figures. A first flange plate ( 22 ) is rigidly attached to the support rotor stub shaft ( 20 ) and a second flange plate ( 24 ) is attached to the driven rotor stub shaft ( 18 ). The two flange plates are arranged concentric with the axis of rotation of the rotor shaft assembly ( 17 ).
[0023] The Figures provide a first head disk ( 26 ) that is fixedly attached to the first flange plate ( 22 ). A second head disk ( 28 ) is fixedly attached to the second flange plate ( 24 ). Both the first and second head disks are disposed concentric with the axis of rotation of the rotor shaft assembly ( 17 ). The preferred method of attaching the flange plates ( 22 , 24 ) to the head disks ( 26 , 28 ) is by plug welds ( 44 ), though other equivalent attachment methods will readily present themselves to those skilled in the art.
[0024] Again with reference specifically to FIG. 3, spacer rings ( 32 ) are disposed between the first flange plate ( 22 ) and the second flange plate ( 24 ) and concentric with the axis of rotation of the rotor shaft assembly ( 17 ). When assembled, the spacer rings ( 32 ) create a tubular space within the rotor shaft assembly ( 17 ). The spacer rings ( 32 ) are also disposed concentrically around the axis of rotation of the rotor shaft ( 17 ). The two end spacer rings ( 34 ) are fixedly attached to the first flange plate ( 22 ) and the second flange plate ( 24 ), respectively. Center spacer rings ( 36 ) are arranged between, and adjacent to, the two end spacer rings ( 34 ). One or more center spacer rings ( 36 ) may be used depending on the size requirements of the hammermill. If more than one center spacer ring ( 36 ) is required, the additional spacer ring ( 36 ) will be arranged adjacent the first center spacer ring. The conjunction between the end spacer rings ( 34 ) and the center spacer ( 36 ) ring adjacent the end spacer ring ( 34 ) is notched or keyed with a pilot groove ( 37 ). Each end spacer ring ( 34 ) is circumferentially notched on one edge while the center spacer rings ( 36 ) are circumferentially notched on both edges to form the pilot groove ( 37 ) when the rings are assembled. If more than one center spacer ring ( 36 ) is used, the conjunction between the two center spacer rings is also circumferentially notched or keyed with a pilot groove ( 37 ). Thus, a pilot groove ( 37 ) extends circumferentially around each conjunction of the spacer rings ( 32 ).
[0025] Intermediate disks ( 30 ) are disposed concentric with the axis of rotation of the rotor shaft assembly ( 17 ) and between the first head disk ( 26 ) and the second head disk ( 28 ). The intermediate disks ( 30 ) are disposed along the pilot groove ( 37 ) to ensure that the intermediate disks are aligned substantially parallel with the head disks and concentric with the axis of rotation of the rotor shaft ( 17 ). Hammer pins ( 38 ) are disposed through the first head disk ( 26 ), intermediate disks ( 30 ) and second head disk ( 28 ). The spacer rings ( 32 ) maintain the alignment and spacing of the intermediate disks ( 30 ) relative to each other as well as to the head disks ( 26 , 28 ).
[0026] Tie rods ( 40 ) connect the first flange plate ( 22 ) with the second flange plate ( 24 ). The tie rods ( 40 ) are secured by nuts ( 42 ) that can increase or decrease the tension by tightening or loosening the nuts ( 42 ). Increasing the tension on the tie rods provides sufficient compression to hold the entire rotor shaft assembly ( 17 ) in proper alignment and the components properly spaced relative to each other during operation. The number and combined preload compression of the tie rods is determined by the particular requirements of the rotor assembly ( 17 ). Generally, the minimum compression preload that must be applied by the tie rods ( 40 ) is the highest unit compression force at the interface joint between the spacer rings ( 32 ) and the intermediate disks ( 30 ) based on one of the two following conditions:
[0027] (1) The unit compression loading between the interface of the spacer rings ( 32 ) and the intermediate disks ( 30 ) must be equal to or greater than the maximum unit bending stress, including allowance for safety factors to be anticipated under operating conditions;
[0028] (2) The unit compression loading between the interface of the spacer rings ( 32 ) to the intermediate disks ( 30 ) in conjunction with the coefficient of friction at that interface must provide a torsional resistance force greater than the torque being transmitted by the driven rotor stub shaft ( 18 ).
[0029] A tubular cross-section is more structurally efficient than is a solid round rotor shaft. Thus, in addition to providing the functional spacing and alignment of the intermediate disks ( 30 ), the spacer rings ( 32 ) in the present invention also provide increased structural bending support to the rotor and torsional power transmission to the intermediate disks ( 30 ).
[0030] By way of example, if the cross sectional area of the spacer rings ( 32 ) in the present invention is equal to that of the known solid rotor shaft design, and if the outside diameter of the spacer ring is twice the known solid rotor shaft diameter, it can be shown mathematically that the section modulus “Z” of the spacer ring ( 32 ) will be 3.5 times that of the known solid shaft and that the moment of inertia “I” will be 7 times that of the solid shaft. In other words, using the exemplary parameters, the inventive rotor shaft may reduce the maximum bending stress in the rotor shaft assembly ( 17 ) by a factor of 7/2 and increase the stiffness of the rotor shaft assembly ( 17 ) by a factor of 7 when compared with the known solid rotor shaft. The outside diameter of the inventive tubular rotor shaft assembly ( 17 ) in multiples of the known solid shaft diameter greater than one may be used to suit the particular physical parameters and constraints of the hammermill design or to optimize the balance between structural stiffness and the mass of the rotor assembly ( 17 ). Further, because the inventive rotor shaft assembly ( 17 ) is stiffer than the known solid through-shaft, the tubular rotor shaft assembly ( 17 ) is less sensitive to vibration. The decreased sensitivity to vibration allows for more efficient operation, less potential for breakdown of the moving parts, and operation at rotational speeds that are higher than the known rotor shafts.
[0031] The known solid through-shaft is necessarily relatively massive. The inventive tubular rotor shaft assembly ( 17 ) may provide a reduction in rotor assembly weight, and thus in the overall hammermill weight, of approximately 15 to 20%. This reduction in mass results in a more efficient start-up procedure that consumes less energy to reach the desired rotational speed. In addition, the reversal of the hammermill's rotational direction will be accomplished more efficiently, more quickly, consume less energy and be less expensive as compared with the known solid shaft rotor shafts.
[0032] The inventive tubular rotor shaft assembly ( 17 ) also allows for a more efficient method of manufacturing parts for hammermills. Current hammermill solid through-shaft rotors of a given diameter are typically made in number of incremental lengths to meet processing capacity requirements. It is readily seen that the inventive tubular rotor assembly ( 17 ) width is adjusted simply by adding additional center spacer rings ( 36 ) as required by the parameters of the individual hammermill design. The center spacer rings ( 36 ) are interchangeable for hammermills with the same diameter specifications. In addition, the driven rotor stub shaft ( 18 ), the support rotor stub shaft ( 20 ), head disks ( 26 , 28 ) and intermediate disks ( 30 ) are all interchangeable for hammermills with the same diameter parameters. This interchangeability of components has the benefit of reducing the variety of different components that must be inventoried to support a product line.
[0033] Thus, the present invention allows for an improved economy of scale in the manufacturing process of the common interchangeable components and reduced inventory carrying costs. Instead of manufacturing and inventorying varied lengths of the known solid through-shaft, the invention allows for manufacture and inventorying one size component for a hammermill of given diameter. The hammermill length is modified by simply adding or removing as appropriate center spacer rings ( 36 ) and intermediate disks ( 36 ). The result is a more efficient and cost-effective manufacturing and inventory process for the hammermill tubular rotor shaft components.
[0034] Further, the invention allows for replacement of the stub shafts, components that are smaller, less expensive and easier to replace than the known solid through-shaft.
[0035] The above specification describes certain preferred embodiments of this invention. This specification is in no way intended to limit the scope of the claims. Other modifications, alterations, or substitutions may now suggest themselves to those skilled in the art, all of which are within the spirit and scope of the present invention. It is therefore intended that the present invention be limited only by the scope of the attached claims below: | An improved rotor design for hammermills. The invention eliminates the solid rotor shaft and replaces it with a tubular structure comprised of two stub rotor shafts with plate flanges and grooved spacer rings therebetween. End head disks, attached to the plate flanges, and intermediate disks are concentrically positioned with the axis of rotation of the assembly. The intermediate disks are held in alignment by the pilot groove located in the spacer rings. The flanges, stub shafts, spacer rings and intermediate disks are supported and held in proper alignment by tension rod compression. The resulting tubular rotor shaft assembly is less massive, more stiff, less susceptible to vibration, has a reduced bending stress, is less expensive to startup and operate and less expensive and more flexible in terms of component inventory than known solid through-shaft rotors. | 8 |
RELATED APPLICATIONS
[0001] None
FEDERALLY SPONSORED RESEARCH AND DEVELOPMENT
[0002] None
APPENDICES
[0003] None
BACKGROUND OF THE INVENTION
[0004] This invention is related to mounted optics for laser processing of materials, particularly where the lasers are controlled by a closed-loop system using feedback data from a “control” beam that measures or illuminates, but does not process, the material. This invention is particularly applicable to ablation laser systems controlled by autofocus mechanisms, but can also be useful in laser cutting, welding, or annealing systems that use control beams to track and correct beam-pointing errors or to illuminate markers or fiducials.
[0005] Laser processing tools are widely used in many industries. Factories mass-producing high-precision components or products often have tens or hundreds of working lasers operating simultaneously. Processing lasers generally produce much more powerful beams than most lasers used in other common applications such as displays, data recorders and readers, and printers. High-power lasers often have shorter operating lifetimes and more reliability problems than their lower-power counterparts, because high-power lasers routinely exert more thermal, electrical, or other wear and tear on both internal and external components, and they can quickly and catastrophically damage their internal and external optics and mechanics if even a small amount of contaminant that absorbs the laser wavelength—such as a tiny speck of dust or a light film of outgassing residue—enters the beam path on or near a surface. The more processing lasers a factory operates simultaneously, the greater the probability that a laser or part of its beam train will fail, and need to be replaced, at any given time.
[0006] The time it takes to replace the laser on a laser-processing tool is “down-time” that increases ongoing production costs and may lead to costly missed delivery deadlines. Therefore, when a laser processing tool fails on a factory floor, it is highly desirable to replace the failed components quickly. For the reasons discussed above, the working laser and its beam-train optics are often the components most likely to fail.
[0007] However, most processing lasers and their optics cannot be quickly replaced when they fail because the unit-to-unit tolerances of these components exceed the alignment sensitivity of the process. The peak laser intensity, spot size, and position of the spot on the workpiece must almost always be tightly controlled. Some processes are also sensitive to the spot intensity profile, the shape of the wavefront at the workpiece, or the angle between the beam axis and the normal to the workpiece surface. Some of these key parameters (particularly spot size, spot intensity profile, and wavefront shape) are sensitive to changes in the optical path length (OPL) from the final component in the working-beam train to the workpiece. Surface contours on the workpiece, thermal alterations of workpiece thickness and other characteristics, thermal effects on the tool optics, and even thermal or pressure gradients in the atmosphere can change the OPL while a processing operation is ongoing. To ensure consistent performance after replacement of a laser or any of the beam-train optics, the system must be realigned before resuming use. Where multiple components are involved, realignment can take hours, and those hours of downtime add to production overhead costs.
[0008] The time, cost, and need frequency of alignments is further increased when laser-processing tools incorporate closed-loop control systems with active mechanisms to make “on-the-fly” adjustments during a processing cycle. Such control systems—for example, autofocus or leveling systems—are necessary to highly sensitive processes to compensate for variations in the characteristics of the working laser, the workpiece, or the surrounding environment. Sometimes the feedback for a closed-loop control system is an attenuated fraction of working laser itself; however, separate control beams are commonly used when the working laser is invisible, pulsed, or operating at a peak power that would damage readily available attenuators and detectors.
[0009] Depending on the sensitivity of the process to the parameter that the control beam controls, and on what type of light yields the best control data, control light sources may be low-power continuous-wave lasers, LEDs, or broadband lamps. Most control beams need to be aligned to run parallel or coaxial to the working beam they control. Some control beams, such as autofocus control beams, need to be calibrated to individual working beams when the laser-to-laser variations are too wide for the process to tolerate otherwise. The ability to calibrate control beams to a variety of individual working beams can relax tolerances on the expensive working lasers, reducing their cost. Therefore, replacement of failed processing lasers and beam-train optics must, in many cases, include recalibration of a separate control beam.
[0010] Quickly replaceable optical modules have been developed in such industries as fiber optic communications, printing, and information encoding and decoding. The modules include lasers and optics that have been pre-aligned on alignment fixtures and locked in place, and kinematic mounting features that precisely mate to corresponding features in the surrounding device. Commonly used kinematic features include spheres, sections of cones, rods, holes and slots, flats, and line contacts. However, the lasers in these modules are much lower in power, and both the lasers and the optics are both smaller in size and lighter in weight, than processing lasers and their optics. Many of the lasers incorporated into prior-art quickly replaceable modules also produce better beam quality and a smaller spot size over a longer distance, and therefore may have looser alignment tolerances in some cases, than higher-power multimode or superradiant lasers. Besides, although the prior-art modules often must maintain alignment over a wide range of ambient temperatures, the low-power lasers involved generally create very little heat of their own; nor are thermal effects on the workpiece usually a significant problem either. For these reasons, kinematic-module solutions that work well for low-power lasers cannot generally be easily adapted to high-power processing lasers.
[0011] Some pre-aligned kinematic modules have been devised specifically for processing lasers. In U.S. Pat. No. 5,748,827, Holl & Sabeti use a two-stage mount including a “macrostage” for coarse alignment, a “microstage” for fine alignment, and a compliant layer between the two stages. However, while their beam-positioning tolerance of ±10 μm is acceptable for their application of photocytometry and for some processing applications such as annealing, it is too loose for other applications such as holography and high-precision laser ablation.
[0012] In Published U.S. Pat. App. No. 2006/0249488, Jurgensen pre-aligns diode pump laser assemblies for fiber lasers that engrave ink-holding cavities on a metal printing drum. The working-spot size of 100 μm is too large for some ablation, micro-marking, and micro-bonding applications. Furthermore, while the '488 application's storage of spare lasers in place on the working laser support platform does reduce down-time, many factory environments, such as clean rooms where each cubic foot adds significant expense, cannot cost-effectively spare that much extra space on or around the tool for equipment that is not operating. Even where the space is available, ambient vibration, local shocks, or thermal cycling could gradually cause the pre-alignment to drift out of tolerance while the replacement lasers are stored on the platform.
[0013] In U.S. Pat. No. 6,424,670, Sukhman et al. pre-align laser modules and optics modules to be automatically interfaceable with each other when they are mounted on a common laser support platform. While '670 has an advantage of being able to replace either a laser module or an optics module, depending on where the failure occurs, it does not address thermal concerns—possibly because the '670 lasers seem to operate in enclosed cabinets whose temperature may be regulated—or situations where some separate element of a closed-loop control system needs to be calibrated to the individual replacement laser.
[0014] From the above discussion, none of the prior-art replaceable modules fully address the needs of high-power working lasers with separate control beams. Therefore, an unaddressed need exists for such a system.
[0015] When multiple working lasers operate together on a single tool, sometimes they all must be replaced at once. Sometimes two or more reach the end of their useful life at the same time. Also, in some settings such as job-shops where space is limited, budgets for expensive platforms and workpiece stages are tight, and processing needs change constantly, the ability to quickly exchange a group of processing lasers for a group with a different power, wavelength, or optical configuration type would be a significant economic advantage. Therefore, a largely unaddressed need exists for quickly replaceable groups of processing-laser modules that include aligned optics and calibrated control sources for each working laser in the group.
BRIEF SUMMARY OF THE INVENTION
[0016] An object of this invention is rapid replacement of processing lasers that use individually calibrated control beams with no need for substantial in situ alignment or recalibration, to reduce down-time resulting from a component failure. Accordingly, the invention includes a lightweight pre-aligned modular assembly that combines a working laser, a control light source, and the beam trains for both light sources on a baseplate with kinematic features that enable the module to be mounted in a self-aligned position on a mating subassembly baseplate.
[0017] Another object of this invention is rapid replacement of groups of processing lasers to reduce down-time, either in the event of performance degradation or to change the process performed by a laser processing tool. Accordingly, the invention includes a kinematically-mounted subassembly of multiple pre-aligned laser modules that can be replaced as a single piece without substantial in situ alignment.
[0018] Another object of this invention is to provide replaceable laser modules and subassemblies with sufficiently high spot-position accuracy for high-precision processes such as laser ablation. Accordingly, this invention includes pre-aligned modules with a pre-calibrated control beam and associated active mechanism.
[0019] Another object of this invention is to provide replaceable laser modules and subassemblies with small working-spot size. Accordingly, this invention includes a group of individual, relatively low-power lasers with relatively high beam quality, each generating its own small working spot, rather than splitting the output of a relatively higher-power laser into multiple working spots with relatively low beam quality.
[0020] Another object of this invention is temperature insensitivity of the alignment of each working beam. Accordingly, this invention includes kinematic bases that register at their physical, thermal, or optical midpoints and matching of coefficients of thermal expansion (CTE) between mating parts.
[0021] Another object of this invention is to detect problems with replacement modules before they adversely affect a workpiece. Accordingly, this invention includes a “spot-check”tool for verifying that a replacement module delivers its beams to the intended process target position.
[0022] Other objects of this invention are small physical footprint and high process speed. Accordingly, this invention could include a staggered module-mounting arrangement within a multi-module subassembly so that the working spots can be spaced closer together than the module diameter. This allows simultaneous processing of closely-spaced process targets during a single pass.
[0023] Other objects of this invention are low cost and simplicity. Accordingly, this invention includes a mechanism by which multiple processes can be performed either simultaneously on the same tool, or in series on the same tool with minimal down-time associated with changing lasers.
BRIEF DESCRIPTION OF THE DRAWINGS
[0024] FIG. 1 shows two shaded perspective views of an exemplary module mounting base and mating base according to this invention.
[0025] FIGS. 2 a - 2 d show successive stages of a pre-aligned laser module according to this invention being assembled and pre-aligned on an offline alignment fixture.
[0026] FIG. 3 shows a pre-aligned laser module according to this invention being installed on a subassembly base, with other laser modules shown in operation.
[0027] FIG. 4 shows a subassembly base according to a preferred embodiment of this invention with pre-aligned laser modules attached, and a platform base to which it kinematically mates and reversibly locks.
[0028] FIG. 5 is a top view, with perspective, of an exemplary pair of laser modules designed for staggered arrangement on the subassembly base to allow a spacing between working beams that is narrower than the widest component mounted to either of the module bases.
DETAILED DESCRIPTION OF THE INVENTION
[0029] Aspects of this invention improve the cost-effectiveness of replacing processing lasers and optics at three levels: (1) the individual laser-module level, (2) the subassembly level, and (3) the laser platform assembly level.
[0030] FIG. 1 shows the basic building block of this invention, a module mounting base (MMB) 100 designed to kinematically mate to a locating surface 150 . MMB 100 includes assorted features 111 for attaching the working laser, the control light source, and the mounted optics, mechanics and detectors on the surface shown here as the top. MMB 100 also includes locating features 101 , 102 a , and 102 b on the surface shown here as the bottom. These locating features mate with receiving features 151 , 152 a , and 152 b on locating surface 150 . When mated and locked in place by temporary locks (not shown; can be clamps, magnets, bolts, springs, etc.), the locating features and receiving features constrain all the degrees of freedom of motion of MMB 100 with respect to locating surface 150 . The most constrained point is the registration point where locating feature 101 mates with receiving feature 151 .
[0031] In the preferred embodiment, the registration point is at the thermal midpoint of MMB 100 , so that thermal expansion and contraction take place around a point that makes alignment insensitive to temperature. For instance, in many systems the condenser assembly that forms the working spot has the tightest alignment tolerances. Positioning the registration point under it, so that it stays stationary when the temperature changes, can make the alignment less temperature-sensitive in some cases. The figure shows the registration point at the physical midpoint for simplicity. However, the thermal midpoint may be removed from the physical midpoint because the main heat source, the working laser, is usually at one end of the module rather than in the center. Both thermal and optical modeling contribute to locating the best registration point for a given system. In addition, the tolerant direction of non-registration receiving features (here, shown for example as slots 152 a and 152 b , though any suitable pairing of kinematic locating and receiving features can be used) should preferably be arranged to minimize bending stress on MMB 100 in case of thermal expansion.
[0032] Initially, each module is built on an alignment fixture base located off the laser-processing line, preferably well before it is needed on the manufacturing line. FIGS. 2 a - 2 d show an example of a module according to one embodiment of this invention being aligned in several stages. In FIG. 2 a , MMB 200 is initially positioned by mating locating features 201 , 202 a and 202 b (with only 202 b visible in this view) to receiving features 251 , 252 a , and 252 b (with only 252 b visible in this view) on alignment base 250 , and fixed in position by temporary locks, shown here as clamps 220 that may be fastened to clamp receivers 253 in alignment base 250 . (Locks 220 will eventually be used to attach the finished module to the laser processing tool. For very alignment-sensitive optical trains—for instance, those that create a particular interference pattern—having locks 220 engaged during alignment phase can be critical to ensuring correct alignment during operation, because even the small difference in stress on MMB 200 caused by engaging locks 220 can throw an acceptable alignment out of tolerance. However, if the optical train is not that alignment-sensitive, locks 220 may not need to be engaged during alignment). Alignment base 250 has additional receiving features 254 for the various alignment tools that can be used to align components of the module.
[0033] If alignment tolerances are very tight (microns or less, as is typical of ablation and some other processes), careful attention must be given to ensuring that locks 220 exert the same forces on MMB 200 in the alignment fixture that they eventually will when the finished module is locked to a subassembly base on the manufacturing line. Two recommendations applicable to bolted clamps are (1) keep the clamps used for alignment with the module and use them again for installation, and (2) use a fixed torque setting when tightening the bolts, both for alignment and for installation.
[0034] In FIG. 2 b , working laser 230 is mounted on MMB 200 , and the position and angle of working beam 231 is aligned to a pair of alignment tools 261 and 262 , which can comprise visual or electronic means of detecting beam position and angle (or beam position at two points, from which angle can be calculated). Depending on the types of alignment required, the configuration of the lasers and optics on the module, the size of the alignment tools, and the space available, the alignment tools can be either permanently or removably-and-replaceably mounted to alignment base 250 . The position and angle of the laser beam can be aligned by moving the laser body, by adding and adjusting beam-steering optics such as flat mirrors, windows, and prisms, or by designing MMB 200 such that the mounting features can be translated or tilted relative to the locating features. Once the beam alignment is satisfactory, working laser 230 is locked in position. In FIG. 2 c , control light source 240 and beam combiner 242 have been added and aligned so that control beam 241 has the desired spacing and relative angle with respect to the working beam (here shown as collinear and coaxial). Once alignment tools 261 and 262 show satisfactory alignment of control beam 241 , control light source 240 and beam combiner 242 are locked in place. FIG. 2 d shows the addition of beam-forming optics (here shown as beam expander 243 and condenser 244 , but those skilled in the art will recognize that this invention will work with any suitable beam-forming optics), which have been aligned with the help of other alignment tools, for example beam profiler 263 . After all the components are aligned and locked in place, and any necessary calibration of working beam 231 to control beam 241 and its control electronics (not shown) has been performed, housings or covers (if any) are added, locks 220 are unlocked (in preferred designs, the locks are designed to be engaged and disengaged without disturbing a module's components, housings, or covers), and the finished pre-aligned module is removed from the alignment fixture and stored in a safe place offline.
[0035] FIG. 3 shows a multi-module subassembly on a manufacturing line. Here, finished laser modules 345 . 1 and 345 . 2 are already installed and locked on subassembly base 350 , and finished laser module 345 . 3 is in the process of being installed. Installed modules 345 . 1 and 345 . 2 are shown emitting working beams 331 . 1 and 331 . 2 and control beams 341 . 1 and 341 . 2 , which focus on vertical workplane 370 (this aspect of the drawing is to show operating conditions; the installed modules would not necessarily be turned on while a new module was being added). Modules with folding optics for processing a horizontal workplane may be just as easily designed. Like the alignment base in FIG. 2 , subassembly base 350 has receiving features 351 , 352 a , and 352 b for mating to locating features 301 (not visible in this view), 302 a , and 302 b on module 345 . 3 . The process of replacing a laser module on subassembly base 350 can thus be reduced to placing module 345 . 3 with its locating fixtures matched to the appropriate receiving fixtures and engaging locks 320 with lock receivers 353 . A spot-check with a fixture or sample may be desirable, but no further alignment is generally necessary. Down-time associated with replacing a failed laser is thus reduced from hours to minutes and substantial production cost is saved.
[0036] FIG. 4 shows a preferred embodiment of a subassembly base 450 that allows quick, easy replacement of an entire subassembly of laser modules. This capability is useful if several lasers, installed together, are nearing the end of their useful life, or when it is economically advantageous to use the same tooling platform for different kinds of laser processing at different times. Here, subassembly baseplate has pre-aligned laser modules 445 . 1 , 445 . 2 , and 445 . 3 installed and locked to its top surface. On its bottom surface, it has locating features 454 , 455 a , and 455 b , of a suitable scale and precision for positioning an entire subassembly with the desired accuracy. These locating features mate to receiving features 481 , 482 a , and 482 b in platform base 480 . Then subassembly plate 450 is locked to platform base 480 using scaled-up reversible locks 421 that engage to lock receivers 483 . (In the embodiment shown in the drawing, all features 481 - 483 go all the way through to the top of platform base 480 and are available on that surface). Just as with the module bases, the registration point (where locating feature 454 meets receiving feature 481 ) is at the thermal-expansion center of the subassembly.
[0037] FIG. 5 is a top view, with perspective, of two modules 545 and 546 attached to a subassembly baseplate 550 in an embodiment designed for applications where the working beams must be spaced closer together than straightforward side-by-side module mounting would allow—that is, with a spacing narrower than the widest component mounted on the MMB. Although the drawing shows only two lasers, this staggered pattern or mirror-images of this staggered pattern could be repeated with more lasers, and other staggered arrangements could be devised for differently-arranged beam trains. This requirement sometimes arises in, for instance, scribing of parallel lines in large photovoltaic panels, vehicle or architectural “smart glass,” or display screens. In this alternate embodiment, there are two or more module types that stagger the position of the bulkier components, so that less clearance is needed between the beams. If the locating features need to be in different places on the different module types for mechanical or thermal stability, both the subassembly baseplate and the corresponding alignment baseplate need to have receiving features for both module types. The economic advantage of quick and easy replacement of lasers on the line will often justify this extra layer of complexity, if the process requires it.
[0038] Several other mechanical and thermal considerations apply to the overall design of various embodiments of this invention. The optical mounts, module base, alignment base, subassembly base, platform base, and whatever supports the platform base should preferably have very similar coefficients of thermal expansion. Light weight is also desirable to prevent overburdening of the platform and its support structure, which over long-term use might change its shape or weaken any stressed joints, and to make switching modules and subassemblies easier and safer. Channeled or honeycombed bases can sometimes reduce the weight of modules and subassemblies while still providing enough stiffness to maintain optical alignment.
[0039] A system of replaceable subassemblies of multiple pre-aligned modules according to this invention has been shown to can maintain micron tolerances of working-spot size and position over ambient temperature variations of ±10° C. This performance is adequate for ablation processes on large-area substrates in open factory environments, which were previously very difficult and involved significant down-time for alignment maintenance.
[0040] Some processes may involve modules that produce different types of working beams mounted together on the same subassembly. Particularly if the different modules look similar from the outside, using different kinematic feature geometries for the different modules, making it impossible to mount the wrong module in the wrong position on the subassembly may be helpful.
[0041] In summary, this invention reduces downtime on a laser processing line by providing quickly replaceable pre-aligned modules and quickly swappable multi-module subassemblies. The modules include aligned optics and, where needed, calibrated control light sources as well as the working laser. Those skilled in the art will recognize that neither this description nor the accompanying drawings, but only the claims, limit this invention's scope. | Pre-aligned, kinematically mounted modules including processing lasers, beam trains, and individually calibrated control beams are quickly and easily replaced on subassembly bases with minimal in situ alignment, and can maintain working-spot position to micron tolerances over ambient temperature variations of ±10° C. Subassembly bases, with features for kinematically mating to a plurality of pre-aligned laser modules and to a platform base incorporated in the laser processing tool, enable multi-module subassemblies to be quickly replaced with spare subassemblies of the same type, or swapped for subassemblies of a different type. The mating features and reversible locks are designed to mitigate thermal effects that are often a dominant cause of alignment drift in processing lasers. | 1 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] The present application is a continuation application of International Application No. PCT/JP2011/060047, filed Apr. 25, 2011, the entire contents of which are incorporated herein by reference and priority to which is hereby claimed. The PCT/JP2011/060047 application claimed the benefit of the date of the earlier filed Japanese Patent Application No. 2010-103482 filed Apr. 28, 2010, the entire contents of which are incorporated herein by reference, and priority to which is hereby claimed.
BACKGROUND
[0002] 1. Technical Field
[0003] The present invention relates to a photoelectric conversion device.
[0004] 2. Related Art
[0005] There have been known solar cells using polycrystalline, microcrystalline, or amorphous silicon. In particular, photoelectric conversion devices of laminated structure in which thin films of microcrystalline or amorphous silicon are laminated have been receiving attention, in view of resource consumption, cost reduction, and an increase in efficiency. In general, the photoelectric conversion devices are formed by sequentially laminating a first electrode, one or more semiconductor thin film photoelectric conversion cells, and a second electrode on a substrate whose surface has an insulation property. Each photoelectric conversion unit is composed of a p-type layer, an i-type layer, and an n-type layer laminated in that order from a light incident side.
[0006] As a method for increasing conversion efficiency of such a photoelectric conversion device, laminating two or more photoelectric conversion cells in a light incident direction has been known. On the light incident side of the photoelectric conversion device, a first photoelectric conversion unit including a photoelectric conversion layer with a wider band gap is disposed, and subsequently a second photoelectric conversion unit including a photoelectric conversion layer with a band gap narrower than that of the first photoelectric conversion unit is disposed. In this way, photoelectric conversion of incident light with a wide range of wavelengths can be achieved, to thereby improve the conversion efficiency of the device as a whole. For example, there has been known a structure in which an amorphous silicon photoelectric conversion unit (a-Si photoelectric conversion unit) is formed as a top cell, and a microcrystalline photoelectric conversion unit (μc-Si photoelectric conversion unit) is formed as a bottom cell.
[0007] Further, the photoelectric conversion device is often employed as integrated modules obtained by dividing the a-Si photoelectric conversion unit and the μc-Si photoelectric conversion unit into a plurality of rectangular cells by means of a laser and connecting the plurality of divided cells in series-parallel combination.
[0008] Meanwhile, in a state where a current generated in the μc-Si photoelectric conversion unit governs a current of each cell, currents are limited by a current that passes through a cell that is located in a region where a crystalline fraction of the μc-Si photoelectric conversion unit is lower in a plurality of series-connected cells. For this reason, there has been a problem in that it is impossible to enhance overall power production efficiency in the integrated modules of the photoelectric conversion device.
SUMMARY
[0009] In an aspect of the present invention, there is provided a photoelectric conversion device of a tandem type in which an amorphous photoelectric conversion unit including an amorphous i-type layer and a microcrystalline photoelectric conversion unit including a microcrystalline i-type layer are connected on a substrate. The photoelectric conversion device comprises an intermediate layer disposed between the amorphous photoelectric conversion unit and the microcrystalline photoelectric conversion unit and having a refractive index lower than that of layers in contact with the front or back surfaces of the intermediate layer. In the photoelectric conversion device, the intermediate layer having a smaller film thickness is formed in a plane of the substrate where a crystalline fraction of the microcrystalline i-type layer is lower.
[0010] According to the present invention, photoelectric conversion efficiency in the photoelectric conversion device can be improved.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] FIG. 1 is a diagram showing a structure of a photoelectric conversion device according to an embodiment of this invention.
[0012] FIG. 2 is a diagram for explaining the distribution of crystallization properties of an i-type layer in a μc-Si unit and the distribution of film thicknesses of an intermediate layer in the embodiment of this invention.
DETAILED DESCRIPTION
[0013] FIG. 1 is a cross sectional view showing a structure of a photoelectric conversion device 100 according to an embodiment of this invention. The photoelectric conversion device 100 in this embodiment has a laminated structure formed on a transparent insulating substrate 10 , which is defined as a light incident side. The laminated structure is composed of, from the light incident side, a transparent conductive layer 12 , an amorphous silicon (a-Si) (photoelectric conversion) unit 102 functioning as a top cell with a wider band gap, an intermediate layer 14 , a microcrystalline silicon (μc-Si) (photoelectric conversion) unit 104 functioning as a bottom cell with a band gap narrower than that of the a-Si unit 102 , and a back electrode layer 16 , in that order. It should be noted that FIG. 1 shows both a region A, which is a high crystallization region of an i-type layer in the μc-Si unit 104 and will be described below, and a region B which is a low crystallization region of the i-type layer.
[0014] A substrate composed of a material that is transparent at least in a wavelength range of visible light, such as a glass substrate or a plastic substrate, for example, may be used as the transparent insulating substrate 10 . The transparent conductive layer 12 is formed on the transparent insulating substrate 10 . For the transparent conductive layer 12 , there is preferably used at least one or a combination of a plurality of transparent conductive oxides (TCO), such as a tin oxide (SnO 2 ), a zinc oxide (ZnO), and an indium tin oxide (ITO), doped with tin (Sn), antimony (Sb), fluorine (F), aluminum (Al), or the like. Among them, the zinc oxide (ZnO) is particularly preferable due to its high transmittancy, low resistivity, and excellent plasma-resistant property. The transparent conductive layer 12 can be formed by means of, for example, a sputtering method, a CVD method, or the like. It is preferable for the transparent conductive layer 12 that a film thickness thereof is in a range of from 0.5 μm to 5 μm. Further, it is also preferable that the transparent conductive layer 12 is provided on the surface thereof with projections and depressions that have a light-trapping effect.
[0015] On the transparent conductive layer 12 , the a-Si unit 102 is formed by sequentially laminating silicon-based thin films of a p-type layer, an i-type layer, and an n-type layer. The a-Si unit 102 can be formed with a plasma CVD method for forming a film by means of a plasma generated from a gas mixture in which a silicon-containing gas, such as silane (SiH 4 ), disilane (Si 2 H 6 ), or dichlorosilane (SiH 2 Cl 2 ); a carbon-containing gas such as methane (CH 4 ); a p-type dopant containing gas such as diborane (B 2 H 6 ); an n-type dopant containing gas such as phosphine (PH 3 ); and a diluent gas such as hydrogen (H 2 ) are mixed. For example, RF plasma CVD at 13.56 MHz is preferably employed as the plasma CVD method.
[0016] The p-type layer is formed on the transparent conductive layer 12 . The p-type layer is embodied as a p-type amorphous silicon layer (p-type a-Si:H) or a p-type amorphous silicon carbide layer (p-type a-SiC:H), which is no less than 10 nm and no more than 100 nm in film thickness and is doped with a p-type dopant (such as boron). The film quality of the p-type layer can be changed by adjusting a mixture ratio of the silicon-containing gas, the carbon-containing gas, the p-type dopant containing gas, and the diluent gas, the pressure, and high frequency power for generating the plasma.
[0017] The i-type layer is implemented as an undoped amorphous silicon film, which is no less than 50 nm and no more than 500 nm in film thickness and formed on the p-type layer. The i-type layer functions as a power production layer in the a-Si unit 102 . The film quality of the i-type layer can be changed by adjusting a mixture ratio of the silicon-containing gas and the diluent gas, the pressure, and the high frequency power for generating the plasma.
[0018] The n-type layer is implemented as an n-type amorphous silicon layer (n-type a-Si:H) or an n-type microcrystalline silicon layer (n-type pc-Si:H), which is no less than 10 nm and no more than 100 nm in film thickness, formed on the i-type layer, and doped with an n-type dopant (such as phosphor). The film quality of the n-type layer can be changed by adjusting a mixture ratio of the silicon-containing gas, the carbon-containing gas, the n-type dopant containing gas, and the diluent gas, the pressure, and the high frequency power for generating the plasma.
[0019] On the a-Si unit 102 , the intermediate layer 14 is formed. The intermediate layer 14 has a refractive index lower than those of layers formed on both surfaces of the intermediate layer 14 . In this embodiment, the refractive index of the intermediate layer 14 is defined to be lower than both refractive indices of the n-type layer in the a-Si unit 102 and the p-type layer in the pc-Si unit 104 . In this way, light that has arrived at the intermediate layer 14 after passing through the transparent insulating substrate 10 , the transparent conductive layer 12 , and the a-Si unit 102 can be partially reflected toward an a-Si unit 102 side, to thereby increase production of electricity in the a-Si unit 102 , while the film thickness of the i-type layer functioning as the power production layer in the μc-Si unit 104 can be reduced.
[0020] For the intermediate layer 14 , a transparent conductive oxide (TCO) such as the zinc oxide (ZnO) or a silicon oxide (SiOx) may preferably be used. In particular, use of the zinc oxide (ZnO) doped with magnesium (Mg) or the silicon oxide (SiOx) is especially preferable. The transparent conductive oxide (TCO) can be formed, for example, by means of the sputtering method, the CVD method, or the like. In addition, a silicon oxide film (SiOx) is also preferably employed. The silicon oxide film (SiOx) can be formed through the plasma CVD method for forming a film by means of a laser generated from a gas mixture in which the silicon-containing gas such as silane (SiH 4 ), disilane (Si 2 H 6 ), or dichlorosilane (SiH 2 Cl 2 ); an oxygen-containing gas such as carbon dioxide (CO 2 ); and a diluent gas such as hydrogen (H 2 ) are mixed. The film thickness of the intermediate layer 14 is preferably defined to be in a range of from 50 nm to 100 nm.
[0021] In this embodiment, the intermediate layer 14 has a film thickness that is varied in a panel plane of the photoelectric conversion device 100 . More specifically, relative to the film thickness of the intermediate layer 14 in a region having a lower crystalline fraction of the i-type layer, which is the power production layer of the below-described μc-Si unit 104 , the film thickness of the intermediate layer 14 is increased in a region having a higher crystalline fraction.
[0022] As shown in FIG. 2 , for example, the crystalline fraction of the i-type layer, which is the power production layer in the μc-Si unit 104 , is typically higher in a region A around the center of the panel plane. Then, the crystalline fraction becomes lower as the i-type layer gets closer to a peripheral region B. With this in view, the film thickness of the intermediate layer 14 is reduced in the peripheral region B so as to be smaller than that of the intermediate layer 14 in the region A around the center as shown in FIG. 1 . It should be noted that FIG. 2 schematically shows a distribution in the panel plane, and in practice, both the crystalline fraction of the i-type layer in the μc-Si unit 104 and the film thickness of the intermediate layer 14 are changed continuously.
[0023] In order to change the film thickness of the intermediate layer 14 , for example, during formation of the intermediate layer 14 with the plasma CVD method, a density of a material gas may be increased in a region where the film is thickened, while the density of the material gas may be decreased in a region where the film is thinned. More specifically, in the plasma CVD method using parallel plate electrodes, an arrangement for supplying the material gas from a central part of the plate electrodes and exhausting the material gas from a peripheral part of the plate electrodes may be employed, to thereby cause the density of the material gas to become higher at the central part than that at the peripheral part in the panel plane. In this way, the intermediate layer 14 can have a greater film thickness in the region A around the center than in the peripheral region B.
[0024] Alternatively, the film thickness of the intermediate layer 14 may be varied by, during formation of the intermediate layer 14 with the plasma CVD method, increasing a supply (a flow rate) of the material gas in the region where the film is thickened while decreasing the supply (the flow rate) of the material gas in the region where the film is thinned. Further, a heating temperature to which the transparent insulating substrate 10 is heated may be raised in the region where the film is thickened while the heating temperature to which the transparent insulating substrate 10 is heated may be lowered in the region where the film is thinned. Still further, a higher density of power may be supplied to generate the plasma in the region where the film thickness is increased, while a lower density of power may be supplied to generate the plasma in the region where the film thickness is decreased. The method for changing the film thickness of the intermediate layer 14 is not limited to those described above, and may be implemented using an appropriate combination of the above-described methods.
[0025] The distribution of film thicknesses of the intermediate layer 14 in the panel plane can be measured through observation using a scanning electron microscope (SEM) or cross-section observation using a transmission electron microscope (TEM) in each region. In the measurement, because the observed structure of the intermediate layer 14 will be different from those of the a-Si unit 102 and the μc-Si unit 104 , and different observations of the μc-Si unit 104 will be obtained depending on the crystalline fraction of the μc-Si unit 104 , a determination can be made as to whether or not a formed film thickness of the intermediate layer 14 is greater in the region having a higher crystalline fraction of the i-type layer, which is the power production layer of the μc-Si unit 104 , than in the region having a lower crystalline fraction.
[0026] It should be noted that the crystalline fraction of the i-type layer, which is the power production layer of the μc-Si unit 104 , is defined as a value obtained as described below. A microcrystalline silicon film is formed as a single film on a flat glass substrate under the same film forming conditions as those used for forming the i-type layer of the μc-Si unit 104 , and the Raman spectrum of the single film is measured with Raman spectroscopy. Then, peaks of a Raman scattering intensity Ic at approximately 520 cm −1 attributable to crystalline silicon and a Raman scattering intensity Ia at approximately 480 cm −1 attributable to amorphous silicon are separated. The intensities (heights) of the peaks are used to derive the value of the crystalline fraction from the below-described equation (1). After the measurement of the crystalline fraction as described above is repeated at a plurality of sites in the panel plane, the distribution of crystalline fraction of the i-type layer in the μc-Si unit 104 can be measured in the panel plane.
[0000] Crystalline fraction (%)= Ic /( Ic+Ia ) (1)
[0027] On the intermediate layer 14 , the p-type layer, the i-type layer, and the n-type layer are sequentially laminated to form the μc-Si unit 104 . The μc-Si unit 104 can be formed with the plasma CVD method for performing film formation by means of the plasma generated from the gas mixture in which the silicon-containing gas, such as silane (SiH 4 ), disilane (Si 2 H 6 ), dichlorosilane (SiH 2 Cl 2 ); the carbon-containing gas such as methane (CH 4 ); the p-type dopant containing gas such as diborane (B 2 H 6 ); the n-type dopant containing gas such as phosphine (PH 3 ); and the diluent gas such as hydrogen (H 2 ) are mixed. The plasma CVD method is preferably implemented, for example, by RF plasma CVD with 13.56 MHz as in the case of the a-Si unit 102 .
[0028] The p-type layer is formed on the intermediate layer 14 . The p-type layer is preferably implemented by a microcrystalline silicon layer, an amorphous layer, or a lamination thereof having a film thickness no less than 5 nm and no more than 50 nm. Further, the amorphous layer is preferably implemented by an amorphous silicon layer (a-Si) or an amorphous silicon carbide layer (a-SiC). The film quality of the p-type layer can be changed by adjusting the mixture ratio of the silicon-containing gas, the carbon-containing gas, the p-type dopant containing gas, and the diluent gas, the pressure, and the high frequency power used for generating the plasma.
[0029] The i-type layer is formed on the p-type layer. The i-type layer is implemented by the undoped microcrystalline silicon layer, which is no less than 0.5 μm and no more than 5 μm in film thickness and is formed on the p-type layer. The i-type layer functions as a power production layer in the μc-Si unit 104 . The film quality of the i-type layer can be changed by adjusting the mixture ratio of the silicon-containing gas and the diluent gas, the pressure, and the high frequency power used for generating the plasma.
[0030] The n-type layer is formed on the i-type layer. The n-type layer is implemented as an n-type microcrystalline silicon layer (n-type pc-Si:H), which is no less than 5 nm and no more than 50 nm in film thickness and doped with the n-type dopant (such as phosphor). However, the μc-Si unit 104 is not limited to the above-described form, and may be implemented in any other form so long as the i-type microcrystalline silicon layer (i-type μc-Si:H) is used as the power production layer.
[0031] On the μc-Si unit 104 , the back electrode layer 16 is formed. The back electrode layer 16 is a laminated structure composed of a reflective metal and the transparent conductive oxide (TCO). For the transparent conductive oxide (TCO), there is used tin oxide (SnO 2 ), zinc oxide (ZnO), indium tin oxide (ITO), or the like, or one of the above oxides doped with impurities. The transparent conductive oxide (TCO) may be, for example, the zinc oxide doped with aluminum as an impurity. Meanwhile, a metal such as silver (Ag) or aluminum (Al) is used as the reflective metal. The transparent conductive oxide (TCO) and the reflective metal can be formed, for example, by means of the sputtering method, the CVD method, or the like. At least one of the transparent conductive oxide (TCO) and the reflective metal is preferably provided with projections and depressions to enhance the light trapping effect.
[0032] In addition, the back electrode layer 16 may be covered with a protective film (not illustrated). The protective film may be a laminated structure composed of PET/Al foil/PET, a monolayer structure of a resin, such as a fluorine-based resin (such as ETFE, PVDF, PCTFE), PC, PET, PEN, PVF, acrylic resin, or a structure in which a metal foil is sandwiched. The protective film may be applied on the back electrode layer 16 by means of a resin filler of EVA, ethylene based resin (such as EEA), PVB, silicone, urethane, acryl, epoxy resin, etc. so as to cover the back electrode layer 16 . In this way, an event such as penetration of moisture into the power production layer of the photoelectric conversion device can be prevented.
[0033] In this connection, a YAG laser (with a fundamental wave of 1064 nm and a second harmonic wave of 532 nm) may be used for separating the transparent conductive layer 12 , the a-Si unit 102 , the intermediate layer 14 , the μc-Si unit 104 , and the back electrode layer 16 into a plurality of cells, to thereby provide a structure composed of the plurality of cells connected in series-parallel combination.
[0034] The photoelectric conversion device 100 in this embodiment can be structured as described above. In the region where the crystalline fraction of the i-type layer in the photoelectric conversion device 100 is low, the power production efficiency in the μc-Si unit 104 is low. For this reason, in a case where the μc-Si unit 104 governs a current value of the photoelectric conversion device 100 , the current value of the photoelectric conversion device 100 will be limited by the region where the crystalline fraction of the i-type layer in the μc-Si unit 104 is low. According to this embodiment, in the region where the crystalline fraction of the i-type layer in the μc-Si unit 104 is lower, the intermediate layer 14 having a smaller film thickness is formed. In this way, the intermediate layer 14 is caused to reflect a smaller amount of light toward the a-Si unit 102 , thereby allowing an increased amount of light to be directed toward the μc-Si unit 104 , which, in turn, allows the μc-Si unit 104 to produce a greater amount of electricity (currents). As a result, a current value obtained from the region having the lower crystalline fraction of the i-type layer and having an effect of limiting the current value in the μc-Si unit 104 can be increased, to thereby raise the overall current value of the photoelectric conversion device 100 accordingly. In other words, a more uniform distribution of production of electricity (currents) in the μc-Si unit 104 can be achieved in a substrate plane as compared to the distribution achieved in a conventional way. On the other hand, the intermediate layer 14 of a greater film thickness is formed in the region where the crystalline fraction of the i-type layer in the μc-Si unit 104 is higher. In this way, the amount of light (in particular, light with a wavelength of 500 nm or greater) reflected from the intermediate layer 14 to the a-Si unit 102 can be increased, and a greater amount of light can be accordingly directed to the a-Si unit 102 , thereby enhancing the production of electricity (currents) in the a-Si unit 102 . Thus, because the production of electricity (currents) can be enhanced without thickening the a-Si unit 102 , it is possible to reduce light deterioration, which becomes pronounced when the film is otherwise thickened. As a result, the overall power producing efficiency of the integrated modules in the photoelectric conversion device 100 can be increased.
DESIGNATION OF NUMERALS
[0000]
10 transparent insulating substrate
12 transparent conductive layer
14 intermediate layer
16 back electrode layer
100 photoelectric conversion device
102 amorphous silicon photoelectric conversion unit (a-Si photoelectric conversion unit)
104 microcrystalline silicon photoelectric conversion unit (μc-Si photoelectric conversion unit) | Disclosed is a photoelectric conversion device with improved photoelectric conversion efficiency. In the disclosed photoelectric conversion device, an amorphous silicon photoelectric conversion unit with an amorphous i-type layer and a microcrystalline silicon photoelectric conversion unit with a microcrystalline i-type layer are laminated, and an intermediate layer, which is disposed between the amorphous silicon photoelectric conversion unit and the microcrystalline silicon photoelectric conversion unit, has a lower refractive index than the layers in contact with the front or back surfaces thereof, wherein the higher the crystalline fraction of the microcrystalline i-type layer in the panel surface, the thicker the film of the intermediate layer. | 8 |
CROSS REFERENCES TO RELATED APPLICATIONS
[0001] This application claims priority to U.S. Provisional Patent Application No. 62/306,266, filed on Mar. 10, 2016, the entire contents of which are hereby incorporated by reference.
FIELD
[0002] This invention relates generally to the field of odor detection by trained animals. Various embodiments improve the delivery and detection of targeted odors (e.g., explosives, illicit drugs, agricultural, chemical, etc.) by animals, such as dogs, trained to alert on such odors. Exemplary embodiments of the system enable screening of odors on persons, animals, or items in a safe and non-offensive manner.
BACKGROUND
[0003] There are many situations in which pedestrians or vehicles may be carrying materials which are prohibited from transport into or out of a designated area, such as, airports, sporting venues and high security facilities. The prohibited materials may include, for example, explosive materials and illegal drugs.
[0004] One method for screening for such materials is to individually search each pedestrian or vehicle for the prohibited material. Unfortunately, individual searching is extremely time-consuming and requires an inordinate number of searchers and an inordinate period of time.
[0005] Another method for screening for certain materials includes the use of detection systems or devices and instrumentalities. Such systems typically use ion mobility spectrometry (IMS) and are designed to detect certain chemicals, more specifically, particular airborne particles associated with the item for which detection is intended. As described in further detail below these types of systems suffer from various problems and prove inefficient and/or ineffective when compared to canine/dog sniffing detection methods.
[0006] The use of dogs as chemical detectors dates back to their use as hunting dogs several thousands of years ago. More recently, however, e.g., since World War II, dog-handler teams have been used extensively by the military to locate explosives. Civilian use of dogs first started with tracking individuals and locating drugs and other illegal contraband, including bombs and other explosive devices. Civilian use has now expanded to include the detection of many other items, such as, guns, pipeline leaks, gold ore and contraband food. In view of recent terrorist activities dogs are now being trained to also detect flammable and ignitable liquid residues to identify individuals that likely have recently handled materials potentially used in bomb manufacture. Such canines are commonly referred to as accelerant detector dogs and results of their odor detection in such situations have been found admissible in court in certain circumstances.
[0007] A general comparison between instrumental chemical detection devices and trained detector dogs demonstrates that for certain aspects instrumental detection may be preferable over canine detection. However, for many, if not most, aspects that are most important to the user, canine detection is the more preferable choice. For example, the selectivity of detector dogs is generally superior to instrumental methods. Dogs are able to generalize odorant signatures enabling the detection of target odors in the presence of additional significant distracting odors, without the false alerts commonly encountered with many instruments. Dogs use a highly sophisticated neural network to confirm explosives from the pattern of odor chemicals emanating from their representative parent molecule(s) rather than relying on the parent molecule required by most instrumental methods.
[0008] Another advantage of detector dogs over instrument methods is the overall speed of detection which is generally significantly faster in canine detection than instrumental methods. The detection of low vapor pressure explosives using typical IMS instruments requires trapping particles containing the adsorbed explosive vapors followed by transferring the particles into the detector for heating and analysis. This additional required step slows down detection times for instrument from seconds to minutes or even longer depending on the screening and swab time as well as the number of subjects/items to be tested in a given period of time. Dogs also utilize an extremely efficient sampling system and can often times go directly to the source of the odor and discover the explosive, unlike machines which are typically fixed.
[0009] Even though canine detection is preferable over machine detection for many reasons, bringing certain dogs into direct contact with a large number of pedestrians, or even vehicles, can present difficulties. For instance, some people are extremely fearful of dogs and other animals and, as a result, a person being screened may act irrationally and cause harm to a highly trained dog or its handler if the situation is not tightly controlled. Traveling among a large number of vehicles may also create the potential for harm to a highly trained dog or its handler. What is needed, therefore, is an accurate and reliable system to screen persons or other individual items, such as packages, baggage and other items, and obtain consistent positive identification of prohibited material while reducing false-positive identifications of prohibited material.
SUMMARY
[0010] An exemplary embodiment includes a screening system comprising an odor delivery unit forcing air in a controlled direction across an object being screened and generating an odor stream including odors emanating from the object being screened. The system of this embodiment also includes a canine trained to detect one or more odors in the odor stream, and an obscuring unit positioned in the odor stream and between the object being screened and the canine.
[0011] In accordance with a further aspect of the exemplary embodiment described above, the odor delivery unit includes one or more fans configured to direct airflow across the object being screened.
[0012] In accordance with a further aspect of the exemplary embodiment described above, at least one of the fans of the odor delivery unit is located above the object being screened and is configured to force air in a downward direction and towards the obscuring unit.
[0013] In accordance with a further aspect of the exemplary embodiment described above, the obscuring unit includes fixed slats that obstruct visibility between the object being screened and the canine.
[0014] In accordance with a further aspect of the exemplary embodiment described above, the obscuring unit includes rotatable louvers that obstruct visibility between the object being screened and the canine and can be adjusted to increase and/or decrease one or more of the visibility and a volume of the air being forced towards the canine.
[0015] According to a further exemplary embodiment a screening system is provided that comprises a fan unit forcing air in a controlled direction across an object being screened generating an odor stream including odors emanating from the object being screened, and an odor detection device configured to detect one or more predetermined odors in the odor stream. A system according to this further embodiment also includes an obscuring panel positioned in the odor stream and between the object being screened and the odor detection device.
[0016] In accordance with a further aspect of this additional exemplary embodiment, the odor delivery unit includes one or more fans configured to direct airflow across the object being screened.
[0017] In accordance with a further aspect of the additional exemplary embodiment described above, at least one of the fans of the odor delivery unit is located above the object being screened and is configured to force air in a downward direction and towards the obscuring unit.
[0018] In accordance with a further aspect of the additional exemplary embodiment described above, the obscuring unit includes fixed slats that obstruct visibility between the object being screened and the odor detection device.
[0019] In accordance with a further aspect of the additional exemplary embodiment described above, the obscuring unit includes rotatable louvers that obstruct visibility between the object being screened and said odor detection device and can be adjusted to increase and decrease one or more of the visibility and a volume of the air being forced towards the odor detection device.
BRIEF DESCRIPTION OF THE DRAWINGS
[0020] The aspects and features of various exemplary embodiments will be more apparent from the description of those exemplary embodiments taken with reference to the accompanying drawings, in which:
[0021] FIG. 1 is a schematic view of an exemplary system in accordance with the disclosure;
[0022] FIG. 2A is a front view of an odor delivery system (ODS) in accordance with the disclosure;
[0023] FIG. 2B is a side view of the odor delivery system (ODS) shown in FIG. 2A ;
[0024] FIG. 3 shows the relative dimensions of various portions of the ODS as shown in FIGS. 2A and 2B ;
[0025] FIG. 4 is a perspective view of an exemplary obscuring permeable partition in accordance with the system shown in FIG. 1 .
DESCRIPTION OF EXEMPLARY EMBODIMENTS
[0026] Referring to FIG. 1 , an exemplary embodiment consistent with the present invention includes a system that permits fast, effective canine detection of specific odors for which the dog has been trained to detect, without requiring the animal to be in direct contact with the person or item being screened. More particularly, according to this embodiment odor delivery system (ODS) ( 100 ) is energized and fans 1 a , 1 b and 1 c are individually calibrated by the system operator, either alone or using various known calibration tools, to a setting related to airflow measured in cubic feet per minute (cfm). The calibration takes ambient conditions into consideration. Such calibration enables, among other things, the unit to be employed in either indoor or outdoor environments and under various ambient conditions. One objective of the calibration procedure is to achieve a cfm level sufficient to ‘push’ odor particles being screened ( 30 ) to achieve the required ‘odor stream.’ However, in most situations the operator calibrates the system to a cfm level that prevents the rapid dispersion or ‘spraying’ of the odor particles.
[0027] The person, or other object, to be screened ( 20 ) stands, or is otherwise placed, on a designated location, such as “feet labels” on the floor/ground, and positioned as shown relative to the ODS. In accordance with the embodiment shown, the person's shoulders are made perpendicular to the front of the ODS ( 100 ). The feet labels are centered and perpendicular to the center of the ODS′ fans ( 1 a - 1 c ) to ensure substantially equal amounts of air to pass by the person/object being screened on each side. This must be estimated much of the time by a handler experienced in the use of the system under variable conditions. The handler would then test and approve of the specific calibration using a test odor planted on a test subject prior to the system being employed.
[0028] The airflow, including particles to be detected, ( 30 ) is directed past the person/object being screened ( 20 ) forcing transport of the subject odor to be screened in the direction of arrows. The air and odor particulates pass through the Obscuring Permeable Partition ( 40 ) that obscures and physically separates the trained animal from the person/object being screened while allowing airflow to reach the trained animal positioned on the other side. The partition's louvers, e.g., 8′×4″×1/8″ design, spaced one inch apart and angled 35 degrees downward toward the trained animal, making the person or object obscured to the animal as well.
[0029] The animal ( 50 ), such as a trained canine, screens for target odors as directed by its handler (e.g., explosives, drugs, agricultural products, etc.) and alerts as trained. The embodiment shown in FIG. 1 illustrates one system of what could be a series of co-located systems as dictated by screening throughput objectives and the amount of people/objects being screened.
[0030] FIGS. 2A and 2B show the front and side views, respectively, of an odor delivery system (ODS) such as the one depicted in FIG. 1 . Fans ( 1 a - 1 c ) are positioned to maximize the amount of odor stream produced in a downward direction across the body of the screened person/object and can be commercial fans, such as that are designed to work indoors or outdoors with blades ( 7 ) approximately 24-36 inches in diameter, with a minimum capability of about 2000 cfm.
[0031] Housing ( 2 ) in the embodiment shown in FIGS. 2A and 2B is a paneled cabinet made of aluminum sheets with a rear access door (not shown). Mounting Brackets ( 3 ) are fixed to the cabinet wall and are attached to and support fans 1 a - 1 c . Modulation Unit ( 4 ), in accordance with the disclosed embodiment, includes three lighting rotary switches (not shown) corresponding to the three respective fans, 1 a - 1 c , for example, 600-Watt Single-Pole, wired to respected fans mounted in an electrical housing. Housing Frame ( 5 ) in the present embodiment is two inch square aluminum tubing to which aluminum sheet is affixed.
[0032] In further reference to the exemplary embodiment of FIGS. 2A and 2B , mesh covering ( 6 ) comprises a flat sheet of aluminum mesh or screen having a mill finish, H 14 temper cut into desired length, e.g., 4 feet, and width, e.g., 4 feet, with an overall thickness of approximately 0.060 inches.
[0033] Air Intake Mesh ( 8 ) is made of the same material as the mesh ( 6 ) covering the fan blades ( 7 ). Electrical Wiring ( 9 ) electrically connects the modulation unit ( 4 ) to the fans 1 a - 1 c and comprises 12-gauge wire rated for 20-amps of current.
[0034] FIG. 3 shows front and side views of the cabinet 100 with designations A-E depicting the relative size dimensions of the various sections of the cabinet. For example, height (A) indicates the overall height of the cabinet which, according to the embodiment shown, is approximately 9-10 feet and (C) represents the cabinet depth, which is approximately 5-7 feet. Dimension (B) depicts the height, and (E) represents the width, of the object chamber. The height (A) is approximately 7-8 feet tall to accommodate the height of most people and (E) is approximately 2-4 feet. The width of the cabinet, represented by (D) is approximately 4-6 feet. The dimensions indicated are exemplary and one of ordinary skill in the art would know that other dimensions can be used and are within the spirit and scope of the invention. For example, if the ODS is being used to detect odors on an object such as a suitcase, as opposed to a person as indicated in the present embodiment, the dimensions would be less than those provided above.
[0035] FIG. 4 illustrates a permeable barrier (e.g., 40 in FIG. 1 ) in accordance with one or more exemplary embodiments. According to the embodiment shown, barrier ( 40 ) includes slats or louvers ( 60 ) which obstruct the visibility of the animal, such as dog ( 50 ) in FIG. 1 , from the perspective of the cabinet, and more specifically the person ( 20 ) being screened. Slats are fixed and louvers can be rotated to allow more or less air to pass through the barrier and conversely provide less or more visibility obstruction. For example, if the object being screened is a person it may be more desirable to provide increased visibility obstruction in order to limit the possible apprehension of the person being screened, e.g., if they are extremely afraid of dogs. On the other hand, of the object is a suitcase or some other inanimate object, it might be desirable to maximize the air flow and limit the visibility obstruction.
[0036] The dimensions of the exemplary permeable barrier ( 40 ) shown in FIG. 4 are indicated by the letters X, Y and Z. Height (X) is approximately 3-5 feet, for example, to provide a sufficient angle in order to obstruct the person's view of the dog. Length (Y), according to this embodiment, is approximately the same as dimension (D) provided in regard to FIG. 3 and width (Z) is approximately 6-12 inches to provide adequate free-standing stability to the barrier; however, it is possible that the barrier could be connected to a platform that also connects to the cabinet and, thus, can be thinner.
[0037] An exemplary embodiment of the invention operates as follows. The owner of a sports stadium employs the system to screen individuals for explosive odor before entering the venue. In accordance with the embodiment shown in FIG. 1 , the person, or other object, to be screened ( 20 ) stands, or is otherwise placed, on a designated location, such as “feet labels” on the floor/ground, and positioned as shown relative to the ODS. The person's shoulders are made perpendicular to the front of the ODS ( 100 ). The feet labels are centered and perpendicular to the center of the ODS' fans ( 1 a - 1 c ) to ensure substantially equal amounts of air to pass by the person/object being screened on each side. The ODS sends odor past the person, captures odors in the airstream, and proceeds through the obscuring permeable barrier. On the opposite side of the barrier, the trained canine “sniffs” the air and alerts its handler of target odor should it be present. The person is detained for further investigation accordance with predetermined law enforcement/security operational procedure.
[0038] The foregoing description of the certain exemplary embodiments has been provided for the purpose of explaining the general principles and practical application, thereby enabling others skilled in the art to understand the disclosure for various embodiments and with various modifications as are suited to the particular use contemplated. This description is not necessarily intended to be exhaustive or to limit the disclosure to the exemplary embodiments disclosed. Any of the embodiments and/or elements disclosed herein may be combined with one another to form various additional embodiments not specifically disclosed. Accordingly, additional embodiments are possible and are intended to be encompassed within this specification and the scope of the appended claims. The specification describes specific examples to accomplish a more general goal that may be accomplished in another way.
[0039] As used in this application, the terms “front,” “rear,” “upper,” “lower,” “upwardly,” “downwardly,” and other orientational descriptors are intended to facilitate the description of the exemplary embodiments of the present application, and are not intended to limit the structure of the exemplary embodiments of the present application to any particular position or orientation. Terms of degree, such as “substantially” or “approximately” are understood by those of ordinary skill to refer to reasonable ranges outside of the given value, for example, general tolerances associated with manufacturing, assembly, and use of the described embodiments. | A system that screens for particularly identified odors, such as those associated with explosive and other bomb-making materials, weapons and illegal drugs, includes an odor delivery unit with one or more fans that force air across the object being screened, such as a person. The airflow from the odor delivery unit passes over and across the object being screened creating an odor stream that passes through a partition that allows the odor stream to flow freely through it and simultaneously obscures a canine positioned on the other side of the partition from view by the person or object being screened. | 5 |
FIELD OF THE INVENTION
[0001] The present invention is generally directed to a system and method for padding macro blocks on and outside a shape boundary of a video object, and more specifically, to an algorithm for performing horizontal and vertical processing to pad macro blocks around a video object of Motion Picture Experts Group Version 4 (MPEG-4) video data.
BACKGROUND OF THE INVENTION
[0002] The MPEG standards specify a lossy type compression scheme that is adapted to handle a variety of audio/video formats. MPEG-1 and MPEG-2 employ frame-based coding standards that are beneficial for primarily single-media video applications. For example, MPEG-2 (i.e., MPEG Version 2) supports standard television signals, high definition television (HDTV) signals, and five channel surround sound. Similarly, MPEG-2 also provides a broadcast-quality image at 720×480 pixel resolution for use in digital video disk (DVD) movies.
[0003] The latest video coding standard, MPEG-4, supports object-based compression/decompression that is beneficial for multimedia applications, especially combining natural video and synthetic graphics objects. MPEG-4 is capable of relatively high compression ratios and is a powerful tool useful for a wide range of applications, including Internet browsing, set-top boxes, video games, video conferencing, and wireless networks. Also, the MPEG-4 standard is capable of handling arbitrary-shaped objects that cannot be accommodated by the frame-based coding standards of both MPEG-1 and MPEG-2.
[0004] Widespread use of MPEG-4 for desktop video is expected, but MPEG-4 acceleration is not widely incorporated into many graphics coprocessors. Fortunately, the techniques used in MPEG-4 video decoding for rectangular video objects is similar to those used in MPEG-2. Thus, MPEG-4 video decoding can be accelerated in a similar way on existing graphics coprocessors, such as Nvidia Corporation's GEFORCE™ graphics coprocessor, S3 Graphic, Inc.'s SAVAGE™ line of graphics coprocessors, ATI Technology, Inc.'s RAGE™ line of graphics coprocessors, and Rendition Corporation's VERITE™ series of graphics coprocessors.
[0005] These graphics coprocessors typically accelerate MPEG-1/2 decoding with separate on-chip fixed function units or programmable/configurable graphics pipelines. These pipelines often perform the last few steps of MPEG-1/2 decoding rather than requiring the host processor to perform these steps. Examples of off-loaded tasks performed by the graphics coprocessors include motion compensation and inverse discrete cosine transformation (IDCT). The last few steps of MPEG-1/2 decoding has a one-way data flow (from the host processor to the coprocessor), thus avoiding the need for synchronization between the host processor and the coprocessor.
[0006] However, if the host processor needs to post-process the resulting macroblocks after an IDCT and motion compensation, the coprocessor must notify the host processor when the IDCT or motion compensation is completed and the data are ready to be transferred back to the host processor. This process has to be repeated in transferring the post-processed data back to the coprocessor's video memory.
[0007] For example, the padding of boundary macroblocks has to be done on texture data after IDCT and motion compensation are completed. For padding to be performed by the host processor, macroblocks have to be transferred from video memory to host memory for padding and then back to video memory for use as a reference in decoding subsequent frames. Unfortunately, boundary macroblock padding, which is one of the key processing steps in decoding arbitrary-shaped video objects in MPEG-4, cannot be efficiently accelerated on typical graphics coprocessors. Unless special hardware and/or a specific set of new instructions are added to the graphics coprocessor, it is typically better for boundary macroblock padding to be performed on the host processor.
[0008] Rather than incurring the processing load on the host processor, and taking the time to pass data back and forth between host memory and video memory, it would clearly be desirable to accelerate MPEG-4 video decoding on the same processing hardware used for MPEG-2 video decoding by implementing boundary macroblock padding more efficiently. Accordingly, it would be preferable to develop a solution that can be readily implemented with existing hardware and without significant synchronization overhead.
SUMMARY OF THE INVENTION
[0009] The present invention is directed to a method for padding a boundary macroblock of a video object without significant synchronization overhead between a host processor and an existing coprocessor, and without redundant transfer of data between a host memory and a video memory. The host processor determines horizontal and vertical graphics primitives as a function of object shape data stored in the host memory and communicates the primitives to the coprocessor, which renders the primitives in an interleaved pipeline fashion to pad the macroblock based on texture data stored in video memory. The flow of primitives is in one direction from the host processor to the coprocessor, and the texture data need not be transferred back and forth between the host processor and coprocessor.
[0010] More specifically, the host processor performs a row-by-row horizontal scan of a macroblock to count pixels in each row that lie outside the boundary of the video object (these pixels are referred to as transparent pixels). The host processor determines a horizontal primitive for each set of transparent pixels in a row. Any row comprised entirely of transparent pixels is flagged for processing during a subsequent horizontal scan. The host processor communicates the horizontal primitives to the coprocessor. The coprocessor can then immediately use the horizontal primitives and texture data stored in video memory to begin horizontal padding of the macroblock.
[0011] While the coprocessor is doing the horizontal padding, the host processor performs a vertical scan of a stack indicating rows that were flagged as being comprised entirely of transparent pixels. The host processor determines a vertical primitive for each set of flagged rows. After the lapse of a latency period that enables the coprocessor to complete the horizontal padding, the host processor communicates the vertical primitives to the coprocessor. The coprocessor uses the vertical primitives and texture data resulting from the horizontal padding to perform vertical padding of the macroblock.
[0012] Other aspects of the present invention are directed to a system for padding a boundary macroblock of a video object and to a machine-readable medium storing machine instructions that cause a processor to generally perform the steps of the method discussed above. The system includes a host processor, a host memory in communication with the host processor, a coprocessor in communication with the host processor; a graphics memory in communication with the coprocessor, a data bus in communication with the host processor and coprocessor, and optionally a buffer. These components carry out functions generally consistent with the steps of the method discussed above.
BRIEF DESCRIPTION OF THE DRAWING FIGURES
[0013] The foregoing aspects and many of the attendant advantages of this invention will become more readily appreciated as the same becomes better understood by reference to the following detailed description, when taken in conjunction with the accompanying drawings, wherein:
[0014] FIG. 1 (prior art) is a schematic functional block diagram illustrating a conventional architecture for padding source texture data;
[0015] FIG. 2 is a schematic functional block diagram illustrating a preferred embodiment of an architecture for padding source texture data in accord with the present invention;
[0016] FIG. 3 is an exemplary video object plane (VOP) bounding rectangle of macroblocks enclosing a video object and the shape data for a portion of the video object;
[0017] FIG. 4 is a flow diagram illustrating an overview of logical steps employed for padding a boundary macroblock in an embodiment of the present invention;
[0018] FIG. 5 is a flow diagram illustrating the logical steps for horizontal scanning and processing a macroblock;
[0019] FIG. 6 is a flow diagram illustrating the logical steps for determining a horizontal primitive or flag to send to the graphics coprocessor;
[0020] FIG. 7 is a flow diagram illustrating the logical steps for vertical scanning and processing a macroblock;
[0021] FIG. 8 is a flow diagram illustrating the logical steps for determining a vertical primitive or indication of extended padding to send to the graphics coprocessor; and
[0022] FIG. 9 illustrates an exemplary boundary block padding according to the process of the above preferred embodiment.
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0023] In MPEG-4, each instance of a video object is called a VOP (sometimes referred to as simply a video object) and when applying this standard, a bitstream that contains VOPs of arbitrary shape, a bounding rectangle confining each VOP and a shape for the VOP must be decoded. IDCT and motion compensation are then performed for macroblocks in the bounding rectangle. During encoding, the macroblocks on and outside the shape boundary are padded to decrease the error values in motion prediction. Accordingly, during decoding, the pixels on and outside the shape boundary should be padded for correct motion compensation.
[0024] FIG. 1 is a schematic functional block diagram illustrating a prior art architecture for padding source texture data associated with pixels that lie outside the boundary of a video object. In this prior art architecture, a host processor 10 performs the padding. Host processor 10 is generally disposed on a mother board and obtains VOP shape data from a host memory 12 , which is generally also disposed on the mother board. Host processor 10 uses the shape data to identify segments of pixels that lie outside the boundary of the VOP, as shown by a block 2 . Each pixel lying outside the boundary of the VOP is considered a transparent pixel. As shown by a block 3 , host processor 10 obtains texture data from a video memory 22 , which is typically disposed on a separate video graphics card that drives a display. To transfer the texture data between the video card and the mother board, the texture data typically passes from video memory 22 to host processor 10 via a bus 14 , such as an accelerated graphics port (AGP) bus, a peripheral component interconnect (PC) bus, or other conventional bus. This transfer requires overhead in processing load to achieve synchronization between host processor 10 and a graphics coprocessor 20 that is disposed on the video graphics board, and which typically controls data on the video graphics board.
[0025] Host processor 10 determines the portions of the texture data that correspond to the segments of pixels lying outside the boundary of the VOP and pads the texture data corresponding to the pixel segments that lie outside the boundary of the VOP. The texture data corresponding to these pixel segments that are outside the boundary are padded with texture data associated with adjacent VOP boundary pixels or with an average of texture data associated with surrounding VOP boundary pixels. The entire padded texture data are next transferred back to video memory 22 over bus 14 , again with the necessary overhead required for synchronization. The padded texture data are then available to graphics coprocessor 20 for further processing.
[0026] Reading the entire texture data from video memory and transferring the texture data over the bus to the host processor requires a substantial amount of time and bandwidth. Moreover, re-transferring the entire padded texture data back from the host processor to the video memory over the bus further increases the time and load on the system. Even in the case of a few video objects with moderate size, the overhead required for synchronization between the host processor and the graphics coprocessor to transfer the data across bus 14 will reduce the overall performance significantly.
[0027] An important characteristic of modem graphics coprocessors is their ability to work asynchronously relative to the host processor. An asynchronous and independent architecture is designed to achieve the maximum utilization of both the host processor and the graphics coprocessor, which would not be possible if “lock-step” handshaking were required between the two. When an asynchronous architecture is utilized, the host processor sends commands or data to the graphics coprocessor asynchronously, which enables pipelined processing. These commands or data can be graphics primitives, macroblocks for IDCT, motion compensation, etc. While the graphics coprocessor is rendering a current frame, the host processor starts processing 2-3 future frames.
[0028] Introducing any operation requiring synchronization into the asynchronous interaction between the host processor and graphics coprocessor, such as transferring data that has been modified by the graphics coprocessor back to the host processor, results in breaking down the pipeline and flushing all of the commands that were issued to the graphics coprocessor by the host processor. This flushing of commands is very inefficient because the host processor will remain idle, waiting for the flushing to be completed. After the commands have been flushed, the graphics coprocessor will be idle until the host processor can send a new set of commands to the graphics coprocessor. These delays and the inactivity of the two devices defeat the purpose of an asynchronous architecture in which the host processor and the graphics coprocessor can work independently. The flushing of commands that is necessary for synchronization is employed in the prior art architecture described above. Clearly, it would be desirable to minimize or eliminate any need for synchronization, and ensure that the data flow is unidirectional, from the host processor to the graphics coprocessor.
[0029] FIG. 2 is a schematic functional block diagram illustrating a preferred embodiment of an architecture for padding source texture data in accord with the present invention. Instead of twice transferring the entire texture data between the host and graphics coprocessor so that host processor 10 can be used for padding, graphics coprocessor 20 performs the padding on the video board by executing a small set of padding commands in the form of graphic primitives that are received from host processor 10 . Thus, only the primitives are transferred, only a single time over bus 14 , and in one direction, thereby reducing the time and bandwidth needed for padding, and allowing asynchronous processing by host processor 10 and graphics coprocessor 20 to continue without the interruption incurred to pass data synchronously.
[0030] Specifically, host processor 10 obtains the shape data from host memory 12 as above. Host processor 10 again uses the shape data to identify segments of pixels outside the boundary of the VOP, as again shown by block 2 . However, instead of next reading the texture data from video memory 22 over bus 14 , host processor 10 constructs primitives to be issued to graphics coprocessor 20 , as shown by a block 5 . As shown by a block 6 , host processor 10 then optionally uses a buffer 16 to interact with a video card device driver to transfer the primitives to graphics coprocessor 20 over bus 14 . Graphics coprocessor 20 directly obtains the texture data from video memory 22 , and locally performs the padding on the texture data according to the primitives. Graphics coprocessor 20 then transfers the padded texture data back to video memory 22 , without ever needing to transmit the texture data over bus 14 .
[0031] FIG. 3 illustrates a VOP bounding rectangle 30 of macroblocks enclosing a video object 36 . Each macroblock preferably comprises 16 by 16 pixels, although those skilled in the art will recognize that other size macroblocks may be processed in accord with the present invention. There are three types of macroblocks. One type of macroblock is an interior block 31 that is completely within a boundary 37 of video object 36 . Interior blocks do not need to be padded, because all of the texture data associated with an interior block is within the boundary of the video object. Another type of macroblock is an exterior block 32 that includes no portion of video object 36 , but is needed to complete VOP bounding rectangle 30 around video object 36 . An exterior block is padded with texture values from an adjacent block, since exterior blocks fall entirely outside boundary 37 of video object 36 . The third type of macroblock is a boundary block 34 , which includes some portion of video object 36 and some transparent portion outside boundary 37 of video object 36 .
[0032] A boundary block 38 illustrates a complex portion of boundary 37 for purposes of the discussion that follows. Shape data 40 for the 16 by 16 pixels of boundary block 38 are also shown in FIG. 3 . Within shape data 40 , portions of boundary 37 are shown as dashed lines. The shape data for pixels within video object 36 , or on boundary 37 , such as a pixel 42 have a binary value equal to one. Pixels within video object 36 are sometimes referred to as opaque pixels. Opaque pixels are associated with a specific texture value in the texture data for the macroblock. The shape data for pixels outside boundary 37 of video object 36 , such as pixel 44 , have a binary value equal to zero. As noted above, pixels outside boundary 37 of video object 36 are often referred to as transparent pixels.
[0033] A transparent pixel corresponds to a portion of the texture data that must be padded with a value related to the texture data of one or more nearby pixels. For example, the portion of the texture data associated with a transparent pixel 45 in the upper left corner of shape data 40 is padded with the same value as the texture data associated with an opaque pixel 46 . This padding step can be accomplished with a command issued to the graphics coprocessor to employ a dot primitive at pixel 45 to provide pixel 45 with the texture value of pixel 46 . Transparent pixels 47 through 48 are padded with an average value of the texture data of opaque pixels 46 and 49 . This step can be accomplished by issuing a command to the graphics coprocessor to employ a horizontal line primitive extending between pixels 47 through 48 to provide them with the average value of the texture data of opaque pixels 46 and 49 . Similarly, transparent pixel 44 can be padded by employing a line primitive that applies the average of the texture data for the nearest opaque value above pixel 44 and for the nearest opaque value below pixel 44 . This second line primitive is employed during a vertical processing step, so is referred to as a line-v primitive to distinguish it from the other line primitive referred to as the horizontal line primitive.
[0034] FIG. 4 illustrates an overview of the general logic applied for padding a boundary macroblock. At a decision step 52 , the host processor determines whether another macroblock must be padded. If so, at a step 54 , the host processor performs a horizontal scan from left to right across each row of the macroblock and computes primitives for padding transparent pixels in each row. Once all of the primitives are computed for each row of the macroblock, the host computer sends these horizontal primitives to the graphics coprocessor, at a step 56 , to enable the graphics coprocessor to immediately start padding the macroblock.
[0035] The shape data in some rows are all zeros, having no opaque pixels, and thus, these rows cannot be padded with a horizontal primitive. Therefore, the host processor performs a vertical scan from top to bottom down each column of the macroblock, at a step 58 , and computes vertical primitives for each column. Steps 54 through 58 are skipped if the host processor determined in decision step 52 that no more macroblocks need to be processed. Instead, the host processor just sends the last of the vertical primitives after a latency period has passed, as explained below.
[0036] Vertical primitives cannot be processed by the graphics coprocessor until all of the horizontal primitives have been processed. Rather than expend the time and overhead communicating with the graphics coprocessor to determine whether the graphics coprocessor has completed the horizontal primitives, the host processor preferably waits for a predefined latency period. The latency period is the expected period of time required by a graphics coprocessor to process all of the horizontal primitives for one macroblock. This latency period will vary, depending on the capabilities of the graphics coprocessor being used. Thus, at a decision step 60 , the host processor determines whether the latency period has been surpassed. If the latency period has not yet been surpassed, the host processor simply buffers the vertical primitives, at a step 62 , and returns ready to process another macroblock at decision step 52 . If the latency period has been surpassed, the host processor sends the vertical primitives to the graphics coprocessor, at a step 64 . This technique enables the graphics coprocessor to process sets of horizontal and vertical primitives in a pipelined fashion.
[0037] The host processor then determines, at a decision step 66 , whether the last vertical primitive for all of the macroblocks has been sent to the graphics coprocessor. If not, the host processor returns to decision step 52 , to start processing the next macroblock. Once the last vertical primitive has been sent, the host processor is done, and the graphics coprocessor macroblock padding process terminates. Those skilled in the art will recognize that exterior blocks may be padded with similar horizontal and vertical primitives, based on texture values at the edges of adjacent boundary blocks.
[0038] FIG. 5 is a flow diagram illustrating the logic for horizontal scanning and processing of a macroblock. FIG. 5 provides detail of step 54 in FIG. 4 . At a step 72 of FIG. 5 , the host processor initializes a row number to zero. At a step 74 , the host processor initializes a column number to zero. At a step 76 , the host processor sets a first horizontal value variable X1 and a second horizontal value variable X2 equal to −1. X1 will generally correspond to a left opaque pixel texture value in a horizontal row, and X2 will generally correspond to a right opaque pixel texture value in a horizontal row. At a step 78 , the host processor initializes a count equal to zero.
[0039] At a decision step 80 , the host processor determines whether the column number is less than a total number of columns (e.g., J=16) plus one. Using one more than the total number of columns enables the host processor to detect a single transparent pixel at the end of a row. If the column number is equal to, or greater than, the total number of columns plus one (e.g., col#=17), the current row has been completed. However, if the column number is less than the total number of columns plus one (e.g., col#<17), additional pixels in the current row must still be processed.
[0040] The host processor begins processing the current pixel at the coordinate of the current row# and the current column# by determining, at a decision step 81 , whether the current pixel is transparent (i.e., has a shape data value that is equal to 0) and must be padded. If the current pixel is transparent, the host processor increments the count by one, at a step 82 . The host processor then increments the column number by one, at a step 83 . This loop of steps 81 through 83 counts a number of consecutive transparent pixels within a row of pixels in the macroblock. The host processor again determines, at decision step 80 , whether the end of the row has been exceeded. If the end of the row has not been exceeded, the host processor determines whether the next pixel in the current row is transparent, at step 81 .
[0041] Once the host processor finds an opaque pixel in the current row (e.g., having a shape data value equal to 1), the host processor determines, at a decision step 84 , whether X1 has previously been set to a texture value other than −1. If X1 has not previously been set to a texture value other than −1 the host processor sets X1 equal to the current column number, at a step 86 . This step identifies the current column number in the current row as the coordinate of the texture pixel in the texture data to be used by the graphics coprocessor for obtaining a first texture value for padding the counted transparent pixels. X2 remains set to its initial value of −1. The first texture value will be used as the only texture value for padding in two circumstances. In one circumstance, the first texture value will be used alone to pad one or more transparent pixels that occur at the beginning of a row up to the first opaque pixel. For example, in FIG. 3 , the texture value associated with pixel 46 will be used alone to pad pixel 45 with a dot primitive. Conversely, in the second circumstance, the first texture value will be used alone to pad one or more transparent pixels at the end of a row that follow an opaque pixel, but no other opaque pixels occur to the end of the row. For example, in FIG. 3 , the texture value associated with pixel 43 will be used to pad all the transparent pixels that follow pixel 43 in the row of pixel 43 , using a line primitive.
[0042] However, if the host processor determines, at decision step 84 of FIG. 5 , that X1 was previously set to a column number associated with a first texture value (i.e., that X1 is not equal to −1), the host processor sets X2 equal to the current column number, at a step 88 . This step identifies the current column number in the current row as the coordinate of the texture pixel in the texture data to be used by the graphics coprocessor for obtaining a second texture value for padding the counted transparent pixels. The graphics coprocessor will use this second texture value in conjunction with the first texture value to produce an average texture value. The graphics coprocessor will then use the average texture value to pad transparent pixels that fall between the first opaque pixel and the second opaque pixel. For example, in FIG. 3 the average of the texture values associated with pixels 46 and 49 will be used to pad transparent pixels 47 through 48 , using a horizontal line primitive.
[0043] Once X1 and X2 are defined, the host processor determines the appropriate horizontal primitive to send to the graphics coprocessor, at a step 90 , based on the count of transparent pixels. During step 90 , the host processor may alternatively determine that the entire row contains transparent pixels. Instead of sending a horizontal primitive, the host processor may send a flag to the graphics coprocessor that the row of transparent pixels must be processed during the vertical pass of the macroblock.
[0044] At a decision step 92 , the host processor next determines whether the current column number is less than the total number of columns in the macroblock (e.g., less than J). This step determines whether any more pixels remain to be processed in the current row. If the current column number is less than the total number of columns in the macroblock, then at least one more pixel remains to be processed in the current row. Thus, the host processor increments the current column number by one, at a step 96 , and resets the count to zero at step 78 , to prepare for counting another set of transparent pixels in the same row. If the current column number is equal to, or greater than, the total number of columns in the macroblock, all of the pixels in the current row have been processed.
[0045] In that case, the host processor determines, at a decision step 94 , whether the current row number is less than the total number of rows in the macroblock (e.g., less than K). This step determines whether any more rows of pixels remain to be processed in the macroblock. If the current row number is less than the total number of rows in the macroblock, then at least one more row of pixels remains to be processed in the macroblock. Thus, the host processor increments the current row number by one, at a step 98 , and resets the column number to zero at step 74 to prepare for processing another row of pixels. If the current row number is equal to, or greater than, the total number of rows in the macroblock, all of the pixels in the current macroblock have been processed through the horizontal pass.
[0046] FIG. 6 is a flow diagram illustrating the logical steps for determining a horizontal primitive or flag to send to the graphics coprocessor. FIG. 6 provides detail for step 90 in FIG. 5 . At a decision step 104 of FIG. 6 , the host processor determines whether the count of transparent pixels is equal to the total number of columns in the macroblock plus one (e.g., J+1). If the count of transparent pixels is equal to the total number of columns in the macroblock plus one, the entire row of pixels contains only transparent pixels. In that case, the host processor cannot identify any column number that the graphics coprocessor can use to obtain a texture value for use in padding any of the pixels in the current row. Instead, the host processor must look for a nearby opaque pixel above or below each pixel in the entire current row of transparent pixels. Thus, the host processor simply flags the current row number, at a step 106 , as a row that must be processed during the vertical pass. The flag for the current row number is preferably simply stored in a stack or a one-dimensional array.
[0047] If the current row is not entirely comprised of transparent pixels, the host processor determines, at a decision step 108 , whether the current count of transparent pixels is equal to one. If so, the host processor defines a dot primitive, at a step 110 , to be sent to the graphics coprocessor. The dot primitive has four arguments. The first argument is a U coordinate, corresponding to the column number of the pixel to be padded. However, the current column number is incremented at step 83 of FIG. 5 , after counting a transparent pixel. Thus, the column number of the pixel to be padded is actually set to one less than the current column number. The second argument is a V coordinate, corresponding to the row number of the pixel to be padded. In this case, the current row number is not incremented beyond the row number corresponding to the pixel to be padded. Thus, V is simply set to the current row number.
[0048] The third argument is the column number of the opaque pixel, corresponding to the first texture value that will be used to pad the transparent pixel. The column number of the first opaque pixel identified is stored as X1. Note that the dot primitive need only use the texture value associated with the first opaque pixel identified next to the transparent pixel to be padded, if the single transparent pixel is in the first column or the last column. Thus, X1 may represent the opaque pixel to the left of the transparent pixel to be padded, if the opaque pixel occurred before the transparent pixel (e.g., if the shape data equal 1 0 for the two pixels). In contrast, X1 may represent the opaque pixel to the right of the transparent pixel to be padded, if the opaque pixel occurred after the transparent pixel (e.g., if the shape data equal 0 1 for the two pixels), and the transparent pixel to be padded is the very first pixel in a row.
[0049] Specifically, when a transparent pixel is the very first pixel in a row and is followed immediately by an opaque pixel, the transparent pixel is padded with the texture value associated with the subsequent opaque pixel. There is no other opaque pixel on the opposite side of the transparent pixel, so an average texture value cannot be computed. Similarly, when a transparent pixel is the very last pixel in a row, and is preceded immediately by an opaque pixel, the transparent pixel is padded with the texture value associated with the preceding opaque pixel. Again, there is no other opaque pixel on the opposite side of the transparent pixel, so an average texture value cannot be computed. In both cases, for purposes of the dot primitive, X1 corresponds to the texture value to be used for padding. The fact that the single texture value is to be used is communicated to the graphics coprocessor by sending the fourth argument, X2, with a value of negative one (−1).
[0050] However, in many cases, a single transparent pixel falls between two opaque pixels. In that case, the fourth argument, X2, provides the column number of the second opaque pixel. The coprocessor can pad the single transparent pixel with an average of the texture value associated with the first opaque pixel and the texture value associated with the second opaque pixel. Note that a separate row coordinate is not needed for the transparent pixel, first opaque pixel, and second opaque pixel, because they all fall within the same horizontal row that is identified by the V argument.
[0051] If the count of transparent pixels is not equal to one, the host processor determines, at a decision step 112 , whether the count is equal to zero. This step occurs when an opaque pixel is detected before counting any transparent pixels, such as in the row of pixel 42 in FIG. 3 . A true result of decision step 112 effectively leads to a null operation that is needed to make the logic flow consistent before incrementing the column number. Although no padding operation will be sent to the graphics coprocessor if the count is equal to zero, the host processor must determine whether the value of the first opaque pixel variable, X1, must be replaced with the value of the second opaque pixel variable, X2.
[0052] For example, in the row of pixel 42 in FIG. 3 , there are three opaque pixels. Thus, for the first three increments in the column number, the count of transparent pixels will remain zero. Since no transparent pixels occur between the three opaque pixels, for purposes of identifying a texture value that will be used to pad, the column number corresponding to the “first” opaque pixel, X1, must be shifted to the right until a transparent pixel is found. Specifically, while evaluating the first pixel in the row, pixel 42 , the host processor will set X1 to column number 1 . X2 will retain its initial value of negative one (−1). After incrementing to the second pixel in the row, the host processor will set X2 to column number 2 . However, because the count of transparent pixels remains zero, the column number corresponding to the “first” opaque pixel, X1, for purposes of identifying a texture value to pad a subsequent transparent pixel, must be shifted right to column number 2 . Similarly, when incremented to the third pixel in the row, the count of transparent pixels still remains zero, but the host processor will now set the value of X2 to column number 3 . To keep X1 up to date, because the count of transparent pixels remains zero, the column number corresponding to the “first” opaque pixel, X1, must again be shifted right to column number 3 .
[0053] To accommodate this shifting, the host processor determines, at a decision step 114 , whether X2 already has a value other than negative one (−1). If X2 still has a value of negative one (−1), the value of X1 does not need to be updated. However, if X2 already has a value other than negative one (−1), the value of X1 is updated at a step 116 . The update is accomplished simply by assigning the current value of X2 to X1. The value of X2 is then reset to negative one (−1).
[0054] For any other count of transparent pixels between two and the total number of columns (e.g., I), at a step 118 of FIG. 6 , the host processor defines a horizontal line primitive to be sent to the graphics coprocessor. The horizontal line primitive has five arguments. The first argument is a U coordinate, corresponding to the column number of the first pixel in the line to be padded. This first column number follows the column number of the first opaque pixel, which is stored in X1. Thus, the value of U is set to one more than the column number stored in X1 (i.e., to X1+1).
[0055] As was true of the second argument for the dot primitive, the second argument of the horizontal line primitive is a V coordinate, corresponding to the row number of the pixels to be padded with a line. Again, the current row number is not incremented beyond the row number corresponding to the pixels to be padded. Thus, V is simply set to the current row number.
[0056] The third argument of the horizontal line primitive is a length of the line primitive. The length of the line is simply the count of consecutive transparent pixels that must be padded. The fourth argument of the horizontal line primitive is the column number of the opaque pixel, corresponding to the first texture value that will be used to pad the line of transparent pixels. This pixel, of course, is identified by the column number stored in X1. Similarly, the fifth argument of the horizontal line primitive is the column number of the opaque pixel, corresponding to the second texture value that will be used to pad the line segment of transparent pixels. This pixel is identified by the column number stored in X2. For the horizontal line primitive, the graphics coprocessor uses an average of the first texture value and the second texture value to pad the line of pixels.
[0057] Once the arguments of a horizontal line primitive are set, the host processor resets the value of X1 to the column number stored in X2, at step 116 . This step ensures that X1 is shifted to the right and ready for any further transparent pixels that may follow. Correspondingly, the value of X2 is reset to negative one (−1).
[0058] FIG. 7 is a flow diagram illustrating the logical steps for vertical scanning and processing of a macroblock. This Figure provides detail for step 58 in FIG. 4 , similar to the detail for horizontal scanning, shown in FIG. 5 . At a step 124 of FIG. 7 , the host processor initializes a row number to zero. At a step 126 , the host processor sets a first vertical variable Y1 and a second vertical variable Y2 equal to −1. Y1 will generally correspond to a top opaque pixel texture value in a vertical column, and Y2 will generally correspond to a bottom opaque pixel texture value in a vertical column. At a step 128 , the host processor initializes a count equal to zero.
[0059] At decision step 130 , the host processor determines whether the row number is less than a total number of rows (e.g., K=16) plus one. Using one more than the total number of rows enables the host processor to detect a single transparent pixel at the bottom of a column. If the row number is equal to, or greater than, the total number of rows plus one (e.g., row#=17), the current column has been completed. However, if the row number is less than the total number of row plus one (e.g., row#<17), additional pixels in the current column must still be processed.
[0060] The host processor begins processing the current row of pixels by first determining, at a decision step 131 , whether the current row was flagged during the horizontal scan, as containing all transparent pixels (e.g., shape data all equaling zeros). If the current row was flagged, the host processor increments the count by one, at a step 132 . The host processor then increments the row number by one, at a step 133 . This loop of steps 131 through 133 counts a number of consecutive rows containing all transparent pixels in the macroblock. The host processor again determines, at decision step 130 , whether all of the rows have been processed. If all of the rows have not been processed, the host processor determines whether the next row was flagged, at step 131 .
[0061] Once the host processor finds a row that has at least one opaque pixel, the host processor determines, at a decision step 134 , whether Y1 has previously been set to a texture value other than −1. If Y1 has not previously been set to a texture value other than −1, the host processor sets Y1 equal to the current row number, at a step 136 . This identifies the current row number as the row coordinate of the texture pixels in the texture data to be used by the graphics coprocessor for obtaining a first set of texture value for padding the row of transparent pixels. Y2 remains set to its initial value of −1. Similar to horizontal scanning, the first set of texture values will be used as the only texture values for padding in two circumstances. In one circumstance, the first set of textures value will be used alone to pad one or more rows of transparent pixels that occur at the top of a macroblock down to the first row flagged to includes at least one opaque pixel. Conversely, in the second circumstance, the first set of texture values will be used alone to pad one or more rows at the bottom of a macroblock that follow a row flagged to include at least one opaque pixel, but no other rows flagged to include opaque pixels occur to the end of the macroblock. For example, in FIG. 3 , the set of texture values associated with the pixels of the second-to-last row will be used to pad all the transparent pixels in the last row of the macroblock with a line-v primitive. A line-v primitive provides a line through each column of a row in which only transparent pixels are found. Each pixel of a transparent row may be padded with a unique texture value, depending on the value of each pixel above and below the row of transparent pixels. Thus, the line-v primitive may pad the row on a pixel-by-pixel basis. However, a dot primitive is not available for vertical processing, because vertical processing will never result in padding a single pixel by itself, since a whole row of transparent pixels is a prerequisite to vertical processing. Thus, a line-v primitive is used, even for a single row that is only one pixel high.
[0062] However, if the host processor determines, at decision step 134 of FIG. 7 , that Y1 was previously set to a row number associated with a first vertical texture value (i.e., Y1 is not equal to −1), the host processor sets Y2 equal to the current row number, at a step 138 . This step identifies the current row number as the row coordinate of the texture pixels in the texture data to be used by the graphics coprocessor for obtaining a second set of texture values for padding the row of transparent pixels. The graphics coprocessor will use this second set of texture values in conjunction with the first set of texture values to produce an average texture value in each column of the row to be vertically padded. The graphics coprocessor will use each average texture value to pad transparent pixel that falls between the rows identified by Y1 and Y2. For example, in FIG. 3 the average of the texture values associated with the twelfth (12 th ) row and the fourteenth (14 th ) row will be used to pad the transparent pixels of the thirteenth (13 th ) row with a line-v primitive.
[0063] Once Y1 and Y2 are defined, the host processor determines the appropriate vertical primitive to send to the graphics coprocessor, at a step 140 , based on the count of flagged rows. During step 140 , the host processor may alternatively determine that all rows of the entire macroblock contains transparent pixels. Instead of sending a vertical primitive, the host processor may send an indication to the graphics coprocessor to use extended padding for the entire macroblock.
[0064] At a decision step 142 , the host processor then determines whether the current row number is less than the total number of rows in the macroblock (e.g., less than K). This step determines whether any more rows remain to be processed in the current macroblock. If the current row number is less than the total number of rows in the macroblock, then at least one more row remains to be processed in the current macroblock. If so, the host processor increments the current row number by one, at a step 144 , and resets the count to zero at step 128 , to prepare for counting another set of flagged transparent rows in the same macroblock. If the current row number is equal to, or greater than, the total number of rows in the macroblock, all of the rows in the current row have been processed through the vertical pass.
[0065] FIG. 8 is a flow diagram illustrating logical steps for determining a vertical primitive or indication of extended padding to send to the graphics coprocessor. FIG. 8 provides details for step 140 in FIG. 7 . At a decision step 152 of FIG. 8 , the host processor determines whether the count of flagged rows is equal to the total number of rows in the macroblock plus one (e.g., K+1). If the count of flagged rows is equal to the total number of rows in the macroblock plus one, the entire macroblock contains only transparent pixels. In that case, the host processor cannot provide any primitives to the graphics coprocessor to obtain any texture values to use for padding any of the pixels in the macroblock. Instead, the host processor can only instruct the graphics coprocessor to use extended padding for the macroblock, at a step 154 .
[0066] If the macroblock is not entirely comprised of transparent pixels, the host processor determines, at a decision step 156 , whether the current count of flagged transparent rows is equal to one. If the current count of flagged transparent rows is equal to one, the host processor defines a line-v primitive to be sent to the graphics coprocessor, at a step 158 . The line-v primitive has three arguments. The first argument is a V coordinate, corresponding to the row number of the row of transparent pixels to be padded. However, the current row number is incremented at step 133 of FIG. 7 , after counting a flagged row. Thus, the row number of the row to be padded is actually set to one less than the current row number.
[0067] The second argument of the line-v primitive is the row number of the nearest row with at least one opaque pixel, corresponding to the first set of texture values that will be used to pad the flagged row of transparent pixels. The row number of the nearest row identified is stored as Y1. Note that the line-v primitive need only use the set of texture values associated with the nearest row of at least one opaque pixel that is identified above the row of transparent pixels to be padded, if the single row of transparent pixels is in the first row or the last row. Thus, Y1 may represent the nearest row of at least one opaque pixel above the row of transparent pixels to be padded, if the nearest row with at least one opaque pixel is disposed before the row of transparent pixels (e.g., 1 0 vertically). Or, Y1 may represent the nearest row with at least one opaque pixel below the row of transparent pixels to be padded, if the nearest row with at least one opaque pixel is disposed below the row of transparent pixel (e.g., pixels with shape data equal to 0 1 vertically) and the row of transparent pixels to be padded is the very first row in a macroblock.
[0068] When a flagged row of transparent pixels is the very first row of the macroblock and is followed immediately by a row with at least one opaque pixel, the flagged row of transparent pixels is padded with the texture values associated with the subsequent row of at least one opaque pixel. There is no other row with at least one opaque pixel above the flagged row of transparent pixels, so a set of average texture values cannot be computed. Similarly, when a flagged row of transparent pixel is the very last row in a macroblock, and the flagged row is preceded immediately by a row with at least one opaque pixel, the row of transparent pixels is padded with the texture values associated with the preceding row having at least one opaque pixel. Again, there is no other row with at least one opaque pixel on the opposite side of the flagged row of transparent pixels, so a set of average texture values need not be computed. In both cases, for purposes of the line-v primitive, Y1 identifies the row of texture values to be used for padding. The fact that the single set of texture values is to be used, is communicated to the graphics coprocessor by sending the third argument, Y2, with a value of negative one (−1).
[0069] However, in many cases, a single row of flagged transparent pixels falls between two rows, each with at least one opaque pixel. In that case, the third argument, Y2, provides the row number of the second row with at least one opaque pixel. The coprocessor can pad the single row of transparent pixels with the set of average texture values associated with the nearest row with at least one opaque pixel and the set of texture values associated with the opposite row with at least one opaque pixel. A separate column coordinate is not needed for the flagged row of transparent pixels, for the first row with at least one opaque pixel, and for the second row with at least one opaque pixel, because these rows include all the columns of the macroblock (i.e., K).
[0070] If the count of flagged rows is not equal to one, the host processor determines, at a decision step 160 , whether the vertical count is equal to zero. This condition occurs when a row with at least one opaque pixel is detected before counting any flagged rows of transparent pixels, such as the first six rows in FIG. 3 . As in the horizontal scan, a positive determination at decision step 160 effectively leads to a null operation that is needed to make the logic flow consistent before incrementing the row number. Although no padding operation primitive will be sent to the graphics coprocessor, if the vertical count is equal to zero, the host processor must determine whether the value of variable Y1, must be shifted down a row by being replaced with the value of variable Y2.
[0071] For example, in the expanded macroblock in FIG. 3 , the first six rows include at least one opaque pixel. Thus, for the first six increments in the row number, the count of flagged rows will remain zero. Since no flagged rows occur between any of the first six rows, the row number corresponding to the “first” row with at least one opaque pixel, Y1, for purposes of identifying a set of texture values to pad with, must be shifted down until a flagged row of transparent pixels is found. Specifically, while evaluating the first row of the macroblock, the host processor will set Y1 to row number 1 . Y2 will retain its initial value of negative one (−1). After incrementing to the second row in the macroblock, the host processor will set Y2 to row number 2 . Because the count of flagged rows remains zero, the row number corresponding to the “first” row with at least one opaque pixel, Y1, for purposes of identifying a set of texture values to pad a subsequent flagged row of transparent pixels, must be shifted down to row number 2 . Similarly, when incremented to the third row, the count of flagged rows still remains zero, but the host processor will now set the value of Y2 to row number 3 . To keep Y1 up to date, because the count of flagged rows remains zero, the row number corresponding to the “first” row with at least one opaque pixel, Y1, must again be shifted down to row number 3 . This shifting continues until Y1 is set to row six, after which a flagged row of transparent pixels is detected.
[0072] To accommodate this shifting, the host processor determines, at a decision step 162 , whether Y2 already has a value other than negative one (−1). If Y2 still has a value of negative one (−1), the value of Y1 does not need to be updated, such as for the first row. However, if Y2 already has a value other than negative one (−1), the value of Y1 is updated at a step 164 . The update is accomplished simply by assigning the current value of Y2 to Y1. The value of Y2 is then reset to negative one (−1).
[0073] For any other count of flagged rows between two and the total number of rows (i.e., K), the host processor defines a rectangle primitive, at a step 166 of FIG. 8 , to be sent to the graphics coprocessor. The rectangle primitive has four arguments. The first argument is a V coordinate, corresponding to the row number of the first flagged row in a rectangular box of rows to be padded. This first row number follows the row number of the “first” row with at least one opaque pixel, which is stored in Y1. Thus, the value of V is set to one more than the row number stored in Y1 (i.e., to Y1+1).
[0074] The second argument of the rectangle primitive is the height of the rectangle. The height of the rectangle is simply the count of consecutive flagged rows. The third argument of the rectangle primitive is the row number of the “first” row with at least one opaque pixel, corresponding to the first set of texture values that will be used to pad the rectangle of transparent pixels. This, of course, corresponds to the row number stored in Y1. Similarly, the fourth argument of the rectangle primitive is the row number of the “second” row with at least one opaque pixel, corresponding to the second set of texture values that will be used to pad the rectangle of transparent pixels. This value corresponds to the column number stored in Y2. To pad the rectangle of pixels with the rectangle primitive, the graphics coprocessor uses a column-by-column average of each pixel associated with the first set of texture values and each corresponding pixel in the same column associated with the second set of texture values. In general, the texture value associated with a column pixel of row Y1 is averaged with the texture value associated with the pixel in the same column or row Y2. Effectively, this creates a series of vertical padded lines, each pixel in a vertical padded line having an average of the texture value of the pixel at the top end of the line and of the pixel at the bottom end of the line.
[0075] Once the arguments of a rectangle primitive are set, the host processor resets the value of Y1 to the row number stored in Y2, at step 164 . This step ensures that Y1 is shifted down and ready for any further flagged rows of transparent pixels that may follow. Correspondingly, the value of Y2 is reset to negative one (−1).
[0076] FIG. 9 shows an example of boundary block padding according to the process of the above preferred embodiment. A simple 4×4 block is shown for simplicity. As described above, each pixel with a shape value of zero (0) represents a transparent pixel, and each pixel with a shape value of one (1) represents an opaque pixel. An original boundary block 170 illustrates original shape data. An original texture block 180 illustrates texture data corresponding to the original shape data of original boundary block 170 . Note that pixels of original texture block 180 that have a dash are not necessarily empty. Instead, a dash simply means that the texture value of those pixels is irrelevant to the corresponding shape data.
[0077] An intermediate shape block 172 illustrates logical intermediate shape data that results from the horizontal padding process. Note that the intermediate shape data generated by horizontal padding always comprise rows with either all zeros or all ones. Similar to the intermediate shape data, an intermediate texture block 182 illustrates intermediate texture data that results from the horizontal padding process. A dot primitive is used to effectively copy texture value A and texture value B in the first row to their adjacent transparent pixels. A horizontal line primitive is used to compute an average texture value for the transparent pixel between opaque pixels corresponding to texture value D and texture value E in the second row. The third row of original shape block 170 contains only transparent pixels. Thus, the third row of corresponding intermediate texture block 182 is still empty after horizontal padding. This third row is flagged for vertical processing.
[0078] A final shape block 174 illustrates logical final shape data that results after the vertical padding process. After vertical padding, each pixel in the block has an original texture value or a padded texture value, so all pixels in final shape block 174 have a shape data value equal to one. Similar to the final shape block, a final texture block 184 illustrates final texture data that results after the vertical padding process is complete. During vertical padding, each pixel of the flagged row is filled with an average texture values from each corresponding pixel in the second and fourth rows. Note that the third pixel of the third row has an average texture value of two pixels that were previously padded during the horizontal padding process.
[0079] Although the present invention has been described in connection with the preferred form of practicing it and modifications thereto, those of ordinary skill in the art will understand that many other modifications can be made to the present invention within the scope of the claims that follow. Accordingly, it is not intended that the scope of the invention in any way be limited by the above description, but instead be determined entirely by reference to the claims that follow. | A boundary macroblock of a video object is padded without significant synchronization overhead between a host processor and an existing coprocessor. The host processor determines horizontal and vertical graphics primitives as a function of shape data stored in a host memory. The shape data determine whether a dot, a line, or a rectangle primitive should be used to pad transparent pixels in the macroblock. The host processor communicates the primitives to a coprocessor, which renders the primitives in an interleaved pipeline fashion to pad transparent pixels of the macroblock based on texture data stored in video memory. The flow of primitives is in one direction from the host processor to the graphics coprocessor, and the texture data is not transferred back and forth between the host processor and coprocessor. This technique is especially useful for enabling acceleration of MPEG-4 video decoding utilizing existing coprocessors capable of accelerating MPEG-1/2 video decoding. | 7 |
CROSS-REFERENCE TO RELATED APPLICATION
[0001] The present application is a continuation of U.S. patent application Ser. No. 14/828,908, filed on Aug. 18, 2015, which is a continuation of U.S. patent application Ser. No. 13/255,067, filed on Sep. 6, 2011, which is a national phase of PCT International Application No. PCT/EP2010/001242, filed on Mar. 1, 2010, which claims priority to German Patent Application No. 10 2009 011 124.7, filed on Mar. 3, 2009, each of which is expressly incorporated herein in its entirety by reference thereto.
FIELD OF THE INVENTION
[0002] The present invention relates to a system for the contactless sealing of a rotatably mounted shaft with respect to a housing, and a gear unit.
BACKGROUND INFORMATION
[0003] In sealing systems having shaft sealing rings, it is well-known that friction losses increase as the rotational speed increases.
[0004] German Published Patent Application No. 602 16 474 describes a contactless sealing in which a centrifugal disk, having radial bores as slinger ports (FIG. 1 there, reference 44), is provided on a shaft. The radial bores permit lubricating oil, which was accumulated in a radially inner centrifuging chamber, to flow out, the bores then centrifuging the oil off at their other end area into a collection chamber. The centrifugal disk has an axial gap with respect to a non-rotating part, the gap joining the centrifuging chamber to the collection chamber.
[0005] A labyrinth seal is described in German Published Patent Application No. 479 388.
[0006] U.S. Pat. No. 2,598,381 describes connecting an interior space of a gear unit, partially filled with lubricating oil, via an air channel (FIG. 1 there, reference numeral 9) to the outside air, for example, for compressed-air compensation. In that case, oil is conveyed radially and axially inward by centrifugal force, by providing a suitable bevel. Independently of this air channel, a contactless sealing is achieved by a centrifugal edge which, during rotational movement, centrifuges the oil off into a collection chamber (FIG. 1 there, reference numeral 13) that is connected by a downward running bore to the oil-pan space.
[0007] German Published Patent Application No. 10 2007 014 657 describes a shaft sealing device in which oil, likewise centrifuged off, is recirculated.
[0008] German Published Patent Application No. 698 18 914 describes a shaft sealing system in which a shaft sealing ring is provided.
[0009] A sealing ring for a water-pump bearing is described in German Published Patent Application No. 601 30 871.
[0010] German Published Patent Application No. 42 20 754 also describes a sealing system that functions in non-contact fashion during rotational movement of the shaft of a gear unit, in which oil, likewise centrifuged off, is recirculated.
[0011] German Published Patent Application No. 39 30 280 likewise describes such a sealing system functioning in non-contact fashion during rotational movement of the shaft.
[0012] A sealing system acting in contacting fashion is described in German Published Patent Application No. 35 44 783.
[0013] A sealing system that functions in non-contact fashion during rotational movement of the shaft, in which oil, likewise centrifuged off, is recycled is also described in German Published Patent Application No. 33 30 473.
[0014] German Published Patent Application No. 11 2004 000 627 also describes a sealing system that functions in non-contact fashion during rotational movement of the shaft, and in which oil spun off by a plurality of shaft grooves is likewise recycled.
[0015] A sealing system that functions in non-contact fashion during rotational movement of the shaft and in which oil spun off by pointed edges is likewise recirculated is described in German Published Patent Application No. 470 121, as well.
[0016] U.S. Pat. No. 5,538,258 describes a contactless sealing in which a centrifugal disk, having radial bores as slinger ports (FIG. 1 there, reference numeral 44), is provided on a shaft. The radial bores permit lubricating oil, which was accumulated in a radially inner centrifugal chamber, to flow out, the bores then ejecting the oil at their other end area into a collection chamber. The centrifugal disk has an axial gap with respect to a non-rotating part, the gap joining the centrifugal chamber to the collection chamber.
SUMMARY
[0017] Example embodiments of the present invention reduce maintenance costs and losses in the case of a sealing system.
[0018] Among features of example embodiments of the present invention with regard to the system are that it is provided for the contactless sealing of a rotatably mounted shaft with respect to a housing, oil being provided in the interior of the housing,
[0019] in particular, the rotating shaft protruding from the interior into the outer area,
[0020] wherein
[0021] a centrifugal disk, joined in rotatably fixed manner to the shaft, has at least partially radially extending bores that connect oil from a centrifugal chamber to a collection chamber surrounding the centrifugal disk.
[0022] In particular, a centrifugal disk, joined in rotatably fixed manner to the shaft, thus has bores extending at least partially in the radial direction, so that lubricating oil is able to be conveyed from a centrifugal chamber to a collection chamber surrounding the centrifugal disk,
[0023] the bores opening through with their radially inner end area into the centrifugal chamber, and opening through with their radially outer end area into the collection chamber,
[0024] between the centrifugal disk and a flange part of the housing, a gap region being provided which
connects the centrifugal chamber to the collection chamber and into which a bore leads with its first end area, the bore opening through with its other end area into a further collection-chamber area, so that lubricating oil, centrifuged off into the further collection-chamber area by a centrifugal edge joined in rotatably fixed fashion to the shaft, is able to be collected and fed through the bore to the gap region,
[0027] a gap region connecting the further collection-chamber area to the centrifugal chamber.
[0028] The bore between the gap region and the further collection-chamber area preferably extends axially.
[0029] Of advantage is that the oil is able to be conveyed out of a centrifugal chamber—which at least partially surrounds the centrifugal disk and is bounded by housing parts and the shaft or centrifugal sleeve provided on the shaft—through the centrifugal disk, namely, through bores in the centrifugal disk. Thus, effective emptying of the centrifugal chamber is attainable. In so doing, the oil is emptied out not into the oil-pan area or the interior space, e.g., into the interior of the gear unit, but rather into a collection chamber, therefore, a spatial area which is bounded by the flange parts and the rotating part, thus, the shaft or a centrifugal sleeve provided on the shaft.
[0030] In this manner, it is possible to avoid wear to the seal, particularly in comparison to shaft sealing rings which are subject to wear. Furthermore, maintenance costs are improved and reliability is likewise improved.
[0031] It is further advantageous that oil, which is caught in a collection chamber situated axially further outside, is able to be fed into the gap region between the co-rotatable centrifugal disk and the stationary flange part. Since this gap region extends radially, a pressure gradient exists between the centrifugal chamber and the collection chamber that has a conveying effect which acts as return. Thus, even if oil on the centrifugal disk were to arrive further axially to the outside, a return from a downstream collection chamber would be made possible through the bore between the gap region and the collection-chamber area.
[0032] An advantage is that an active pumping action is attainable, accompanied by a contactless sealing.
[0033] In example embodiments, the centrifugal disk is secured on a centrifugal sleeve which is provided on the shaft. This is advantageous because assembly is easy, and in addition, diameter variations, such as an axial area with increasing or decreasing diameter, may be produced in an inexpensive and uncomplicated manner. The reason is the centrifugal sleeve does not pass any substantial torque through, the centrifugal disk being secured on the centrifugal sleeve, however. Thus, centrifugal grooves are able to be provided easily and inexpensively in the centrifugal sleeve, as well.
[0034] In example embodiments, the centrifugal chamber is bounded at least partially by a channel running round on the centrifugal disk, the channel being formed as the local maximum of the radial distance of the surface of the centrifugal disk; thus, in particular, the radial distance of adjacent surface areas of the centrifugal disk increases with decreasing axial distance toward the channel. This offers the advantage that oil propelled by the centrifugal force is driven into this channel, and from there, is then conveyed away with the aid of the bores.
[0035] In example embodiments, at least in one axial partial area, the outside diameter of the centrifugal sleeve increases toward the centrifugal disk, particularly with the aid of a chamfer provided on the centrifugal sleeve, especially so that oil is conveyed in the direction of the centrifugal disk, especially in the direction of the channel of the centrifugal disk. The advantage in this context is that a conveying action is able to take place in the direction of the channel, and therefore the oil is able to be discharged, especially in an easy manner, via the associated bore in the centrifugal disk, into the collection chamber.
[0036] In example embodiments, provided between the centrifugal disk and a flange part of the housing is a gap region, especially a radially extended gap region, into which a bore leads that is connected to a collection groove, thus a collection-chamber area, provided in the flange part,
[0037] in particular, the bore being situated at smaller radial distance than the radial distance of the end area of the gap region, which opens through into the collection chamber, in particular, the collection groove being provided axially further outside than the centrifugal disk. The advantage in this case is that a pumping action is attainable in the gap region, since the gap region is bounded at a first lateral surface by the centrifugal disk, and at the lateral surface opposite this first lateral surface, by the housing part that does not co-rotate, thus, especially the outer flange part. Therefore, an underpressure is obtained for emptying the bore leading in, in the direction of the collection chamber connected at greater radial distance.
[0038] In example embodiments, a gap is provided between the centrifugal sleeve and a further flange part joined to the flange part, the gap being implemented as a radial gap in a first partial area, and as an axial gap in a further partial area. This is advantageous in that oil must traverse the radial gap coming from outside to the inside, since the end area of the radial gap with greater radial distance is disposed toward the interior, and the end area of the radial gap with smaller radial distance must first be reached against the centrifugal force.
[0039] In example embodiments, the gap opens through into a collection groove that is provided in the further flange part and is connected to the collection chamber via a further gap which is situated between the further flange part and the centrifugal sleeve. The advantage here is that the gap represents a further barrier for penetrating oil. In particular, it may be implemented as a capillary gap, and therefore also represents a barrier very difficult to overcome.
[0040] In example embodiments, the collection chamber is connected in its lower area via a bore to the interior of the housing, especially to the oil-pan area. This is advantageous because oil which has penetrated or been caught in the collection chamber is able to be evacuated to the oil pan, especially driven by the force of gravity.
[0041] In example embodiments, the flange parts are screw-connected and a seal, especially an O-ring seal, is disposed between them. The advantage here is that the housing may be made strong and leak-proof. In particular, the joint of the two flange parts is sealed up, so that the O-ring seal lies further inside in the joining surface and the screw connection lies further outside. Therefore, no oil penetrates from the interior space via the joining surface, thus the contact surface, to the thread area of the screw, and from there into the outer area. FIG. 1 shows a screw passing through from the outer area through the outer and the inner flange part. In a further improved exemplary embodiment, the screw does indeed penetrate through the outer flange part, but is screwed into a non-through bore in the inner flange part.
[0042] In example embodiments, a first baffle area having a first drainage channel is disposed on the further flange part, in particular, a second baffle area having a second drainage channel being disposed on the further flange part, the baffle area and drainage channel in particular being axially symmetric. This offers the advantage that each baffle area is able to be provided combined with a corresponding drainage channel, so that the liquid portions which have struck are able to be carried away quickly and easily. Therefore, the main quantity of the oil sprayed around during operation above the oil level is able to be collected and recirculated, particularly at the periphery of the overall sealing system.
[0043] In example embodiments, in each case a centrifugal groove is disposed on the centrifugal sleeve, radially opposite the collection groove(s). This is advantageous, because the centrifugal groove may be produced easily and inexpensively.
[0044] In example embodiments, the gap regions are each implemented as capillary gap regions. The advantage here is that the resistance to flow for oil is very high, and this is therefore hindered in respect to the at least rapid flow through the gap.
[0045] In example embodiments, a dust protector, which is in contact with the flange part, is disposed on the shaft. The advantage in this case is that the functioning method of the sealing system is not disturbed, for in the event great quantities of dust penetrate, a bore could be stopped up, for example. The spatial area protected by the dust protector is connectable directly or with the aid of a gap to a collection groove or to some other collection area such as the collection chamber, for instance.
[0046] The dust protector does not contribute to the actual sealing action of the sealing system, for it protects only against penetrating dust and contacts the flange part, belonging to the housing, at its outer surface.
[0047] In example embodiments, the oil level lies below—thus below in the gravitational direction—the system when the gear unit is at rest. The advantage in this context is that in the state of rest, there is no possibility that oil will pass through the sealing system, and then penetrate into the outer area.
LIST OF REFERENCE NUMERALS
[0000]
1 Shaft
2 Axial gap, capillary cap region
3 Entry labyrinth, including radially extended gap section, capillary cap region
4 Drainage channel
5 Calming space
6 Baffle surface
7 Collection groove
8 Drainage channel
9 Baffle surface
10 Collection chamber
11 Centrifugal bore
12 Gap, particularly radial gap, capillary cap region
13 Collection groove, further collection-chamber area
14 Third centrifugal groove
15 Second centrifugal groove
16 First centrifugal groove
17 Dust protector
18 Inner return bore
19 Flange, outer sealing flange
20 Retaining screw
21 Outer return bore
22 Centrifugal disk
23 Inner sealing flange, further flange apart
24 Drain bore
25 Centrifugal sleeve
26 O-ring seal
27 Centrifugal chamber
28 Chamfer
29 Widening
[0077] Example embodiments of the present invention are explained in greater detail with reference to the Figures.
BRIEF DESCRIPTION OF THE DRAWINGS
[0078] FIG. 1 illustrates a system according to an example embodiment of the present invention.
[0079] FIG. 2 is an enlarged cross-sectional view of the system illustrated in FIG. 1 .
DETAILED DESCRIPTION
[0080] A system according to an example embodiment of the present invention is shown schematically in FIG. 1 . An enlarged section is shown in FIG. 2 .
[0081] According to example embodiments of the present invention, a contactless sealing is attained between a rotating shaft 1 and a housing.
[0082] In this context, disposed on shaft 1 is a centrifugal sleeve 25 on which, in addition, a centrifugal disk 22 is situated, in particular, joined with material locking or as a press-fitted connection.
[0083] An outer sealing flange 19 and an inner sealing flange 23 are provided on the housing, the centrifugal disk being set apart from outer sealing flange 19 by a gap 12 , and centrifugal sleeve 25 being set apart from inner sealing flange 23 by a gap, including entry labyrinth 3 and axial gap 2 .
[0084] The sealing system is set up in multiple stages, and in this manner, the oil passing through each obstacle is in each instance met with a further obstacle.
[0085] The entire sealing system is disposed above the oil level which sets in when shaft 1 is at rest. During operation of shaft 1 , oil foam or spraying oil may be produced, for example, by gear wheels connected directly or indirectly with the shaft. Preferably, this oil level is below return bore 21 .
[0086] The oil striking against baffle surface 9 is drained off via an annularly formed drainage channel 8 , and downward toward the oil pan.
[0087] Provided axially somewhat further inside, but radially deeper, is baffle surface 6 , which is bounded radially to the inside by an annular calming space 5 that has a drainage channel 4 situated radially inside. Entry labyrinth 3 , which is provided between centrifugal sleeve 25 and inner sealing flange 23 , begins directed inwards in the axial direction, then goes over into a radially running section and ends as axial gap 2 situated radially further inside, which then runs directed outwards in the axial direction, and at its end area, widens in the direction of collection groove 7 . The flaring, thus the widening denoted by reference numeral 29 , is realized by a suitable chamfer, so that the capillary effect is interrupted in this area. A centrifugal groove 16 is disposed on centrifugal sleeve 25 , opposite collection groove 7 , and is provided to spin oil off in the direction of collection groove 7 . At the lower area of collection groove 7 , a drain bore is provided that is aligned in the axial direction and leads into a collection chamber 10 , which in turn returns oil via a bore, namely, outer return bore 21 in inner sealing flange 23 , back into the oil pan.
[0088] Between centrifugal sleeve 25 and inner sealing flange 23 , a gap is provided that connects collection groove 7 to collection chamber 10 .
[0089] A centrifugal groove 15 is again disposed in the axial region of collection chamber 10 , so that oil which penetrates via the indicated gap is centrifuged off.
[0090] In addition, provided axially following is centrifugal disk 22 that likewise centrifuges oil off into collection chamber 10 .
[0091] Axially following centrifugal disk 22 , a further centrifugal groove 14 is again provided, opposite which a collection groove 13 is located on flange part 19 . Thus, oil is spun off from the edges of centrifugal groove 14 into collection groove 13 .
[0092] Centrifugal sleeve 25 is implemented with a chamfer 28 such that its outside diameter increases in an axial area which is located between centrifugal groove 14 and centrifugal disk 22 , and specifically, increases with decreasing distance to centrifugal disk 22 , so that oil possibly appearing is conveyed in this direction, thus, toward centrifugal disk 22 . Therefore, chamfer 28 contributes in connection with the return flow. The oil is then conveyed into centrifugal chamber 27 , which is emptied into collection chamber 10 with the aid of centrifugal bores 11 that are introduced into centrifugal disk 22 in the radial direction. A plurality of such centrifugal bores 11 , especially between four and twenty, are provided at the periphery of the centrifugal disk.
[0093] Collection groove 13 , situated axially further to the outside, has at its lower region, especially including the deepest point, a bore 18 directed axially toward the gap region, thus, gap 12 , which is provided between centrifugal disk 22 and outer flange 19 . Collection groove 13 is assigned a centrifugal groove 14 , which is provided on centrifugal sleeve 25 .
[0094] This gap region of gap 12 is open toward collection chamber 10 . Since bore 18 discharges into gap region 12 at a radial distance that is smaller than the radial distance of radially outside end area of gap region 12 , where gap region 12 discharges into collection chamber 10 , a conveying effect is provided. The reason is that due to the rotational movement, an underpressure is generated, which causes bore 18 , and therefore collection groove 13 , to be pumped out.
[0095] Thus, not only is the well-known centrifuging provided for the discharge, but also the pumping effect of a gap region 12 .
[0096] Collection grooves 7 and 13 are therefore emptied into collection chamber 10 , and not directly into the interior and/or the oil-pan area. To that end, bore 24 connects collection groove 7 to collection chamber 10 .
[0097] Inner sealing flange 23 and outer sealing flange 19 are joined to each other, sealed off by an O-ring seal 26 , a plurality of successive retaining screws 20 in the circumferential direction joining the two sealing flanges. Thus, a one-piece construction of the two sealing flanges 19 and 23 is also possible. A dust protector 17 is just provided externally.
[0098] A further collection-chamber area is formed by collection groove 13 , that is situated separate from collection chamber 10 and is provided further axially outwards. | A system for the contactless sealing of a rotatably mounted shaft with respect to a housing, and a gear unit, oil being provided in the interior of the housing, in particular, the rotating shaft protruding from the interior into the outer area; a centrifugal disk, joined in rotatably fixed manner to the shaft, having at least partially radially extending bores that connect oil from a centrifugal chamber to a collection chamber surrounding the centrifugal disk. | 5 |
TECHNICAL FIELD
[0001] The invention relates to a nickel-base alloy for the electro-welding of nickel alloys and steels, in particular non-alloyed or low alloy steels and stainless steels.
[0002] The invention also relates to wires and electrodes for the electro-welding of parts made of nickel alloy and/or steel, in particular in the field of the construction, assembly and repair of components of nuclear reactors.
BACKGROUND TO THE INVENTION
[0003] It is known to use chromium-containing nickel-base alloys for the production of certain components or units of nuclear reactors.
[0004] In particular, a nickel alloy containing approximately 15% of chromium, known as alloy 600, has been used for the production of units or components of pressurised water-cooled nuclear reactors.
[0005] To improve the corrosion resistance of the units or components of pressurised water-cooled nuclear reactors, there is a tendency to replace the alloy 600 containing approximately 15% of chromium by an alloy 690 containing approximately 30% of chromium and approximately 10% of iron.
[0006] Electro-welding wires or electrodes of nickel alloy of which the composition is adapted to the welding of the alloy 600 or the alloy 690 are used to produce welds on these nickel alloy units or components.
[0007] Table 1 below shows typical compositions of commercially available wires for the welding of the alloy 690 and for the welding of the alloy 600 (alloy 52 or alloy 82).
[0008] The first four columns of Table 1 show the compositions of alloy 52 wires known by the trade name Inconel 52 from the American company, Special Metals, produced on the basis of four separate castings and used to weld the alloy 690.
[0009] The last column of the table gives a typical analysis of an alloy 82 wire with the trade name Phyweld 82 made by Sprint Metal, for welding the alloy 600.
[0010] Alloy 52 wires or 82 may be used, in particular, for the inert gas electro-welding of the alloy 690 or the alloy 600.
TABLE 1 Analysis of wires for welding the alloys 600 and 690 Alloy Alloy Alloy Alloy 52 52 52 52 Comparison Comparison wire wire wire wire example CF example CF Inconel Casting 1 2 3 4 52 wire 52 wire 82 wire C 0.022 0.020 0.020 0.020 0.022 0.020 0.030 S 0.001 0.001 0.001 0.001 0.002 0.001 0.002 P 0.004 0.004 0.003 0.004 <0.003 0.003 0.003 Si 0.150 0.140 0.140 0.170 0.020 0.03 0.170 Mn 0.25 0.24 0.25 0.25 0.88 0.92 3.04 Ni 61.13 60.46 60.40 59.13 58.20 60.10 70.54 Cr 29.00 28.97 28.91 28.94 30.93 30.13 20.99 Cu 0.010 0.010 0.010 0.010 0.03 0.005 Co 0.040 0.010 0.010 0.010 0.010 Mo 0.010 0.010 0.010 0.010 0.012 0.02 Nb 0.021 0.010 0.010 0.010 0.918 0.93 2.287 Al 0.660 0.690 0.670 0.680 0.065 0.08 Ti 0.560 0.580 0.560 0.530 0.193 0.22 0.200 Fe 8.14 8.86 9.03 10.25 9.12 8.50 2.72 Zr 0.0013 0.006 B 0.0028 0.0040 Nb/Si 0.14 0.07 0.00 0.00 45.90 31.0 13.45
[0011] The alloy 52 welding wires are used, in particular, in the nuclear field, to produce welds in zones of the nuclear reactor components in contact with the primary fluid, which is water at a very high temperature (approximately 310° C.) and under very high pressure (approximately 155 bars), in the case of pressurised water-cooled nuclear reactors.
[0012] Alloy 52 is used for the homogeneous welding of alloy 690 parts and for producing heterogeneous welds. These heterogeneous welds may be, for example, welds on an alloy 600 containing 15% of chromium in solid form or deposited on a base metal, wherein the chromium content of the deposited metal may be from 15% to 20%.
[0013] Another application for alloy 52 in heterogeneous welding is the coating of low alloy steels such as the steels 16MND5, 18MND5 or 20MND5 or the welding of low alloy steels to austenitic stainless steels.
[0014] The alloy 52 may also be used to repair zones of nuclear reactor units or components consisting of various metals such as low alloy steels (for example of the type 18MND5), stainless steels of the type 304L (for example in solid form), of the type 308L (in deposited form) or else 316L (in solid or deposited form). These zones may comprise a plurality of these materials on which heterogeneous welds made of alloy 52 are produced.
[0015] Certain defects, mainly in the form of small cracks, have been demonstrated when using commercial alloys 52 such as the alloys 52 from Special Metals.
[0016] In particular, when the molten welding wire is deposited on a layer consisting of a nickel alloy deposited by welding, hot cracking was observed and may be due to one of the following phenomena: solidification, liquation, reassignment or else lack of hot ductility. It was noted that a single type or a plurality of types of crack may be found in a weld. Small-dimension cracks formed in these conditions will be called type 1 cracks.
[0017] Tests were carried out on welding wires of different compositions under variable welding conditions, in particular by fusing these wires on various base metals such as: nickel alloys as mentioned above and stainless steels, in the form of solid metals or of layers pre-deposited by welding.
[0018] During these tests, it was demonstrated that commercially available wires, in particular alloys 52 for the welding of nickel 690 alloys, gave poor results when they were deposited on nickel alloys containing 15% or 30% of chromium or else stainless steels deposited by welding, in the form of a coating of low alloy steel components.
[0019] In addition to small type 1 cracks, other larger cracks, which will be called type 2 hot cracks, were observed in certain cases.
[0020] Type 2 cracks were observed, in particular, in the zones of pronounced dilution of the welding alloy (in the metal deposited during the first welding passes or in the region of the parts to be joined) or more generally in the case of the welding of stainless steels.
[0021] Commercial welding wires of which the grades had been modified to improve the resistance to hot cracking and the resistance to oxidation were also used during these tests.
[0022] The modified composition of these commercially available wires is given in columns 5 and 6 of Table 1. Grades modified to improve the resistance to hot cracking and defects due to oxidation have a substantially higher niobium content (higher than 0.9%) and substantially lower aluminium and titanium contents than unmodified commercial grades.
[0023] In these improved grades, the niobium to silicon ratio is high (higher than 30 or even 45). Finally, these grades contain boron and zirconium as complementary elements.
[0024] It has been found that the improved commercially available alloys gave good results in the diluted zones during the welding of nickel alloys containing 15% or 30% of chromium, these zones being virtually free of hot cracking, but poor results in diluted zones in the case of welding on stainless steels, the type 2 hot cracks being detected in these diluted zones.
[0025] The tests carried out showed that there are no commercially available wires for producing homogeneous or heterogeneous electro-welds, which are free of cracking and oxidation, on nickel alloys and on steels.
SUMMARY OF THE INVENTION
[0026] The object of the invention is therefore to propose a nickel-base alloy for the electro-welding of nickel alloys and steels, in particular stainless steels, which allow the production of homogeneous or heterogeneous welds on these materials, which are free of hot-cracking and of traces of oxidation.
[0027] Accordingly, the alloy according to the invention contains, by weight, less than 0.05% of carbon, from 0.015% to 0.5% of silicon, from 0.4% to 1.4% of manganese, from 28% to 31.5% of chromium, from 8% to 12% of iron, from 2% to 7% of molybdenum, from 0.1% to 0.8% of titanium, from 0.6% to 2% in total of niobium and tantalum, the ratio of percentages of niobium plus tantalum and of silicon being at least 4, from 0.05% to 0.75% of aluminium, less than 0.04% of nitrogen, from 0.0008% to 0.0120% of zirconium, from 0.0010% to 0.010% of boron, less than 0.01% of sulphur, less than 0.020% of phosphorus, less than 0.30% of copper, less than 0.15% of cobalt and less than 0.10% of tungsten, the remainder of the alloy, with the exception of unavoidable impurities of which the total content is at most 0.5%, consisting of nickel.
[0028] The invention also relates to a welding wire for the electro-gas welding of nickel-base alloy according to the invention.
[0029] The invention additionally relates to the application of the alloy and of the electro-welding wire to the welding of units or components of nuclear reactors, in particular pressurised water-cooled nuclear reactors, for the realization of joints during the construction of nuclear reactors, the coating of components by metal deposition and for making repairs, wherein these welding operations may be operations for the homogeneous or heterogeneous welding of any nickel alloy or steel component.
DESCRIPTION OF PREFERRED EMBODIMENTS
[0030] To assist understanding of the invention, a plurality of grades of alloy according to the invention used for the production of wires will be described by way of examples which have been used during homogeneous and heterogeneous welding tests on nickel alloys and stainless steels.
[0031] In Table 2, column 1 shows the minimum contents of the various elements of the alloy, column 2 the maximum contents of these elements and column 3 the preferred contents.
[0032] Columns 4 and 5 of the table give alloy compositions according to two embodiments which will be described hereinafter.
[0033] The effect of the various elements of the alloy and the reasons for the claimed ranges or the limitations of these elements will be explained hereinafter.
TABLE 2 Elements in the alloy Mini Maxi Preferred Example 1 Example 2 C / 0.05 0.020 0.015 S / 0.010 0.001 0.001 P / 0.020 0.003 0.003 Si 0.015 0.5 <0.05 0.025 0.15 Mn 0.4 1.4 1 1 Ni balance balance balance balance balance Cr 28 31.5 30.0 29.0 Cu / 0.30 0.020 0.020 Co / 0.15 0.01 0.01 Mo 2 7 4 4.00 5.50 Nb (+Ta) 0.6 2 0.80 1.2 Al 0.05 0.75 0.15 0.07 0.25 Ti 0.1 0.8 0.30 0.35 0.20 Zr 0.0008 0.012 0.006 0.0015 0.006 B 0.001 0.010 0.004 0.003 0.004 N / 0.040 0.01 0.01 W / 0.10 0.01 0.01 Fe 8 12 9.00 8.5 Nb/Si 4 32 8
[0034] Carbon, Sulphur, Phosphorus
[0035] These elements are residual elements of which the contents have to be limited as far as possible and, in any case, fixed below 0.05% in the case of carbon, 0.010% in the case of sulphur and 0.020% in the case of phosphorus. Depending on the methods of production and the starting products for preparation of the alloys, the effective contents of carbon, sulphur and phosphorus may be substantially lower than the given maximum limits. As shown in columns 4 and 5 relating to the examples 1 and 2, the effective carbon, sulphur and phosphorus contents of the castings carried out are substantially lower than the maximum values given hereinbefore.
[0036] Silicon
[0037] Silicon is an element which is always present in the alloy but of which the content is to be limited to a low value, preferably lower than 0.05%. In all cases, this content must be lower than 0.5% to limit hot cracking of the welding metal. However, the silicon must be present in a content of at least 0.015% to obtain good weldability on account of the fact that it influences the wetting and the viscosity of the bath during welding.
[0038] It will be seen hereinafter, with respect to niobium, that the important parameter for resistance to fissuration in heat is the ratio of the percentage by weight of niobium and silicon.
[0039] Manganese
[0040] The manganese must be at least 0.4% to achieve satisfactory conditions for the production of the alloy in the presence of sulphur (limited to the value of 0.01% mentioned hereinafter).
[0041] The manganese contributes to the resistance to fissuration in heat, but this effect is rapidly saturated as a function of the manganese content, and a manganese content limited to 1.4% leads to satisfactory results.
[0042] Chromium
[0043] The chromium must be close to the percentage of chromium in the alloy 690, and the composition range of 28% to 31.5%, which is also that of the alloys 52, has been found to be satisfactory in the case of homogeneous and heterogeneous welds employing the alloy 690 or stainless steels. This level of chromium is required for achieving good anti-corrosion behaviour in a primary PWR medium.
[0044] Copper
[0045] Copper must be strictly limited to less than 0.30% to avoid a deterioration in the properties of the alloy.
[0046] Cobalt
[0047] The cobalt must necessarily be limited to a value below 0.15%. In fact, this element, which is activated in the presence of radiation in a nuclear reactor, must be avoided as far as possible in any application to the construction or repair of nuclear reactors.
[0048] Molybdenum
[0049] Molybdenum is a particularly important element in the production of the alloys according to the invention, and this represents a significant difference relative to previously known alloys (see Table 1) which have only very low molybdenum contents.
[0050] Tests carried out by the Applicant of the present patent application have shown that the molybdenum had a decisive influence on the resistance to cracking of the metal deposited by fusion of a nickel alloy welding wire, in particular when the welding wire is deposited on stainless steels, for example steels containing 18% of chromium and 8% of nickel with or without an addition of molybdenum, in solid form or in the form of a deposit obtained by covered electrode or TIG electro-welding.
[0051] The tests carried out showed that:
[0052] the formation of type 2 cracks is observed with low levels of molybdenum in the molten metal of the welding wire, typically lower than 0.5%, in particular when welding stainless steels,
[0053] as the molybdenum content increases, for example to 1% in the molten metal, it is found that the cracking resistance of the welding alloy is substantially improved if the alloy contains sufficient quantities of titanium (and/or of aluminium). A minimal titanium and/or aluminium content of 0.3% to 0.4%, with a molybdenum content of 1% in the alloy, limits the number of type 2 cracks in the welding metal to a low level, particularly in the case of the welding of stainless steels; these results suggest that the molybdenum, titanium and/or aluminium contents should be increased beyond these limits in order to limit or eliminate crackings,
[0054] when the molybdenum content increases to at least 2% in the molten metal, the tests show that the type 2 cracks completely disappear and that the titanium and/or the aluminium have less influence on the cracking resistance than in the case of a molybdenum of about 1%.
[0055] The molybdenum contents have been fixed in the alloy welding wire or rod according to the invention while agreeing that, in the region of the defects, the dilution is high and may reach 50% but does not exceed this limit which has been considered as respected in all the work forming the basis of the present patent application and corresponds to normal welding conditions.
[0056] As a result of the tests, it has been possible to establish that the molybdenum content has to be at least 2% in order to obtain, in all cases of use in welding, very high resistance to cracking and, in particular, a total disappearance of type 2 cracks, while limiting the total titanium and aluminium content to a level at which oxidation of the welding metal is avoided.
[0057] A molybdenum content higher than 7% is possible, but not essential, in so far as the influence of the molybdenum on the cracking resistance is saturated at a value of approximately 7%. A content higher than 7% increases the price of the alloy and may undesirably modify the properties of the welding metal.
[0058] The molybdenum should preferably be in the region of 4%.
[0059] Aluminium and Titanium
[0060] As mentioned hereinbefore, the presence of titanium and/or aluminium improves the cracking resistance, but this effect diminishes if the molybdenum content is higher than 1%.
[0061] The aluminium and titanium are used, in particular, as deoxidising and denitriding agents and lead to the formation of oxide films. These elements also reduce the grain size of the welding alloy during solidification. The oxides and nitrides formed in the form of fine particles in the liquid metal initiate the germination of the solidification grains and refine the structure.
[0062] It is therefore necessary to have a certain proportion of titanium and aluminium in the welding metal and to limit the proportion of aluminium to a value at which the undesirable oxidation effects of the molten bath are avoided during welding.
[0063] The titanium must be present in the alloy in a proportion of between 0.1% and 0.8% and, for example, close to 0.30%.
[0064] The aluminium must be present in the alloy in a proportion of between 0.05% and 0.75% and, for example, in the region of 0.15%.
[0065] Zirconium and Boron
[0066] When combined, these elements have a favourable influence on the cracking resistance owing to the ductility dip cracking. However, these elements alone are not sufficient to solve the cracking problems which the alloy according to the invention rectifies. Furthermore, zirconium, like aluminium, affects the oxidation of the molten bath during welding. The zirconium and boron must therefore be present in the alloy but in limited quantities.
[0067] The zirconium must be present in the alloy according to the invention in a proportion of between 0.0008% and 0.012% and preferably in a proportion of approximately 0.006%.
[0068] In relation to these proportions of zirconium, the boron must be between 0.001% and 0.010% and, preferably, in the region of 0.004%.
[0069] Niobium and Tantalum
[0070] Niobium affects the resistance to hot cracking. To avoid increasing the risks of hot cracking and undesirably modifying the characteristics of the deposited metal, this element must not be present in an excessively large quantity.
[0071] As a result, the proportion of niobium must be at least 0.6% to obtain the desirable effects of resistance to hot cracking and at most 2%.
[0072] The proportion of niobium within this range must be fixed at a value which is such that the ratio of the percentage of niobium to the percentage of silicon is higher than 4 to obtain a satisfactory effect on the resistance to hot cracking.
[0073] Iron
[0074] As in commercial alloys, the iron is fixed at a content of between 8% and 12% for good resistance to stress corrosion in a PWR medium.
[0075] Nitrogen
[0076] Nitrogen, which is a residual element, is not necessary in the alloy. The nitrogen will be limited, in all cases, to a value of less than 0.040%.
[0077] Tungsten
[0078] Tungsten is an element which is not desired in the alloy, this residual element being limited to 0.10% in any case to avoid undesirable modification of the properties of the welding metal.
[0079] The alloy may contain small proportions of other residual elements; these elements may be, for example, tin, vanadium, lead, cadmium, magnesium, zinc, antimony, tellurium, calcium or cerium. These elements, which are in a very small quantity in the alloy, are in a total proportion with the other residual elements considered above (carbon, sulphur, phosphorus, copper, cobalt, nitrogen and tungsten) of less than 0.5% by weight.
[0080] Nickel
[0081] As a base alloy, it makes up the remainder of the composition to 100%.
[0082] The compositions of two welding alloys according to the invention are shown in Table 2 under columns 5 and 6 (example 1 and example 2).
EXAMPLE 1
[0083] In the case of example 1, the molybdenum content is at the optimum value (4%). The aluminium content is in the region of the lower limit of the range of aluminium and the titanium content has a value close to the typical value of 0.30%.
[0084] The silicon content of the alloy is low (0.025%) and is clearly below the preferred upper limit. Although the niobium content is only 0.80%, the niobium/silicon ratio is high and is approximately the same as in commercial alloys of the improved type shown in Table 1 (32). The value of this ratio is much higher than the lower limit imposed. The zirconium and boron contents lie towards the bottom of the claimed range.
EXAMPLE 2
[0085] In the case of example 2, the molybdenum content is higher than the mean content considered as preferred (4%). The aluminium content which is substantially higher than in the case of example 1 is fixed above the typical value of 0.15% and the titanium content is lower than the typical value, the entirety of the aluminium and titanium representing a percentage by weight which is substantially identical in the case of example 1 and in the case of example 2.
[0086] The boron content is higher than in the case of example 1 and corresponds to the preferred values.
[0087] The silicon content is substantially higher than in the case of example 1. The niobium content is also slightly higher than in the case of example 1. Owing to the presence of a fairly large quantity of silicon, the niobium to silicon ratio is substantially lower in the case of example 1.
[0088] However, this ratio is twice as high as the minimum required value.
[0089] Welding wires in the two grades corresponding to examples 1 and 2 were produced. The welding wires were used for diverse homogeneous or heterogeneous welding of nickel alloys containing 30% and 15% of chromium and stainless steels.
[0090] The total absence of type 2 cracks in the deposited metal was observed, even in the diluted zones of the weld.
[0091] The deposited metal is also virtually exempt from type 1 cracks in all cases.
[0092] No trace of oxidation which could lead to deterioration of the deposited metal was found.
[0093] It has never been possible to obtain results of this type in the case of alloy wires according to the prior art.
[0094] Considering the comparison examples in columns 5 and 6 of Table 1, it can be seen that the comparison alloy in column 5 (CF 52) has a silicon content comparable to that of example 1 according to the invention and a slightly higher niobium content, the niobium to silicon ratio being 50% higher than the niobium to silicon ratio of example 1. However, this alloy according to the prior art contains only a very small proportion of molybdenum (0.012%) whereas the alloys according to the invention contain more than 2% and generally 4% or more of molybdenum. Despite a higher niobium to silicon ratio and similar contents of aluminium and titanium, the alloy CF 52 does not result in a resistance to cracking which is comparable to that of the alloys according to the invention.
[0095] In the case of the second comparison example (alloy 52 M) in column 6 of Table 2, the silicon and niobium contents and the niobium to silicon ratio are similar to those of the alloy of example 1. The aluminium and the titanium, on the other hand, are limited to values comparable to those of the examples according to the invention. The zirconium and boron contents of the comparison alloys are, moreover, similar to those of the alloys of examples 1 and 2 according to the invention respectively.
[0096] It is perfectly clear that a quasi-absence of molybdenum (0.02%) in the second comparison alloy explains the differences in welding behaviour and the good results achieved with the examples of alloy according to the invention and, in particular, example 1.
[0097] A comparison of the examples according to the invention and the examples of alloys according to the prior art therefore shows that a welding alloy having a molybdenum content of approximately 4% or slightly higher, an adequate niobium content to obtain a niobium to silicon ratio substantially higher than 4 and moderate aluminium and titanium contents solves the welding problems of nickel alloys containing approximately 15% and 30% of chromium as well as stainless steels.
[0098] The alloy according to the invention leads to electro-gas welding wires for the perfect homogeneous or heterogeneous welding of nickel alloys and stainless steels for the construction and repair of nuclear reactor components.
[0099] The invention is not strictly limited to the described embodiments.
[0100] The contents of the various elements of the alloys for electro-welding in the considered applications may be adapted within the claimed ranges to optimise the properties of the welding metal and the welding conditions.
[0101] The alloy according to the invention may be used not only in the form of electro-gas welding wires or rods but also in other forms, for example in the form of coated electrodes.
[0102] Although the alloy is intended, in particular, for applications in the field of the construction and repair of nuclear reactors, its use in other industries may be considered. | The alloy contains, by weight, less than 0.05% of carbon, from 0.015% to 0.5% of silicon, from 0.4% to 1.4% of manganese, from 28% to 31.5% of chromium, from 8% to 12% of iron, from 2% to 7% of molybdenum, from 0.05% to 0.75% of aluminium, from 0.1% to 0.8% of titanium, from 0.6% to 2% in total of niobium and tantalum, the ratio of percentages of niobium plus tantalum and of silicon being at least 4, less than 0.04% of nitrogen, from 0.0008% to 0.0120% of zirconium, from 0.0010% to 0.0100% of boron, less than 0.01% of sulphur, less than 0.020% of phosphorus, less than 0.30% of copper, less than 0.15% of cobalt and less than 0.10% of tungsten, the remainder of the alloy, with the exception of unavoidable impurities of which the total content is at most 0.5%, consisting of nickel. The alloy is used, in particular, for the production of wires for the electro-gas welding of units or components of nuclear reactors and, more particularly, of pressurised water-cooled nuclear reactors. | 1 |
FIELD OF THE INVENTION
This invention relates to a polyester yarn with good rubber adhesion made of core-sheath fibers with two different types of polyesters and a process for making it.
BACKGROUND OF THE INVENTION
Most rubber items contain textile reinforcing materials as an integral constituent to provide for dimensional stability and to reduce the high elongation of the rubber. Good adhesion of the rubber to the textile material is an indispensable prerequisite for satisfactory function and lengthy life of rubber items that contain textile reinforcing materials, for example motor vehicle tires, V-belts, and conveyor belts. If the adhesion is inadequate, the bond between the elastomer and the fiber material is broken with time, which results in destruction of the textile reinforcement from chafing, or by melting in case of local overheating. Rubber adhesion presents difficulties, particularly with the polyester fibers present as yarn filament, since there are hardly any mechanical anchoring possibilities for the rubber because of their molecular structure, as is the case with cotton fiber yarns, so that special binders are necessary.
While impregnation with resorcinol-formaldehyde resins combined with latices (RFL dip), especially vinyl-pyridine latex, is already sufficient to improve the adhesion of nylon yarns to rubber, special additional measures are necessary for polyester yarns. For them to provide adequate rubber adhesion with a conventional nylon dip (or with adhesive mixtures), the so-called spin-finish types of polyester were developed. To make them, specific adhesion promoters are applied to the polyester fibers immediately after they are spun, simultaneously with the spinning preparation, to improve rubber adhesion; they consist of definite epoxy compounds and amine hardeners, and impregnation is carried out on the cord yarn with an aqueous dispersion of resorcinol-formaldehyde resins and vinylpyridine latex. The drawbacks to applying epoxy compounds and amines consist on the one hand of the contamination of machine parts, and also of the fact that the production rates of polyester yarns are impaired, and furthermore, substantial environmental problems occur.
To avoid the application of adhesion promoters, it is known how to produce two-component yarns whose core consists of polyethylene glycol terephthalate and whose sheath consists of a polyamide (cf., for example, EP 0 398 221 A1), since polyamides by nature show better rubber adhesion than polyesters. However, this presents the problem that the adhesion of the polyester core to the polyamide sheath is inadequate. For this reason, it is necessary to reduce the core/sheath ratio of the fibers for practical application as tire cords in a way that results in insufficient utilization of the good and desirable polyester properties.
A problem underlying this invention was to avoid the procedural step of applying the aforementioned adhesion promoters, and to make available new polyester yarns made of core-sheath fibers with good rubber adhesion, for which there is no longer inadequate adhesion between core and sheath even with very large core/sheath ratios of the fibers.
This problem is solved by the features of the invention.
SUMMARY OF THE INVENTION
Polyester yarns made of core-sheath fibers pursuant to the invention are characterized first by the fact that the core of the core-sheath fibers is comprised of a high-melting fiber-forming polyester. Fundamentally, all high-melting fiber-forming polyesters and copolyesters are suitable for this, such as polyethylene glycol terephthalate, poly(ethylene 2,6-naphthalenedicarboxylate), poly(1,4-dimethylenecyclohexane terephthalate) and their copolymers based on high proportions of homopolyester. In a preferred embodiment, the core of the core-sheath fibers consists at least substantially of polyethylene glycol terephthalate. This means particularly the homopolyester polyethylene glycol terephthalate and its copolyesters that contain at least 90 mole-% ethylene glycol terephthalate units. The remaining dicarboxylic acid and diol components of these copolyesters can be the usual coconstituents for producing extended polyester structures, for example isophthalic acid, p-hydroxybenzoic acid, p,p′-diphenyldicarboxylic acid, all possible naphthalenedicarboxylic acids, hexahydroterephthalic acid, adipic acid, sebacic acid, and glycols such as 1,4-dihydroxymethylcyclohexane, trimethylene glycol, tetramethylene glycol, hexamethylene glycol, and decamethylene glycol, etc.
The polyesters and copolyesters preferred for the core of the core-sheath fibers should have a viscosity as high as possible, i.e., a relative solution viscosity of at least 1.8, preferably from 1.9 to 2.3, measured at 25° C. as a 1 wt. % solution in m-cresol, and a melting point of at least 250° C. The desired high viscosities can be obtained using known procedures, for example condensation in the melt, additional post-condensation in the melt with or without condensation accelerator(s), or post-condensation in the solid state.
The polyester yarns made of core-sheath fibers pursuant to the invention are also characterized by the fact that the sheath of the core-sheath fibers is comprised of a high-melting unsaturated copolyester that has been made, based on the dicarboxylic acid components, with one or more unsaturated dicarboxylic acid coconstituent(s) comprising at least 2 mole-% alkylmaleic acid with an alkyl group having from 1 to 18 carbon atoms and/or alkylenesuccinic acid with an alkylene group having from 1 to 18 carbon atoms and/or their polyester-forming derivatives. In principle, all high-melting fiber-forming polyester and copolyester structures that are used for the core of the core-sheath fibers are suitable for the polyester modification with the unsaturated dicarboxylic acid components, but especially those that contain at least 90 mole-% ethylene glycol terephthalate units. Citraconic acid and itaconic acid and their polyester-forming derivatives are preferred as unsaturated dicarboxylic acid components; they are used in amounts of at least 2 mole-% based on the dicarboxylic acid components.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
In a particularly preferred embodiment, the sheath of the core-sheath fibers may consist of an unsaturated copolyester that contains 95 to 98 mole-% ethylene glycol. terephthalate units and has been made with 2 to 5 mole-%, preferably with 3 to 4 mole-% citraconic acid and/or itaconic acid and/or their polyester-forming derivatives, Ethylene glycol is preferably used alone as the glycol component of such unsaturated copolyesters. Especially preferred polyester-forming derivatives of citraconic acid and itaconic acid are citraconic anhydride, dimethyl citraconate, and dimethyl itaconate.
To avoid crosslinking, it may be advantageous when preparing the unsaturated copolyesters to carry out the transesterification and/or polycondensation in the presence of antioxidants. Especially suitable for this are sterically hindered phenols such as di-n-octadecyl (5-t-butyl-4-hydroxy-3-methylbenzyl)malonate (Irganox 420), octadecyl 3-(3,5-di-t-butyl-4-hydroxyphenyl)propionate (Irganox 1076), 1,1-bis(5-t-butyl-4-hydroxy-2-methylphenyl)butane (Irganox 414), tetrakis[methylene(3,5-di-t-butyl-4-hydroxyhydrocinnamate)]methane (Irganox 1010), N,N′-1,6-hexamethylenebis-3-(3,5-di-t-butyl-4-hydroxyphenyl)propionamide (Irganox 1098), 1,3,5-tri(3,5-di-t-butyl-4-hydroxybenzyl)-2,4,6-trimethylbenzene (Irganox 1330), and tris(2,6-dimethyl-3-hydroxy-4-t-butylbenzyl)-s-triazine-2,4,6(1H,3H,5H)trione (Cyanox 1790).
The above unsaturated dicarboxylic acid components can be cocondensed with the mentioned antioxidants with no problematical increase of viscosity, even in rather large quantities, for example 8 mole-%. In general, however, for polyesters that contain at least 90 mole-% ethylene glycol terephthalate units, 5 mole-% of the unsaturated dicarboxylic acid components based on the total of all dicarboxylic acid components is sufficient. With larger quantities of unsaturated dicarboxylic acids, a disadvantageous drop of melting point to below 245° C. would occur with this type of copolyester.
Unsaturated copolyesters that contain 96 mole-%, for example, of ethylene glycol terephthalate units and 4, mole-% of ethylene glycol citraconate units or 4 mole-%; ethylene glycol itaconate units, show melting points of 248.9 and 246.8° C., respectively, so that the necessary dipping of cord yarns can be carried out at 240° C. without any temperature change and with no problems. The important glass transition temperatures T g are 79° C. and 76° C., respectively; therefore, they only insignificantly differ from the glass transition temperature of the polyethylene glycol terephthalate homopolyester, which is 80° C. This is particularly beneficial for the stretchability of the two-component yarn. The appropriate modifying quantities of alkylmaleic and/or alkylenesuccinic acids for other unsaturated types of copolyester that are not made up essentially based on ethylene glycol terephthalate units can be determined readily by determining their melting points and glass transition temperatures.
The copolyesters preferred for the sheath of the core-sheath fibers in general may have a relative solution viscosity of at least 1.5, preferably from 1.6 to 2.0, measured at 25° C. as a 1 wt. % solution in m-cresol, and a melting point of at least 245° C.
To produce core-sheath ratios at uniform levels, the yarns made of core-sheath fibers pursuant to the invention are preferably prepared by the procedure described in EP 0 398 221 A1. In this procedure, the extruded core component is fed through a first spinneret plate to a second spinneret plate in several separate streams, the extruded sheath component being fed in to flow around each separate core component stream between the first and second spinneret plates. The two components are spun, stretched, and wound up jointly, and the sheath component is exposed to flow resistance at least around the area of the separate streams of core component. A wire mesh netting is particularly suitable as flow resistance. Even though the weight ratio of the different core/sheath polymers may be varied within extremely wide limits, the core polymer is preferably melt-spun with the sheath polymer in a weight ratio of 95:5 to 80:20.
The core-sheath polymer combinations pursuant to the invention can be spun at the same speeds as the core-sheath fibers made up of polyethylene glycol terephthalate and Polyamide 66 from EP 0 398 221 A1 intended for tire cords, for example at a speed of 500 m/min or 900 m/min In the case of the latter spinning speed, the polyester yarn is then stretched in a first stretching step to the extent of about 1:3, and in a second stretching step to a total stretch ratio of about 1:5, while the total stretch ratio in the case of the spinning speed mentioned first is about 1:6.
Surprisingly, the core-sheath combinations pursuant to the invention can also be fast-spun at the spinning speeds of 3000-5000 m/min, speeds customary in the fast-spinning of polyester single-component yarns. The polyester yarns thus obtained are then stretched in a first stretching step to about 1:1.8 to 1:1.2, and in a second stretching step to a total stretching ratio of about 1:2.4 to 1:1.6.
Although the tensile strength and elongation at break of the yarns can naturally be varied considerably depending on the degree of stretching chosen, the polyester yarns thus obtained generally have a tensile strength of 600 to 850 mN/tex, an elongation at break of 10 to 14%, and rubber adhesion of 180 to 260 N/2 cm. With compliance with the customary physical data of polyester yarns intended for tire cords, these surprisingly high figures for rubber adhesion permit dispensing with the previous use of the specific adhesion promoters described above.
The invention will be described in detail with reference to the following examples.
EXAMPLE 1
A. In preparing unsaturated copolyesters, 48 kg of dimethyl terephthalate, 40 kg of ethylene glycol, and 16.3 g of Mn(CH 3 COO) 2 .4 H 2 O are placed in a stirred 270-liter steel reactor equipped with a stirrer. When the dimethyl esters of alkylmaleic acid(s) and/or of alkylenesuccinic acid(s) are used as modifying comonomers, they are added to the transesterification mixture, for example 1.58 kg of dimethyl citraconate or dimethyl itaconate=4 mole-%. The transesterification is carried out with temperature increasing gradually to 245-250° C. in about 2 hours and 15 minutes.
After transesterification of the components is complete, 17.3 g of carbethoxymethyl diethylphosphonate and 12 g of Sb 2 O 3 are added. When alkylmaleic acid(s) and/or alkylenesuccinic acid(s) or their anhydrides are used as modifying comonomers, they are also added at this time, for example 1.30 kg of citraconic acid or itaconic acid=4 mole-%, or 1.11 kg of citraconic anhydride=4 mole-%. This mixture is then transferred to a 150-liter autoclave equipped with a stirrer. The temperature is raised to about 280° C. and the pressure is reduced stepwise to 1 mbar or lower. The polycondensation is terminated upon reaching a relative viscosity of about 1.6, measured at 25° C., as a 1 wt. % solution in m-cresol. Depending on the temperature and vacuum program and the quantity of modifying comonomers, the time for polycondensation varies between 2 and 3 hours.
0.5 wt. % Irganox 1330 is added to the reactants in each case as antioxidant at the same time as the modifying unsaturated comonomers are added.
B. In preparing polyester yarns from core-sheath fibers, ten different yarns are sample spun with a core-sheath ratio of 90:10 parts by weight. Their core always consists of a polyethylene glycol terephthalate with, a relative viscosity of 2.04, always measured at 25° C. as a 1 wt. % solution in m-cresol. The sheath polymer consisted of the prepared copolyesters corresponding to each sample listed in the table, whose relative viscosity is about 1.6.
One extruder each is used as the melting and transport mechanism for the core-sheath polymer. The five temperatures of the extruder for the polyethylene glycol terephthalate as the core polymer in the transport direction are between 310° C. and 297° C. An adjustable pump provides a throughput of about 100 g/min when spinning is done at a spinning speed of 900 m/min. The throughput for the core polymer is about 126 g/min for a spinning speed of 4000 m/min.
The five zone temperatures of the extruder for the particular copolymer as sheath polymer in the transport direction are between 302° C. and 281° C. An adjustable pump provides for a throughput of about 11 g/min when spinning at a speed of 900 m/min. The throughput for the sheath polymer is 14 g/min for a spinning speed of 4000 m/min.
The core-sheath polymers are spun by the procedure described in EP 0 398 221 A1. A stainless steel 60 mesh screen net is used to provide flow resistance. The spinning plate contains 36 spinning holes with a diameter of 500 μm; the temperature of the spinning unit is kept at 297° C. A heating channel 40 cm long and with a wall temperature of 310° C. is mounted directly below the spinning plate.
The spun two-component yarns are solidified with a lateral stream of air at a temperature of 20° C. and with a velocity of 30 cm/min. About 1 wt. % of a conventional standard preparation is then applied to the polyester yarn; it contains no adhesion promoter such as epoxy compounds, isocyanate compounds, or the like, and the yarn is wound up at a speed of 900 m/min or 4000 m/min.
C. Five spun spools of as-spun yarns are combined and stretched on a steamdrawing frame. The yarns to be stretched contain 180 filaments. The first stretching is done on heated stretching pins at a temperature of 80° C. The stretching ratio of the yarns spun at 900 m/min or at 4000 m/min in the given order is varied slightly so that the main stretching point is located on the fifth stretching pin. The second stretching is carried out in a steam chamber with a steam temperature of 245° C., with the dwell time of the yarn in the steam chamber being 3 seconds. In all cases the total stretch ratio of the yarns spun at 900 m/min or at 4000 m/min is 1:5 and 1:1.8, respectively. The table below shows the yarn properties.
D. To measure the rubber adhesion, the yarns obtained are then each twisted into a tire cord of the construction 1100 dtex X1Z435X2S435. This cord is treated by a known method with an aqueous dispersion based on resorcinol-formaldehyde precondensate and vinylpyridine-styrene-butadiene latex (RFL), with 5 wt. % of solids content being applied to the cord. It is then a) dried for 120 seconds at 150° C. under tension of 20 mN/tex, b) hardened for 30 seconds at 240° C. under tension of 100 mN/tex, and c) hardened and relaxed for 30 seconds at 240° C. under tension of 20 mN/tex.
The dipped cords are covulcanized in a rubber blend in the form of strips according to ASTM D 4393-85 and the rubber adhesion is measured in N/2 cm, as the force to separate the strips 2 cm wide. The results are given in the table as the averages of six measurements each.
COMPARATIVE EXAMPLE
As a comparative example, core-sheath fibers consisting of polyethylene glycol terephthalate are made in the same way at a speed of 900 m/min; their core and sheath consist of the same homopolymer with a relative viscosity of 2.04.
TABLE
Yarn
Unsaturated dicarboxylic
Spinning speed
Yarn count
Tensile strength
Elongation at
Rubber adhesion
Sample No.
acid component
Mole-%
in m/min
in dtex
in mN/tex
break in %
in N/2 cm
1
Citraconic acid
1
900
1242
740
9.9
125
(not pursuant
to invention)
2
Citraconic acid
2
900
1238
767
11.1
190
3
Citraconic acid
3
900
1247
820
10.0
255
4
Citraconic anhydride
4
900
1246
757
10.8
250
5
Citraconic acid
4
900
1245
755
11.1
250
6
Citraconic acid
4
4000
987
605
12.5
220
7
Citraconic anhydride
4
4000
997
613
14.0
225
8
Dimethyl itaconate
3
900
1245
780
10.5
245
9
Itaconic acid
4
900
1573
653
12.1
250
10
Itaconic acid
4
4000
1004
681
10.9
230
Comparative
None
Example
Core = Sheath = PET
0
900
1190
755
11.1
75 | Core-sheath fibers are useful as textile reinforcing materials in rubber items having rubber adhesion of 180 to 260 N/2 cm. The fiber core is a high-melting (co)polyester and the sheath is a high-melting unsaturated copolyester. The high-melting unsaturated copolyester is made from at least one unsaturated dicarboxylic acid coconstituent, which contains at least 2 mole-%, based on dicarboxylic acid components, of alkylmaleic acid, having a 1 to 18 carbon atom alkyl group; alkylenesuccinic acid having a 1 to 18 carbon atom alkylene group; or their polyester-forming derivatives. | 3 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a scripting system by which the functionality present in an application program may be executed via a script. More particularly, the invention pertains to a scripting system in which the application program designates the functionality that may be invoked by a script, and in which a script interpreter, which is instantiated as an object separate from the application program, contains a list of scripts that may be invoked and a list of corresponding events that cause the script to be invoked. The application program signals that events have occurred to the script interpreter which, in turn, interprets corresponding scripts.
2. Description of the Related Art
In an effort to permit users of application programs to customize the functionality of the programs, application programs have recently allowed users to write customized scripts. The scripts include a sequence of script commands such as commands to invoke functionality of the application program, and allow the user to specify how the application program operates. With scripts, a user can customize the application program to meet specific demands of the implementation. Examples of scripts include macros for word processing programs such as WordPerfect® or Word for Windows®, and macros for spreadsheet programs such as Lotus® 1-2-3.
Such scripts, however, are tightly bound to their associated application programs. "Tightly bound" means that the script is designed only for one specific application program. Thus, both the script language that is used in the script as well as the functionality that may be invoked from the script are both defined in the context of one application program.
Because script are tightly bound to their application program, difficulties have arisen in the use of scripts. For example, the script language cannot be used in another application program which ordinarily will define its own scripting language. Further, it is not now possible for a script invoked from one application program to use functionality of another application program.
SUMMARY OF THE INVENTION
It is an object of the present invention to address these difficulties through the provision of a dynamically binding scripting system.
According to one aspect of the invention, a script interpreter which is instantiated as an object separate from the application program is provided to interpret scripts. The script interpreter contains a list of scripts that may be invoked and a list of corresponding trigger events that cause the scripts to be invoked. The scripts, which are separate from both the application program and the script interpreter, contain script language commands which include commands to execute functions in the application program. The application program is responsible both for defining the functions that it will make available for execution from scripts, as well as for indicating to the script interpreter that a particular type of event has occurred. In response to an indication from the application program that a trigger event has occurred, the script interpreter will interpret the appropriate script to execute the scripting commands, and in particular to execute application program functions when they are encountered in the script.
According to this aspect, the invention provides a scripting system for scripting application program functionality. A library list is formed, the library list including an entry point for each function that the application program will make available to scripts. A script interpreter is instantiated, the script interpreter being responsive to trigger events such that in response to a trigger event the script interpreter begins to interpret an attached script. Scripts are attached to the script interpreter, the scripts defining a script trigger event by which the script is triggered and including script commands such as commands to execute the exported application functionality. The script interpreter cross-indexes the list of attached scripts with correlated trigger events. In response to an application program detecting a trigger event and signalling the script interpreter that a trigger event has been detected, the script interpreter interprets the script commands in the script corresponding to the trigger event, and executes any application program functionality that is encountered in the script based on the entry point defined in the library list.
This brief summary has been provided so that the nature of the invention may be understood quickly. A more complete understanding of the invention can be obtained by reference to the following detailed description of the preferred embodiment thereof in connection with the attached drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is perspective view of the outward appearance of an apparatus according to the invention, and FIG. 2 is a block diagram of the FIG. 1 apparatus.
FIG. 3 is a representational view showing the functional interdependence of application programs, a script interpreter, and scripts.
FIGS. 4a, 4b and 4c are representative scripts.
FIG. 5 is a flow diagram for explaining script processing according to the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
FIGS. 1 and 2 show an apparatus according to the present invention in which application program functionality is made available for execution from a script interpreter in accordance with commands in a script. As shown in these figures, reference numeral 100 designates personal computing equipment such as an IBM PC or PC-compatible computer. While it is preferred to implement the invention in such personal computing equipment, it is to be understood that the invention may be incorporated into dedicated and/or stand-alone computing equipment.
Computing equipment 100 includes a CPU 111 such as an 80386 processor which executes stored program instructions such as operator selected applications programs that are stored in RAM 114 or specialized functions such as start-up programs or BIOS which are stored in ROM 112. Computing equipment 100 further includes a local area network interface 115 which provides interface to a local area network 116 whereby the computing equipment 100 can access files on a remote file server or send files for remote printing or otherwise interact with a local area network in accordance with known techniques such as by file exchange or by sending or receiving electronic mail. Computing equipment 100 further includes a monitor 117 and a keyboard/mouse 119 for allowing operator manipulation and input of information.
Mass storage memory 120, such as a fixed disk or a floppy disk drive, is connected for access by CPU 111. Mass storage 120 typically includes stored program instruction sequences such as an instruction sequence according to the invention for exporting application program functionality to a script, as well as stored program instruction sequences for a variety of application programs such as multimedia message manager application programs, text-to-speech conversion application programs, optical character recognition ("OCR") application programs, and the like. In particular, the multimedia message manager application program provides capability for creating, editing and displaying multi-media messages in a multi-media environment and for sending and receiving multi-media messages via different transmission media including facsimile, voice telephone and modem. Other information and data processing programs may be stored in mass storage device 120. Data may also be stored on mass storage memory 120 as desired by the operator.
A modem 121, a facsimile interface 122, and a voice telephone interface 124 are provided so that CPU 111 can interface to an ordinary telephone line 125. Each of the modem 121, facsimile interface 122, and voice telephone interface 124 are given access to the telephone line 125 via a telephone line switch 126 which is activated under control by CPU 111 so as to connect telephone line 125 to one of the modem 121, the facsimile 122, or the voice telephone interface 124, as appropriate to the data being sent and received on the telephone line. Thus, CPU 111 can send and receive binary data such as ASCII text files or document images files via modem 121, it can send and receive facsimile messages via facsimile interface 122, and it can interact on an ordinary voice telephone line via voice telephone interface 124. In this regard, voice telephone interface 124 is provided with a DTMF decoder 124a so as to decode tones on the voice telephone line 125 which correspond to operator depressions of a telephone touch-tone capable keypad. In accordance with stored program instruction sequences in mass storage memory 120, the decoded tones are interpreted by CPU 111 into operator commands, and those operator commands are executed so as to take predesignated actions in accordance with operator depressions of the telephone keypad.
A conventional text-to-speech convertor 127 is connector to the CPU 111. The text-to-speech convertor 127 interprets text strings that are sent to it and converts those text strings to audio speech information. The text-to-speech convertor 127 provides audio speech information either to a speaker 128 for enunciation to a local computer operator, or provides audio speech information to the voice telephone interface 124 for enunciation over ordinary voice telephone lines.
MIDI ("Musical Instrument Digital Interface") synthesizer 130 is also connected to CPU 111 and interprets MIDI music commands from CPU 111 so as to convert those MIDI music commands to audio wave forms. The audio wave forms are, in turn, played out over speaker 128 or provided to voice telephone interface 124 for play out over ordinary voice telephone lines.
Scanner 131 operates to scan original documents printed on a sheet of paper, and to convert the information of those original documents into a bit-by-bit computer readable representation of that document. Scanner 131 may be a simple black and white scanner, but more preferably scanner 131 includes at least half-tone (grey scale) processing capabilities and/or color processing capabilities.
Printer 132 is provided to form images of documents under the control of CPU 111. Printer 132 may be an ordinary black and white printer, but, more preferably, printer 132 includes half-tone and/or color capabilities.
FIG. 3 is a representational view of the functional interdependence of application programs, the script interpreter, and scripts in accordance with the present invention. In FIG. 3, application programs 10, 11 and 12 are application programs stored in mass storage memory 120, such as an application program for managing multimedia messages, an application program for performing text-to-speech conversion of arbitrary text files, and an application program for performing optical character recognition ("OCR") processing on arbitrary image files. Each of these application programs includes various blocks of functionality. Some of those blocks of functionality are made available for execution from a script, and those blocks of functionality are hereinafter referred to as "exported functionality". Each of the application programs defines entry points for the exported functionality into a script initialization file, such as a Windows® ".INI" file, by inserting the entry point in a dynamic link library list (hereinafter "DLL list"). Thus, as shown in FIG. 3, a script initialization file 14 includes a DLL list 15 for application #1, a DLL list 16 for application #2, and DLL list 17 for application #3.
Each application program that makes scripting available to a user instantiates a script interpreter object. One such script interpreter object 19 is illustrated in FIG. 3 and is the script interpreter object instantiated by application #1. The script interpreter interprets script language, such as the script language attached hereto in Appendix A, and executes the function statements that are encountered in scripts. At least two types of function statements are provided in this embodiment: a utility function and an exported application program function. Utility functions are pre-defined library functions such as those set forth in Appendix B attached hereto. The utility functions make basic functionality available to a script user.
Exported application program functions are those functions that each of the application programs has exported and has listed in initialization file 14. When script interpreter 19 encounters an exported application program function, script interpreter 19 refers to initialization file 14 to obtain the proper entry point for the function, and then executes the designated function.
Scripts, such as scripts 20, 21 and 22, are attached to the script interpreter 19. Each script includes a script name by which the script may be accessed by the script interpreter, and also includes a script trigger event which specifies the event upon occurrence of which the script will be invoked. Thus, as seen in FIG. 3, script 20 includes script name 20a, script trigger event 20b, and script commands 20c, all of which are specified in Appendix A.
As each script is attached to the script interpreter 19, the script interpreter forms a correlation list by which script names are correlated to their associated trigger event. Thus, as seen in FIG. 3, script interpreter 19 includes a script/trigger event correlation list 19a. By reference to the correlation list, script interpreter 19 invokes the appropriate one of the attached scripts based on occurrence of a trigger event.
Trigger events are signalled to the script interpreter by the application programs. Thus, as seen in FIG. 3, application program 10 signals a trigger event 24 to script interpreter 19. Based on the trigger event and the script/trigger event correlation list 19a, script interpreter 19 begins interpreting one of its attached scripts. More specifically, the script commands in the triggered script are interpreted line by line until a function statement is encountered. If the function statement is a utility function, then script interpreter 19 executes the utility function in accordance with the specifications of Appendix B. On the other hand, if the function statement encountered is an exported application program function, then script interpreter 19 refers to initialization file 14 so as to obtain an entry point into the appropriate application function. Using the entry point, the script interpreter 19 executes the exported functionality as indicated at 25. After execution of the exported functionality has been completed, control returns to script interpreter 19 which continues to interpret the succeeding line of the invoked script.
As seen in FIG. 3, initialization file 14 includes a DLL list for each of the applications that has exported functionality to the scripting system. Thus, for example, even though application program 10 has detected the triggering event 24, it is possible for the script that is invoked based on the triggering event to execute functionality from different application programs, such as application program 11. Indeed, any of the scripts attached to script interpreter 19 can access any of the exported functionality from any of the application programs, so long as that exported functionality is provided with an entry point in one of the DLL lists in initialization file 14.
FIG. 4 is a representative script according to the invention, and FIG. 5 is a flow diagram illustrating script processing according to the invention. The script depicted in FIG. 4 is used to make a voice telephone call over voice telephone interface 124, play out a greeting requesting for a named person to come to the telephone, and in response to DTMF signals detected on the voice telephone line, generate voice messages. The named person is represented in the scripts by the variable "who" prefixed by token "$" which causes script interpreter 16 to replace the string "$who" with the value of the variable "who", here, the person's name. Variables and variable values are preferably retrieved and stored using the container-based exchange system described in my co-pending application entitled "CONTAINER-BASED METHOD FOR EXCHANGING INFORMATION BETWEEN COMPUTER PROCESSES", filed on even date herewith, the contents of which are incorporated by reference as if set forth in full herein.
As shown in FIG. 4, three scripts are provided: a "CallOut" script, a "MakeACall" script and a "Listen" script. Each of these scripts is triggered by respective trigger events "OutGoingCallEvent" "MakeCall" and "ListenEvent" The "OutGoingCallEvent" is generated by one of the application programs executing in CPU 111, for example, a multimedia message management program.
In step S1, the application program creates a script interpreter object such as script interpreter 19 to interpret scripts. Because the application program is invoking scripts, it already has exported functionality by providing DLL lists in a script initialization file such as initialization file 14.
In step S2, scripts are attached to the script interpreter. As described above in connection with FIG. 3, the script interpreter generates a correlation list which correlates script names to trigger events by which those scripts are invoked (step S3). Thus, in consideration of the scripts shown in FIG. 4, the script interpreter generates a script/trigger event correlation list which correlates the CallOut script with the OutGoingCallEvent trigger event, which correlates the MakeACall to the MakeCall event, and which correlates the Listen script to the ListenEvent event.
In step S4, during execution of the application program, the application program detects that an event has occurred and signals the script interpreter that the detected event has occurred. In response to event detection, flow advances to step S5 in which the script interpreter finds the scripts that correspond to the detected event by reference to the script/trigger event correlation list. Thus, for example, with reference to the scripts shown in FIG. 4, when an OutGoingCallEvent is detected by the multimedia message management program, script interpreter 19 determines that the CallOut script should be invoked, and commences interpretation of the script commands in the CallOut script. Interpretation of the scripts continues until function statements are encountered. In the example of FIG. 4, the "SetEvent" function statement is such a statement.
In response to detection of a function statement, the script interpreter determines whether the function statement is a utility function statement or an application program function statement. "SetEvent" is a utility function statement (see Appendix B) and, accordingly, the script interpreter executes the function in accordance with its internal library of utility functions. In this case, the result of execution is to trigger the MakeCall event.
In response to the MakeCall event, script interpreter 19 activates the script that is triggered by the MakeCall event, here the MakeACall script, and begins interpreting script commands in that script. As before, script interpretation continues until a function statement is encountered, here, the MakeCall function statement. As before, script interpreter 19 determines whether the MakeCall function statement is a utility function or an exported application program function.
In this instance, the MakeCall function is an exported application function. Accordingly, as shown in step S6, the script interpreter resolves the external application function reference by reference to initialization file 14 and calls the appropriate entry point in the appropriate application program. In the present situation, MakeCall is an exported application function from the multimedia message management application program, and accordingly script interpreter 19 causes execution of that functionality, whereby the indicated message is played out over voice telephone interface 124.
As shown in the FIG. 4 scripts, the MakeCall exported functionality attempts to place the telephone call, but if the telephone line is busy (status=busy), then the script interpreter pauses 20 seconds and then again sets the MakeCall event so as to attempt another call. On the other hand, if the call has been placed and the message has been played out (status=ok) then the script interpreter pauses 10 seconds and sets the ListenEvent.
In response to detection of the ListenEvent, the script interpreter invokes the Listen script, again through reference of the script/trigger event correlation list. The script interpreter interprets the script commands in the Listen script until it encounters a functional statement, here the ReadDTMF functional statement. In accordance with the processing described above, the script interpreter determines that the ReadDTMF function statement is an exported application program functionality and accesses the appropriate entry point for that functionality via the initialization file 14. In accordance with the returned value of the DTMF signal on the voice telephone line 125, one of four actions is taken. In particular, if DTMF input=1, then script interpretation proceeds until the script interpreter encounters the PlayTTS functional statement. The script interpreter determines that the PlayTTS functional statement is not a utility function but rather is an exported application function, and via initialization file 14 obtains the entry point for the exported functionality. In this situation, PlayTTS functionality is not exported from the multimedia message management application program, but rather is exported from a text-to-speech conversion application program. But because the exported functionality is listed in the DLL list in initialization file 14, the script interpreter 19 is still able to access the desired entry point for the functionality.
In step S8, script interpreter 19 processes the script until all scripts, including nested scripts as above, have been completed. Flow thereupon returns to step S4 to await further signalling that an event has occurred.
APPENDIX A: Script Language
Each Script has the following format: ##STR1##
Each <ScriptStatement> can be either a <ConditionalStatement> or a <FunctionStatement>.
<ConditionalStatements> have the following format: ##STR2## and thus can include further <ConditionalStatements> and <FunctionStatements>.
<FunctionStatements> are either calls to utility functions or calls to application program-defined functions, as listed in the dynamic link library initialization file.
APPENDIX B: Utility Functions
Abort
This function aborts script processing, displays AbortMessage in a message box, and returns to the client program that initiated the script processing. If AbortMessage is NULL, no message box is displayed.
______________________________________Abort (AbortMessage,fLog)AbortMessage the string to be output in the message box.fLog set to TRUE if the message is to be logged. (where?!)______________________________________
CallScript
This function causes a script to be interpreted from within a script. This mechanism is used to directly cause another script to be interpreted as opposed to the SetEvent function. Interpretation of the script calling CallScript will be halted temporarily until the script handling the event completes.
______________________________________CallScript (ScriptName)ScriptName the name of the script being called.______________________________________
DestroyVar
This function causes a variable to be removed.
______________________________________DestroyVar (VariableName)VariableName the name of the variable being destroyed.______________________________________
IsEventSet
This function returns TRUE if EventName has been set and FALSE otherwise.
______________________________________IsEventSet (EventName)EventName the name of the event being checked.______________________________________
Exit
This function exits script processing and returns to the client program that initiated the script processing.
Exit ()
MessageBox
This function puts up a message box with Message in it.
______________________________________MessageBox (Message,Title,Style)Message the string to be output in the message box.Title the string to be output as the title of the message box.Style Windows ® MB styles supported here.______________________________________
Pause
This function causes script interpretation to pause until the time expires.
______________________________________Pause (time)time the amount of time to pause in 10ths of a second.______________________________________
Return
This function stops interpreting the current script. If the script was being interpreted as a result of being called (directly or indirectly) from another script this function will cause the ScriptInterpreter to resume processing of that script. If script processing was initiated from a client program the ScriptInterpreter will return to the client program.
Return ()
Set
This function sets the value for a variable. If the variable exists the current value is overwritten with the new value. If the variable does not exist it is created and set to the required value.
______________________________________Set (VariableName, value)VariableName the name of the variable whose value is being set.value what the variable is being set to. This may be a string, a number or another variable.______________________________________
SetEvent
This function causes an event to be set. If there is a script for that event the ScriptInterpreter will start interpreting that script. This mechanism allows for a script to indirectly cause another script to be interpreted. Interpretation of the script calling SetEvent will be halted temporarily until the script handing the event completes.
______________________________________SetEvent (EventName)EventName the name of the event being triggered.______________________________________
SetEventDeferred
This function causes an event to be set. If there is a script for that event the ScriptInterpreter will start interpreting that script after it has finished processing the current script.
______________________________________SetEventDeferred (EventName)EventName the name of the event being triggered.______________________________________
IsVariable
This function returns TRUE if VariableName exists and FALSE otherwise.
______________________________________IsVariable (VariableName)VariableName the name of the variable being checked for existence.______________________________________ | A scripting system for scripting functionality in an application program. A script interpreter which is instantiated as an object separate from the application program is provided to interpret scripts. The script interpreter contains a list of scripts that may be invoked and a list of corresponding trigger events that cause the scripts to be invoked. The scripts, which are separate from both the application program and the script interpreter, contain script language commands which include commands to execute functions in the application program. The application program is responsible both for defining the functions that it will make available for execution from scripts, as well as for indicating to the script interpreter that a particular type of event has occurred. In response to an indication from the application program that a trigger event has occurred, the script interpreter will interpret the appropriate script to execute the scripting commands, and in particular to execute application program functions when they are encountered in the script. | 6 |
RELATED APPLICATIONS
This is a continuation of application Ser. No. 08/168,842 filed on Dec. 16, 1993, now abandoned.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates generally to bicycle drive systems, and more particularly, to a hollow shaft and crank arm assembly comprising a tubular housing surrounding first and second shaft members that are matingly engaged.
2. Description of the Background Art
Common bicycle drive systems typically comprise a solid cylindrical shaft connected to solid crank arms. However, in today's market, cyclists desire the reduced drag and increased acceleration benefits provided by reduced weight bike parts. Reduction in weight is accomplished using tubular shafts and hollow crank arms instead of solid shafts and crank arms, respectively. To further reduce the weight, lighter, composite materials have been substituted for the more commonly used heavy metals.
For example, U.S. Pat. No. 2,350,468 describes a crankshaft assembly utilizing hollow crank arms attached to a solid shaft housed in a metallic sleeve. The weight of the solid shaft is not addressed. The solid metal shaft adds undesirable weight to the crankshaft assembly, and the undesirable weight adversely affects bicycle acceleration.
U.S. Pat. No. 4,704,919 describes a two piece crankshaft for a bicycle; the crankshaft comprises a first fixed crank arm welded to one end of a tubular spindle with a spline at its other end. A second removable crank arm is welded to an internally splined boss which engages the splined end of the spindle. This configuration does not permit maximum translation of pedal force to rotation force because the spline junction is disposed at the end of the spindle. While the use of a hollow spindle reduces the overall weight of the crankshaft assembly, the spline junction of the second crank arm to the shaft does not provide the assembly with maximum strength because the junction is disposed proximate an end of the removable crank arm, which is an area of the crankshaft assembly that receives the greatest loads. Because the strength of the crankshaft assembly is reduced by the design of the spline junction, the useful life of the crankshaft assembly is limited. Lastly, the splines on the spindle end and second removable crank arm are more expensive to manufacture than a plain cylindrical shaft end, and thus, increase the overall cost of manufacture for the crankshaft assembly.
U.S. Pat. No. 4,811,626 discloses a hollow crank arm comprising three separate inter-assembled segments made of composite material. The use of composite material decreases the overall weight of the crank arm, and concomitantly the weight of the crankshaft assembly. However, the use of composite material is very expensive and greatly increases the cost of manufacture of the part.
As none of the prior art discussed above successfully provides a crankshaft assembly having the lightweight and high strength characteristics desired by cyclists, what is needed is a light weight crankshaft assembly that includes hollow crank arms and a tubular shaft, that has a simple design to reduce manufacturing costs, and that is made of material having a high strength to weight ratio. Further, there is a need for a crankshaft assembly having the junction coupling the right and left crank arms positioned away from the area of greatest load upon the crankshaft assembly to maximize the strength and useful life of the crankshaft assembly.
SUMMARY OF THE INVENTION
A preferred embodiment of the hollow bicycle crankshaft of the present invention comprises a hollow shaft assembly, fastening means, a hollow left crank arm, a hollow right crank arm, a tubular housing member, a first shaft bearing, a second shaft bearing, and a sprocket bracket. The shaft assembly is housed within the tubular housing member. Together the shaft assembly and housing member are commonly called a `bottom bracket assembly` in the bicycle manufacturing trade. The hollow shaft assembly further comprises a tubular first shaft member which matingly engages a tubular second shaft member. Non-mating ends of the shaft assembly are attached to a first end of the left crank arm and a first end of the right crank arm, where the shaft extends through an aperture in each arm such that each arm surroundingly fastens to a non-mating shaft end. The use of a hollow shaft assembly and hollow crank arms reduces the overall weight of the crankshaft assembly. The union of the first and second shaft members is proximate a midsection of the constructed shaft assembly, where the torque stress on the shaft assembly is the least.
The first and second shaft bearings are disposed at first and second ends, respectively, of the housing member, and secure the tubular housing member about the shaft assembly in coaxial and concentric alignment. In additional to torsional loads, the shaft bearings and the shaft assembly endure bending moments resulting from the alternating downward load on the crank arms which forces the crankshaft assembly to rotate. Positioning the shaft bearings at the ends of the housing member reduces the bending loads on the shaft assembly and bearings by creating a smaller moment arm. Further, by positioning the bearings outside the ends of the tubular housing member as opposed to between the inner surface of the tubular housing member and the outer surface of the shaft assembly, a larger than standard diameter housing member having a reduced wall thickness may be used, which further reduces the overall weight of the crankshaft assembly.
The first shaft bearing is disposed at the end of the tubular housing member that is adjacent to the sprocket bracket, and is larger than the second shaft bearing which is disposed on the opposing side of the housing member. There are greater torsional loads on the bearing that is adjacent to the sprocket bracket because the sprocket bracket transfers the greatest amount of energy, generated during rotation of the crankshaft assembly, to the drive means of a bicycle. To accommodate the heavier loads, the first shaft bearing is larger than the second shaft bearing. The smaller size of the second shaft bearing further lightens the overall weight of the crankshaft assembly.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a crankshaft assembly constructed in accordance with the present invention;
FIG. 2 is a cross sectional view of the crankshaft assembly of FIG. 1 showing fastening means within the shaft as an expansion block assembly, and further including a pedal attached to a left crank arm; and
FIG. 3 is a perspective view of a preferred embodiment of a shaft assembly, exploded to show the alignment of the two members and the cooperation of the node with the key slot.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1 is a perspective view of a hollow bicycle crankshaft 10 constructed in accordance with the preferred embodiment of the present invention. A hollow shaft assembly 12 is comprised of two segments, a first shaft member 14 and a second shaft member 16, which are made of cylindrical metal tubing. The first shaft member 14 includes a second shaft end 20. The second shaft member 16 has a third shaft end 22 and a fourth shaft end 24. The inner diameter of the first shaft member 14 preferably ranges between 0.75 inches and 1.125 inches. The second shaft end 20 of the first shaft member 14 receivingly engages the third shaft end 22 of the second shaft member 16 such that the parts 14,16 are coaxially aligned, and the second and third shaft ends 20,22 are concentrically mated, with approximately a one inch overlap. The outer diameter of the second shaft member 16 is relative to, and slightly smaller than, the diameter of the first shaft member 14. The overlap of the first and second shaft members 14,16 approximates the same aspect ratio as the inner diameter of the first shaft member 14, such that where the inner diameter of the first shaft member 14 is one inch, the overlap of the second and third shaft ends 20,22 are preferably also one inch.
Although the preferred embodiment is comprised of steel, it would be obvious to one skilled in the art that composite materials, high strength plastics, and the like could equivalently be used in the manufacture of the present invention.
A key slot 26 is formed through the second shaft member 16 from proximate the midsection 28 of the second shaft member 16 to the third shaft end 22, and is disposed in parallel with the longitudinal axis of the second shaft member 16. A depression 30 is formed on the outer surface 32 of the first shaft member 14. The key slot and depression form a key slot assembly, which will be described in further detail with the discussion of FIG. 3.
The fourth shaft end 24 is affixed to a hollow left crank arm 40, and projects into the hollow center of the crank arm 40 through an aperture 44 formed at a first end 48. The aperture 44 has a cylindrical shape and has a longitudinal axis that is disposed at a right angle to the longitudinal axis of the left crank arm 40. The right crank arm 38 includes an aperture 42 formed at a first end 46. The aperture 42 is disposed at a right angle to the longitudinal axis of the right crank arm 38.
Holes 50 and 52 are formed at second ends 54 and 56 of the right and left crank arms 38,40, each of which has a cylindrical shape and a longitudinal axis that is disposed at a right angle to the longitudinal axis of the respective crank arm 38,40. In an alternative embodiment, standard, clip-type or clipless pedals are permanently or removably attached to the crank arms 38,40 at the holes 50,52.
A tubular housing member 58 surrounds the shaft assembly 12. The tubular housing member 58 is shown partially broken away to reveal the shaft assembly 12 that is disposed within the tubular housing member 58 coaxially with the longitudinal axis of the tubular housing member 58. A second housing member end 64 is attached to the second shaft member 16 proximate the fourth shaft end 24 by a second shaft bearing 66.
A sprocket bracket 68 is attached to the first shaft member 14 proximate the right crank arm 38. The sprocket bracket 68 is provided for attaching bicycle drive means, such as a chain and sprocket assembly, to the hollow bicycle crankshaft 10.
A frame member 70 is affixed to the outer surface 72 of the housing member 58. A portion of the frame member 70 is shown broken away to reveal the shaft assembly 12. The frame member 70 is part of a fixed frame system (not shown) that provides the main structure of a bicycle. As the crank arms 38,40 are rotated, the shaft assembly 12 which is attached to the first ends 46,48 of the crank arms 38,40, respectively also rotates. The shaft bearing 66 that attaches the housing member 58 to the shaft assembly 12 allows the shaft assembly 12 to rotate, while the housing member 58 is kept stationary by the frame member 70.
FIG. 2 is a cross sectional view of the hollow bicycle crankshaft 10 of FIG. 1. The second shaft end 20 of the first shaft member 14 surroundingly engages the third shaft end 22 of the second shaft member 16. A first shaft end 18 (hidden from view in FIG. 1) mates with, and is welded to, the aperture 42 formed in the first end 46 of the right crank arm 38. The fourth shaft end 24 mates with, and is attached to, the aperture 44 formed in the first end 48 of the left crank arm 40. In an alternative embodiment of the present invention, the hole 50' is internally threaded for removably attaching a pedal assembly having a mating externally threaded pedal shaft.
The sprocket bracket 68 is permanently secured to the first shaft member 14 proximate the first shaft end 18 between the first shaft bearing 62 and the right crank arm 38, and is disposed in alignment with the shaft assembly 12. The housing member 58 provides a means for covering the shaft assembly 12, as it concentrically and coaxially surrounds the shaft assembly 12 to protect the shaft assembly from damage and dirt. A first housing member end 60 is attached to the first shaft member 14 proximate the first shaft end 18 by the first shaft bearing 62. The second housing member end 64 is attached to the second shaft member 16 proximate the fourth shaft end 24 by a second shaft bearing 66. The combination of the housing member 58, shaft assembly 12 and first and second shaft bearings 62,66 is commonly called a `bottom bracket` in the bicycle manufacturing trade.
The shaft bearings 62,66 allow the shaft assembly 12 to rotate within the stationary housing member 58. The load on the first shaft bearing 62 is transferred from the shaft assembly 12 and the sprocket bracket 68, while the load on the second shaft bearing 66 is transferred only from the shaft assembly 12. The first shaft bearing 62 is preferably sized to accommodate the expected load from the shaft assembly 12 and sprocket bracket 68. The second shaft bearing 66 is preferably smaller in size than the first shaft bearing 62, and is concomitantly lighter in weight than the first shaft bearing 62. The inclusion of a diminutive second shaft bearing 66 further reduces the overall weight of the hollow bicycle crankshaft 10 of the present invention.
Fastening means 74 are disposed within the shaft assembly 12 at the second and third shaft ends 20,22. When the first and second shaft members 14,16 are assembled to construct the shaft assembly 12, the fastening means 74 secure the engagement between the second and third shaft ends 20,22. An expansion block assembly 75 is shown as an example of fastening means 74. The expansion block assembly 75, positioned within the hollow third shaft end 22 of the second shaft member 16, is tightened (screwed in) so that the block arms 76 press against the inner surface 78 of the second shaft member 16. The outward pressure from the expansion block assembly 75, together with the expansion flexibility of the third shaft end 22 provided by the key slot 26 (hidden behind the tightening bolt of block assembly 75 in FIG. 2), forces the third shaft end 22 of the second shaft member 16 to expand in diameter until a secure interference fit is achieved between the second and third shaft ends 20,22. Although an expansion block assembly 75 is illustrated as the fastening means 74, it is anticipated that any other type of fastening means could be equivalently used.
The first shaft member 14 is joined with the second shaft member 16 to comprise the shaft assembly 12. The union of the second shaft end 20 of the first shaft member 14 and the third shaft end 22 of the second shaft member 16 is proximate the midsection of the resultant shaft assembly 12. The area of greatest load on the shaft assembly is proximate the first shaft end 18, where pedal force loads are transferred from the right crank arm 38 and where chain and sprocket resistance forces are transferred from the sprocket bracket 68. By welding the right crank arm 38 to the first shaft end 18 of the first shaft member 14 and positioning the union of the first and second shaft members 14,16 away from the area of greatest load, the strength and useful life of the shaft assembly 12 is maximized.
In an alternative embodiment, pedals are either permanently or removably attached to the holes 50,52 at the second ends 54,56 of the crank arms 38,40. A pedal 80 is shown permanently attached to the second end 56 of the left crank arm 40 at the hole 52. The pedal 80 comprises a hollow pedal shaft 82 having a first pedal shaft end 84 and a second pedal shaft end 86. The diameter of the first pedal shaft end 84 is larger than the diameter of the second pedal shaft end 86 such that the pedal shaft's form is tapered from proximate the midsection 88 of the pedal shaft 82 to the second pedal shaft end 86. A generally conically shaped pedal housing 90 surrounds the tapered portion of the pedal shaft 82. A first pedal housing end 92 is attached to the midsection 88 of the pedal shaft 82 by a roller bearing 94. A second pedal housing end 96 is smaller than the first pedal housing end 92, and is attached to the second pedal shaft end 86 by a ball bearing 98. The roller and ball bearings 94,98 allow the pedal housing 90 to remain stationary while the pedal shaft 82 and the left crank arm 40 (to which the pedal shaft is welded) rotate. A U-shaped foot pedal 100 is attached to the pedal housing 90 by cross members 102. Although a standard pedal is illustrated, it is anticipated that a standard, clip-type, clipless or any other type of pedal can also be used.
FIG. 3 is a perspective view of a shaft assembly 12, exploded to show the alignment of the first and second shaft members 14,16 and the cooperation of a node 34 within the key slot 26. The first shaft member 14 is partially cut away to show a node 34 formed in relief on the inner surface 36. The key slot 26 is formed through the second shaft member 16 from proximate the midsection 28 of the second shaft member 16 to the third shaft end 22, and is disposed in parallel with the longitudinal axis of the second shaft member 16. Opposite the depression 30 formed on the outer surface 32 of the first shaft member 14 is a node 34 comprising an area of relief formed on the inner surface 36 of the first shaft member 14 opposite the depression 30. The node 34 and the key slot 26 cooperate to provide a means for aligning the two shaft members 14,16 and in a predetermined disposition.
The location of the node 34 on the first shaft member 14 and the location of the key slot 26 on the second shaft member 16 cooperate to provide a means for aligning the two shaft members 14,16 in a position such that the right and left crank arms 38,40 are (not shown in FIG. 3 but shown in FIGS. 1 and 2) in a parallel and coplanar relationship. The cooperation of the node 34 and the key slot 26 is such that when the first and second shaft members 14,16 are joined, and the node 34 is slideably positioned within the key slot 26, the node 34 is restrained from rotational movement by the inner edges 104 of the key slot 26 such that there is no axial rotation between the first and second shaft members 14,16.
Although the preferred embodiment includes only one key slot 26 and node 34 assembly, those skilled in the art will realize that two or more key slot 26 and node 34 assemblies may equivalently be included.
The present invention has now been explained with reference to specific embodiments. Other embodiments will be apparent to those of ordinary skill in the art in light of this disclosure. Therefore it is not intended that this invention be limited, except as indicated by the appended claims. | A hollow bicycle crankshaft includes a hollow shaft assembly having a first shaft member fastened to a second shaft member, a hollow left crank arm, a hollow right crank arm, a tubular housing member, a first shaft bearing, a second shaft bearing, and a sprocket bracket. The first shaft member matingly engages the second shaft member. Non-mating ends of the shaft assembly are attached to respective hollow crank arms, where the shaft extends through an aperture in each arm. The union of the first and second shaft members is proximate the midsection of the constructed shaft assembly. The shaft assembly is housed within the tubular housing member. The first and second shaft bearings, disposed at each end of the housing member, secure the tubular housing member about the shaft assembly in coaxial and concentric alignment. The first shaft bearing is disposed at the end of the housing member that is adjacent to the sprocket bracket, and is larger than the second shaft bearing which is disposed on the opposing side of the housing member. | 8 |
BACKGROUND OF THE INVENTION
The corn kernel, illustrated in FIG. 1 , has a number of components, each being best suited for various uses. The process of modern dry corn milling seeks to segregate and separately process the below-identified parts of a kernel of corn as each part has a separate use. The hard outer shell is called the pericarp or the bran coat. The end of the corn kernel which adheres it to the corn cob is called the tip cap. The interior of the corn kernel consists of the endosperm and the germ. The endosperm is generally broken into two parts: soft endosperm and hard endosperm. For purposes of human consumption, the hard endosperm generally produces grits and corn meal, and the soft endosperm generally produces corn flour. The germ contains a much higher percentage of fat compared to the other parts of the kernel and is the source of corn oil.
Corn milling is an ancient practice to the human race, dating back many, many years. Historically, mill stones were utilized to grind the corn into meal. Wind and water powered mills developed several hundred years ago allowed for increased efficiency in the processing of corn. For the last hundred years or so, milling operations have utilized roll milling equipment in an effort to separate the components of the corn kernel for more particularized uses.
Modern roll milling equipment utilizes contiguous rollers with varying sized corrugations and varying sized roller gap spacings to achieve the desired particle size fractionation. Typically, mills employ rollers in series with increasingly narrow gaps in a gradual milling process. More specifically, the various parts of the corn kernel are segregated and removed to differing processing pathways, often referred to as streams. Initially, after cleaning the hard outer shell, the kernel is fractured via a mechanical process thereby freeing and removing the germ from the remaining parts of the kernel—a step called degermination. The remaining parts of the kernel are broken up by a series of rollers. As this material is processed, the hard outer shell is removed in the form of bran flakes, and the remaining soft and hard endosperm are further separated into differing streams by passing through a series of rollers and sifters which separate product by particle size. The end products of the dry corn milling operation are bran, grits, meal, flour, and high fat germ.
A flow scheme typical of prior art mills is illustrated in U.S. Pat. No. 5,250,313. In FIG. 5 of the '313 patent (reproduced herein as FIG. 2 ), the incoming corn is cleaned, washed, tempered to the appropriate moisture content, fractured or degerminated, and dried. Various designs exist to carry out the step of degermination. For example, the Ocrim degerminator uses a spinning rotor having combination blades to operate against a horizontal, perforated cylinder that only allows partial kernels to pass. The rotor and breaker bars are set to break the corn against a spiral rotor bar and a cutting bar. Another known degerminator is the Beall degerminator. In the Beall degerminator, grinding occurs through an abrasive action of kernel against kernel, and kernel against a nested conical surface and screen. Impact-type degerminators are also used. An example is the Entoletor degerminator as illustrated in FIG. 3 . The Entoletor includes a vertical drive shaft that operates a rotor. Kernels are fed downwardly towards the rotor where they are forced outwardly by centrifugal motion to impact a liner surface.
Generally, the product out of the degerminator is separated into a first stream which is relatively rich in endosperm and a second stream which is relatively rich in germ and bran. Specifically, with reference again to FIG. 2 , the degerminated corn is aspirated to effect initial density separation of the fractured kernel. The tailings and liftings from the aspirators are further separated through additional aspiration or the use of gravity tables. In general, bran, whole germ and germ contaminated particles obtained via density separation are lighter than other constituent parts and may be partially removed via gravity separation to be directed through a series of germ rollers and sifters. Separated, primarily endosperm-containing streams from the gravity tables and aspirators may be directed to different break rollers depending on the particle size of the stream. For example, those primarily endosperm-containing streams having smaller particle sizes may be directed past the first and second break rollers, or as illustrated in FIG. 2 , beyond to later break rollers.
The “break rollers” used in a gradual break process typically comprise corrugated rollers having roller gaps that cascade from wider roller gaps for the 1 st break roller to more narrow roller gaps for subsequent break rollers. Roller gaps are the spacings between the exterior or “tip” portions of the corrugations on opposing rollers. The use of 5 break rollers is typical, and roller gaps may vary depending on the desired finished product. Typical roller gap distances on prior art systems range from about 0.01 to about 0.07 inches, wherein smaller gaps result in finer particles. In general, the break rollers are operated such that opposing corrugated roller faces rotate at differing rates. FIG. 4 contains examples of typical prior art roller corrugation configurations. Most configurations present a sharp edge and a dull edge as determined by the slope of the corrugation surface. Therefore, breaking may occur under a sharp to sharp, sharp to dull, dull to sharp, or dull to dull arrangement of opposing corrugations.
After break rolling, the further-broken particles are separated, typically by a sifting process. From there, larger particles are further rolled in a subsequent break roller (and the further-broken particles are again sifted), or they are passed on to drying or cooling steps or additional sifting steps to isolate finished products (flour, meal, grits, etc.). Typical finished-product requirements may be found generally in 21 CFR §§ 137.215-285 (1993). Of course other products may be desired by particular purchasers. The remaining particles that fail to pass the post germ sifting steps are typically sent to a germ handling process (labeled oil recovery in FIG. 2 ). The finer particles obtained from the germ roller siftings are processed in a manner generally similar to the finer particles from the break rollers.
Traditionally, large scale corn mills have employed a great degree of redundancy and repetitive processing of the grain. For example, as illustrated in FIG. 2 , a traditional corn milling process involves an initial degermination step, followed by five separate roller, or breaking, steps each of which is followed by sifting steps. In addition, the prior art includes various shorter mill processes wherein fewer roller steps are utilized, germ streams are extracted from the mill stream earlier in the process, and valuable capital, space and time savings are achieved. See for example the process described in the '313 patent. The shortened mill regimes also dramatically reduce production expense by lowering the labor costs associated with the milling process due to the reduced maintenance and monitoring required of a much shorter process.
Nevertheless, even in the prior art “shortened” mill flow regimes, inefficiencies remain. For example, U.S. Pat. No. 4,189,503 (a parent from which the '313 patent is a continuation-in-part), teaches the use of a preferred degermination and rolling process to avoid breakage of the germ. These patents also teach the separation of degermination products into three streams, one of which is a “fine” stream relative to the others (see FIGS. 6, 7, and 8 of the '313 patent and accompanying text). The '313 and '503 patents specifically teach the reintroduction of this fine stream into the other less carefully graded streams after the other streams have been subjected to various other steps, such as tempering and drying (See claim 8 of the '503 patent). The '313 and '503 patents therefore specifically teach the separation or gradation of post degermination product for the purpose of avoiding the addition of moisture to the separated fines (See '313 patent, Col. 11, Lines 4-14) followed by the subsequent reintroduction of the fine stream into a mixed stream. With only a reference to fines, these patents do not teach or provide motivation to isolate finished product streams as early in the milling process as a post degermination sifting. In fact, the '313 patent teaches a process wherein the product stream from the degerminator to the first break roll comprises bran, endosperm and germ. In addition, the reintroduction of the sifted “fines” streams into other streams “contaminates” the sifted stream and increase the flow across subsequent sifters.
FIG. 9 of the '313 patent does disclose a process wherein a combined stream having germ, grit, meal, and flour-sized particles, immediately downstream of a degerminator sifter, is passed to a secondary grading sifter and aspiration processes to separate flour, meal, brewer's grits, and a feed/oil recovery product without post-degermination rolling. It is shown, however, that the process of FIG. 9 in the '313 patent specifically depends upon the preferred degerminator described in the '313 patent and its parent applications. The '313 patent specifically distinguished its preferred degerminator over impact-type degerminators. The preferred degerminator of the '313 patent is described therein and claimed in the '503 patent, claim 1, et. seq.; U.S. Pat. No. 4,301,183, claim 1 et. seq.; and U.S. Pat. No. 4,365,546.
SUMMARY OF THE INVENTION
The present invention is an improvement upon the prior art in that the present invention does not contaminate or intermix the separated streams with less specifically graded streams once the finished product stream has been isolated. This results in a dramatic decrease in handling and a reduction or elimination of flow across subsequent process steps. This also increases the through-put of product allowing for the processing of an increased volume of corn in a given time, or allows for the elimination of excess processing equipment. By contrast, the net result of the process taught in the '313 and '503 patents is the contamination of the initially separated fine stream. In the present invention, a sifted end-product-grade stream is obtained from the degermination sifting or grading step and is directed towards storage or finished product handling (storage, packaging, quality control, etc.). If mixing of this stream occurs, it involves the blending of similarly sifted streams having particles of the same gradations, i.e., addition of a similar finished product stream.
The present invention is a short flow corn mill having a dramatically reduced number of process steps with a commensurate reduction in processing and handling equipment, process monitoring and maintenance labor costs, and process space requirements. This mill design utilizes fewer, but more aggressive break subsystems instead of 5 gradual break subsystems to appropriately shorten the flow while providing exceptional quality and yield performance. The present invention may employ zero to three break rollers in series (or more if parallel operations or redundancies are desired for system stability, etc., preferably from 1 to 3 break rollers. Finished product is withdrawn from process streams when it is first separated, without further intermixing of already separated streams and without a need for further production sifting. This separation occurs early in the short mill process—as early as separation of the degermination stream. In addition, an embodiment of the present invention includes the diversion of other streams at early points in the milling process to a separate hammer-mill process for the production of flour. This diversion of product to a hammer-mill process additionally eliminates product from the stream and further reduces the amount of handling, intermixing, and possible contamination of already separated streams with product of different gradations. Further, these diversions reduce the flow on rollers and on later portions of the mill. Therefore, efficiency is achieved by the rapid isolation and removal of finished product from the stream. Further, yield as well as efficiency is improved. Average corn milling yields for this industry are 180#s (#s representing pounds) (180#s of raw corn to produce 100#s of finished product). The new short flow milling technology produces finished product with a 129# yield which is the best in the industry (it is believed that the industry best has been 135 prior to the new short flow technology).
The dramatic elimination of components and the accompanying conduits and transport equipment needed to combine such components (from as many as 450 machines to produce 260,000 #s/hr in known prior art large scale mill processes to fewer than 85 machines to produce 160,000 #s/hr), allows for tremendous space savings. Additionally, monitoring and maintenance needs can be greatly reduced with the short flow process. Of course, these benefits make possible the method of the present invention for easily transportable, on-site milling applications. Simply put, when the process may be simplified to eliminate redundancy in rolling and sifting, eliminate steps required to attain a finished product, and reduce monitoring and maintenance needs, the milling process may be taken from an isolated production facility and milling may be instituted on location.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a enlarged diagram of a kernel of corn to display the constituent portions of the kernel.
FIG. 2 is a flowchart of a typical prior art gradual break milling process.
FIG. 3 is a front elevational view of a prior art Entoletor impact degerminator.
FIG. 4 is an illustration of prior art break roller corrugations.
FIG. 5 is a block diagram of the short flow grain milling process in a first preferred embodiment.
FIG. 6 is a block diagram of the short flow grain milling process in a second preferred embodiment.
FIG. 7 is a table of preferred corrugation, roller configuration, and roller gap product goals.
DETAILED DESCRIPTION OF THE INVENTION
In the present invention, kernels are received and the kernels may, optionally, be pre-treated in any manner required to maximize the production of the desired end product (grits, meal, flour, etc.). For example, the corn is most commonly cleaned through impact de-infestation or washing. The choice of a cleaning method will depend upon the desired end product, as even the cleaning steps may result in breakage of kernels or an alteration in the moisture content. Additionally, pre-treatment may involve tempering or moisturizing of the corn with water, hot water and/or steam, although this is not necessary.
Because the corn kernel's constituent parts, as illustrated in FIG. 1 and as discussed above, comprise separate components of distinct character, each absorbs moisture differently and this differential absorption impacts degermination efficacy. For example, the pericarp or bran coat may be brittle without tempering, but tempering creates a more pliable bran coat that is more likely to be removed intact or as a particle of larger size. Similarly, tempering may aid the release of the germ still in connection with the tip-cap. This allows the removal of the tip-cap with the germ and a reduction in the number of black tip-caps that may be further milled and result in discoloration of the finished product. In fact, the '313 patent teaches tempering as a method for facilitating the shortened process. However, tempering necessarily increases production costs through energy expense for drying, and tempering is not necessary to practice the present invention.
After cleaning, and the optional and/or desired pre-treatment, the corn is degerminated. In the currently preferred embodiment, the corn is degermed without the use of tempering and is accomplished with an impact degerminator. This preferred method of degermination typically achieves breakage of the kernel into relatively large pieces, dislodging the germ. Degermination is followed by a separation step. Degermination may be followed by a drying step prior to separation if tempering is elected, or drying may occur later.
The post-degermination sifter is herein referred to as a “hominy grader.” The hominy grader segments the broken corn into various streams depending on granulation-the size of the product granules. The finer granulated streams, such as low fat meal and flour streams are directed as finished product from the hominy grader to eliminate excessive handling and deterioration of product quality. Optionally, the meal stock may be directed towards a hammer-mill or flour grinder if greater flour output is desired. By extracting finished product as soon as possible, the mill flow can be greatly reduced as further sifting of an already isolated stream is not required.
The medium granulated streams from the hominy grader are sent directly to aggressive 2 nd and 3 rd (in series) break roll subsystems via aspirators. When sent directly to the 2 nd break roll subsystem, the stream does not pass first through the 1 st break roll subsystem. When sent directly to the 3 rd break roll subsystem, the stream does not pass first through either the 1 st or 2 nd break roll subsystems. Therefore, the present invention allows for the processing of a greater volume without increasing the load on a particular roller. The aspiration step helps to break apart combined particles and further separate any remaining bran, germ or other non-endosperm material from the endosperm material. Preferred aspirators comprise cascading angled surfaces having periodic ports in the sidewalls to allow a cross stream of air to “blow” loosened bran from the falling particles. The liftings removed via aspiration may be directed to bran processing as a high value input.
The coarse granulated streams from the hominy grader are sent to gravity tables via aspiration. From the gravity tables, a lighter germ and germ-contaminated stream may be directed onward to an oil or germ recovery process. The remaining portions of the coarse product stream are sent to the aggressive 1 st break roll (in series) via aspiration.
No whole corn kernels are sent to re-degermination since the degerminator is effectively breaking the corn in one step. From each sifting step, including the hominy grader and the post 1 st , 2 nd , and 3 rd break siftings, finished product flour and meal may be isolated and removed from the mill stream.
With specific reference to FIG. 5 , a first preferred embodiment of the present invention operates as follows. The input corn is cleaned and degerminated prior to arrival at the hominy grader. In the hominy grader, a number 6, 12, 30, and 62 wire mesh screen is employed to separate the particles from degermination. Alternative screen sizes may be employed to produce finished product having the desired particle size profiles and ranges (for example, see 21 CFR 137 regarding classification of finished products). The overs (particles that do not pass through) the number 6 screen are directed towards a gravity table via aspiration. From the gravity table, the lighter germ and germ contaminated material is removed and directed to a germ or oil recovery process. It has been found that at or above 95% of the germ is removed from the process stream at this point. The heavier particles from the gravity table are directed to a first break roller. The overs from the number 12 screen of the hominy grader are directed towards a second break roller via aspiration. The overs from the number 30 screen of the hominy grader are directed towards a third break roller via aspiration. Finally, the overs from the number 62 screen of the hominy grader are directed onward as finished product meal, whereas those portions that pass the number 62 screen are directed onward as finished product flour. Upon inspection, typically based on fat content, the meal finished product stream may be diverted for grinding to flour.
Although the present invention is described with reference to a sharp meal obtained between number 30 and number 62 wire screens, meal may be classified or obtained from other ranges as is known to those in the art. For example, a meal top screen may range from about a number 30 to about a 46 and a meal bottom screen may range from about a 46 to about a 72. Similarly flour may be that portion that passes screens ranging from about a number 46 screen to about a number 72 screen. Therefore, although specific number wire mesh screens are referenced herein to describe the preferred embodiments, it is understood that the present invention may be practiced to achieve alternate finished product particle profiles.
The first break roller typically employs rollers having 14 corrugations per inch with a dull to dull arrangement. The roller distance is typically adjusted after production begins. These adjustments allow operators to achieve target percentages for the differently sized particles coming off the rollers-i.e., the percentage of the roller output that falls into each screen size in the post-roller sifting step. It is, however, to be understood that the corrugations, roller set-up and product output goals disclosed herein are preferred embodiments and that the present invention is intended to encompass those changes instituted to maximize the overall mill output of particular product streams (meal, flour, etc.).
From the first break roller, rolled particles are sifted with a number 12, 30, and 62 wire mesh screen. Flour and meal are removed as finished product from the milling stream, as before. The overs from the number 12 screen are sent to the second break aspirator (along with the overs from the number 12 screen of the hominy grader), and the overs of the number 30 screen are sent to the third break aspirator.
The second break rollers typically employ 14 corrugations/inch, and a dull to dull configuration. From the second break roller, rolled particles are sifted with a number 12, 30, and 62 wire mesh screen. Flour and meal are removed as finished product from the milling stream, as before. The overs from the number 12 screen are sent to the germ or oil recovery, and the overs of the number 30 screen are sent to the third break aspirator. Removal of the largest remaining particles from this step to oil recovery and germ processing further reduces the milling stream and limits the fat content of the remaining product.
The third break rollers employ 20 corrugations/inch, a dull to dull configuration. From the third break roller, rolled particles are sifted with a number 22, 30, and 62 wire mesh screen. Flour and meal are removed as finished product, as before. Overs from the 30 screen are directed to grinding, such as a hammermill process to produce flour. Overs from the 22 screen are directed towards a bran dusting step to abrade remaining bran. The bran recovered from the bran duster may be sent to a bran flour or other bran product process. The remains from the bran dusting process may, if desired be directed to re-enter the process at the hominy grader.
All grinder stock (including the overs from the number 30 screen of the third break sifter and some or all finished product meal if meal production is not desired) is ground, through a process such as hammer-milling to generate flour. Simple sifting with a flour screen (here a 62 wire screen) may be used to isolate additional finished product flour and redirect the overs of the flour screen for additional grinding. Throughout the process disclosed in FIG. 5 , at sifting steps in particular, additional screens may be included. This adds the advantage of further separating streams with potentially valuable uses.
In another preferred embodiment, illustrated in FIG. 6 , the streams from the gravity table separator are further divided to include diversion to a gravity table germ aspirator. From the gravity table germ aspirator, product is directed to a gravity table germ roller and sifter. The gravity table roller preferably includes 12 corrugations per inch. The gravity table germ roller sifter employs a number 12, 30, and 62 wire mesh screen. Flour and meal finished products are directed onward as before. The overs of the number 12 screen are directed to germ or oil recovery processing, and the overs of the number 30 screen are directed onward to third break rollers via aspiration. The roller setting data, corrugation data, and roller arrangement for this preferred embodiment are provided in Table 1. The preferred roller specifications presented herein for the break rollers are more typical of those roller specifications applied in later roller stages of a typical prior art system.
It has been found that the preferred embodiment described in FIG. 6 is capable of producing meal and flour in accordance with the data shown in Table 1 below. Further, Table 2 illustrates the percentage of product obtained from the various sifting steps.
TABLE 1
ROLLER SETTING DATA
Prod
Prod
Corrugations/
Distribution
Distribution
Roll
inch
Roll Set Up
Target
Target
1 st Break
14/inch
Dull to Dull
7% +
9% max +
12 mesh
12 mesh
GTG
12/inch
Dull to Dull
20% +
22% max +
12 mesh
12 mesh
2 nd Break
14/inch
Dull to Dull
8% +
10% max +
12 mesh
12 mesh
3 rd Break
20/inch
Dull to Dull
3% +
5% max +
22 mesh
22 mesh
TABLE 2
Meal Sieving
Meal
Wires
%
Flour
HOMINY GRADER SIFTER 250 CWT/HR HEAD FEED
Fat
1.40%
+20
Trace
Fat
1.17%
Moist
11.70%
+25
1.14%
Moist
12.56%
−70
1.00%
1 st BREAK SIFTER DISTRIBUTION 65 CWT/HR HEAD FEED
Fat
1.12%
+20
Trace
Fat
0.98%
Moist
10.80%
+25
0.71%
Moist
13.50%
−70
0.85%
GT GERM SIFTER DISTRIBUTION 58 CWT/HR HEAD FEED
Fat
3.51%
+20
Trace
Fat
2.26%
Moist
13.26%
+25
0.86%
Moist
12.70%
−70
0.22%
Meal Sieving
Meal
Wires
%
Flour
2 ND BREAK SIFTER DISTRIBUTION 86 CWT/HR HEAD FEED
Fat
1.33%
+20
Trace
Fat
1.49%
Moist
13.55%
+25
1.54%
Moist
13.12%
−70
0.34%
3 RD BREAK SIFTER DISTRIBUTION 152 CWT/HR HEAD FEED
Fat
1.22%
+20
Trace
Moist
13.10%
+25
0.70%
−70
0.02%
It will be apparent to those skilled in the art that the short flow design provides a finished product much faster in the milling process than typical full scale milling operations (hominy grader vs. 1 st or 2 nd break sifter). Each break sifter on the short flow produces finished product as contrasted with typical milling methods where secondary handling and sifting are required. Further, intermediate product streams are reduced to flour unlike other systems which use germ, tailings and purifier subsystems to reclaim poorer quality meal streams. This provides very high quality meal/flour with minimal equipment, reduced monitoring and maintenance needs, and superior yield performance. The basic milling philosophy behind the development of a shorter corn milling flow is to produce finished product faster, cheaper and better. This and the other objectives of the present invention are achieved through the application of the preferred mode and the invention as claimed herein.
Having thus described the invention in connection with the preferred embodiment thereof, it will be evident to those skilled in the art that various revisions can be made to the preferred embodiments described herein without departing from the spirit and scope of the invention. It is my intention, however, that all such revisions and modifications that are evident to those skilled in the art will be included within the scope of the following claims. | The present invention is a short flow milling process wherein finished product is rapidly isolated and removed from the milling process flow regime at early stages. The minimization of handling and the minimization or elimination of intermixing streams of various size gradations prevents size contamination that otherwise necessitates further sifting. Component parts are eliminated along with the accompanying handling and transfer equipment to create a compact and efficient milling regime. The size reductions enable the invention to be practiced in a mobile form. Therefore, the present invention relates also to a method for providing a mobile mill process. | 1 |
BACKGROUND OF THE INVENTION
The present invention relates to a fluid flow regulator for controlling the amount of fluid flow through the regulator and has specific application as a control valve for an internal combustion engine positive crankcase ventilation (PCV) system.
Existing PCV systems conduct crankcase blow-by gases to the intake manifold through a variable orifice valve, and the opening of this variable orifice valve is controlled by intake manifold vacuum. In existing PCV systems at high manifold vacuum the valve is closed; and a small orifice handles the flow. At manifold vacuums of 12 to 15 inches of mercury, the valve begins to open, thus increasing the flow capacity to handle the increased blow-by of the engine as the manifold vacuum decreases.
In the prior art PCV systems the valve is typically a mechanical valve having a tapered valve element that is spring loaded. The tapered valve element moves on and off the valve seat to an extent which is determined by the amount of intake vacuum to thereby provide the metering or regulation of the total amount of PCV gas flow in dependence upon the position of the valve element with respect to the valve seat.
The mechanical PCV valves of the prior art PCV systems present a number of problems.
The valve element itself is subjected to a great deal of mechanical abuse as it is moved back and forth and on and off the valve seat with changes in suction in the engine induction system. The PCV valve slams against the valve seat so hard that it tends to beat itself to death, and these valve elements therefore have to be made of specially hardened steel to provide any useful period of operation.
The mechanical operated PCV valve elements of the prior art also had a tendency to become gummed up by the PCV gases so as to cause sticking of the valve element on the valve seat. The gumming up problem can also cause a change of the orifice size prior to actual sticking; and both the changing of the orifice size and the actual sticking of the PCV valve caused substantial impairment of engine performance.
The prior art, mechanical type PCV valves also present maintenance problems. Major automobile manufacturers require that PCV valves be inspected every twelve months and replaced every two years.
It is a primary object of the present invention to construct a PCV flow regulator which provides a variable orifice valve function without any moving parts and which eliminates and avoids the problems of the prior art PCV valves.
SUMMARY OF THE PRESENT INVENTION
The present invention comprises a fluid flow regulator which provides a variable orifice valve function without any moving parts.
The fluid flow regulator controls the amount of fluid flow or pressure of the fluid flowing through the regulator by producing an impedance to flow through the regulator which varies in relationship to the pressure differential across the regulator and which also varies in relationship to an acceleration in the fluid flowing through the regulator. The regulator has a shape which produces an acceleration in the fluid flowing through the regulator to cause the flow itself to vary the impedance to flow through the regulator.
In a specific embodiment the fluid flow regulator is used as a replacement for existing, mechanical PCV valves for internal combustion engines. The flow regulator has an inlet and an outlet and a variable impedance producing structure between the inlet and the outlet.
In one particular embodiment the structure which produces the variable impedance comprises a vortex chamber which imparts a swirl to the fluid flowing between the inlet and the outlet. A control orifice may be located in either the inlet or the outlet and is formed with a size matched to the displacement of the engine for providing further control of the impedance.
The inlet may include a shaped opening having a varying internal diameter for permitting a swirl to be produced in the incoming fluid to provide a controlled choking of the flow through the inlet. Slots may also be formed in the sidewall of the inlet and arranged tangentially with the inner surface for producing a swirl of the fluid flowing through the inlet.
The PCV flow regulator using the vortex chamber holds the PCV flow more stable than a movable plunger PCV valve and accomplishes this function without any moving parts.
The outlet preferably has an inner surface formed with a plurality of grooves for providing turbulent mixing and ultrasonic wave fronts in the outlet fluid flow. This outlet, in the PCV valve embodiment of the present invention, is connected to an entrance to the induction system of the engine below the butterfly valve.
In one form of the invention the inlet includes an adapter for insertion into the existing PCV outlet of the engine. In another form of the invention, the adapter is formed as an integral part of the flow regulator housing so that the flow regulator housing is mounted directly into the existing PCV opening of the engine.
Other and further objects of the present invention will be apparent from the following description and claims and are illustrated in the accompanying drawings which, by way of illustration, show preferred embodiments of the present invention and the principles thereof and what are now considered to be the best modes contemplated for applying these principles. Other embodiments of the invention embodying the same or equivalent principles may be used and structural changes may be made as desired by those skilled in the art without departing from the present invention and the purview of the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side elevation view, partly in cross section to show details of construction, of a PCV control valve system incorporating a vortex chamber as the control valve element. FIG. 1 also incorporates a variable, adjustable air bleed inlet to the PCV vortex chamber.
FIG. 2 is a cross sectional view, taken along the line and in the direction indicated by the arrows 2--2 in FIG. 1 but showing an alternate embodiment of the PCV control valve in which alternate embodiment the PCV gases do not enter on the axis of the vortex chamber but instead enter perpendicular to the air bleed flow entrance as shown in FIG. 2.
FIG. 3 is a view taken along the line and in the direction indicated by the arrows 3--3 in FIG. 1.
FIG. 4 is a side elevation view of another embodiment of a PCV control valve system incorporating a vortex chamber as the control valve. In the FIG. 4 embodiment the PCV gases are introduced to the vortex chamber tangentially.
FIG. 5 is a view taken along the line and in the direction indicated by the arrows 5--5 in FIG. 4.
FIG. 6 is a view like FIG. 4 but showing an embodiment of the invention in which the PCV valve adapter is made an integral part of the vortex chamber housing structure so that the lower end of the housing can be inserted directly into the existing opening in the rocker box cover of the engine. The FIG. 6 embodiment eliminates the need for the adapter shown in the FIG. 4 embodiment.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 is a side elevation view, partly in cross section to show details of construction of a PCV control valve system incorporating a vortex chamber as the control valve element. The PCV control valve system is indicated generally in FIG. 1 by the reference numeral 17, and the system 17 also incorporates a variable, adjustable air bleed inlet to the PCV vortex chamber.
The air-PCV gas vortex chamber 17 preferably includes a shaped inlet 41 for admitting air and a conduit 43, having an internal control orifice 45, for admitting PCV gases. However, this shaped inlet and swirl produced by slots 47 (as described in more detail below) are not essential. The vortex chamber 17 can be used along with a straight inlet.
The shaped air inlet 41 includes a plurality of slots 47 which, as best illustrated in FIG. 3, are disposed tangentially to the inner surface of the opening 41 for providing swirling motion of the incoming air in the direction indicated by the arrows in FIG. 3. This, in effect, produces two vortexes in series--a vortex within the inlet and a second vortex within the vortex chamber 17.
The curved opening 41 tapers down to a throat 49, and an adjustable screw 51 enables the diameter of the throat to be varied. The screw 51 shown in the FIG. 1 embodiment enables the effective diameter of the throat to be varied but can cause some distortion of flow. The more preferred form of the adjustable screw 51 is shown in FIG. 6. In FIG. 6 the screw 51 is maintained concentric with the throat area throughout all adjustment of the screw 51 to avoid flow distortion. The screw 51 in FIG. 6 is mounted in a flange that has openings 50 for flow off fluid to the orifice 49. The FIG. 6 embodiment can also be incorporated in this FIG. 1 structure, and in this case the mounting plate extends across the entire lower end of the passageway 41 and does not necessarily include openings 50 so that the entire flow of incoming air must pass through the slots 47.
The throat 49 opens into the interior of the vortex chamber 17 on a tangential path so that the incoming air produces a swirling motion with the vortex chamber.
The end 53 of the PCV gas conduit 43 is aligned axially and on the center of the swirling gases, so that the swirling gases produce a suction effect on the end 53. The general principle of operation of the air-PCV vortex chamber 17 is to produce a mass flow through the vortex chamber which is dependent upon the pressure differential between the inlet and the outlet of the vortex chamber and the acceleration of flow within the vortex chamber. However, the air-PCV vortex chamber of the FIG. 1 embodiment of the present invention has an entrance construction which regulates the mass flow through the vortex chamber in dependence upon the restricting or choking effect produced by the spin imparted to the air flowing through the shaped opening 41. Thus, the shaped opening 41, in combination with the slots 47 and the adjustable screw 51 at the throat 49 provide for controlled variation of the mass flow through the air-PCV vortex chamber 17, and this control acts in series with the regulation of the mass flow provided by the spin imparted by the inner surface of the vortex chamber itself.
The inner surface 21 of the outlet of the vortex chamber 17 is preferably formed with grooves 84 which produce turbulent mixing and an ultrasonic effect.
In a particular embodiment of the vortex chamber 17 the diameter of the orifice 45 is 0.1 inch.
The internal diameter of the inlet 53 is 0.210 inch. The maximum internal diameter of the vortex chamber 17 is 0.750 inch.
The minimum diameter of the throat 49, without adjustment of the screw 51, is 0.3125 inch. The screw 51 permits the diameter to be adjusted down to the equivalent of 0.156 inch.
The minimum diameter of the outlet throat 85 is 0.25 inch. The maximum depth of the slots 38 and 84 is 0.05 inch.
The slots 47 have a width of approximately 0.05 inch.
In the operation of the air-PCV gas vortex chamber 17 shown in FIG. 1, the maximum pressure differential between the inlet 41 and the outlet 21 of the vortex chamber 17 occurs at idle, but the PCV-gas flow through the conduit 43 under idle operation of the engine is basically the same as throughout the normal cruising power range. This results because the construction and operation of the inlet 41 provide a choking effect under high engine intake manifold vacuum conditions to restrict intake air flow through the shaped opening 41 and this restriction works in combination with the mass flow stabilizing effect of the vortex chamber itself under changing vacuum conditions within the intake manifold to provide a substantially stabilized flow of PCV gases throughout the operating range of the engine. In this regard, the spinning and restricting effect of the shaped opening 41 decreases as the vacuum below the butterfly valve decreases to permit freer flow of air through the throat 49 into the vortex chamber 17 as the engine power levels go up.
FIG. 2 is a cross-sectional view which is oriented along the line in the direction indicated by the arrows 2--2 in FIG. 1. Howvever, FIG. 2 actually shows an alternate embodiment 61 of the PCV control valve. In this alternate embodiment, the PCV gases do not enter on the axis of the vortex chamber, but instead enter perpendicular to the axis bleed flow entrance 49. That is, the inlet 53 to the vortex chamber for the PCV gases comes in perpendicular to the flow of spinning air that is coming through the air inlet 49. At the point 53, a vacuum is created which is comparable to the vacuum created by the corresponding opening 53 of the FIG. 1 embodiment, which opening in the FIG. 1 embodiment is aligned with the axis of spin of the air within the vortex chamber.
The FIG. 2 embodiment thus provides flexibility in construction of the vortex chamber so that the particular PCV gas entrance 53 can be located in either the FIG. 1 or the FIG. 2 location, depending upon which location is most convenient for a particular application.
FIG. 4 is a side elevation view of another embodiment of a PCV control valve system incorporating a vortex chamber as a control valve. In the FIG. 4 embodiment, the PCV control valve system is indicated generally by the reference numeral 71.
Both the FIG. 4 embodiment (and the FIG. 6 embodiment to be described below) are direct replacements for existing PCV valves, and the FIG. 4 and FIG. 6 embodiments of the present invention provide the valving function without any moving parts.
The FIG. 6 embodiment is basically the same construction, and operates in substantially the same way as the FIG. 4 embodiment, so far as the vortex chamber valve itself is concerned. The FIG. 4 embodiment incorporates an adapter 73 used with the inlet conduit 75 so that the adapter 73 can be placed directly into the existing opening in the rocker box of the engine in place of the original PCV valve.
The FIG. 6 embodiment incorporates an adapter shape 77 molded as a part of the vortex chamber housing itself so that the housing can be inserted directly into the existing opening in the rocker box cover in place of the conventional PCV valve.
The structure of the vortex chamber itself in both the FIG. 4 embodiment and the FIG. 5 embodiment is substantially the same as that of the FIG. 1 embodiment, but without the curved inlet 41, slots 47, or adjustment screw 51.
The FIG. 4 embodiment, as compared with the FIG. 6 embodiment, provides the posibility of a minimum length of travel between the outlet of the vortex chamber 21 and the PCV opening.
The FIG. 6 embodiment offers the advantage of simplicity of the unitary, one piece assembly capable of being inserted directly into the existing opening in the rocker box cover without any additional or auxiliary adapter units.
The FIG. 4 embodiment maximizes the turbulent intermixing of the PCV gases with the air fuel mixture downstream of the butterfly valve 19 because of the short length of the connection between the vortex chamber and ported vent opening.
In each of the vortex chamber valve constructions shown in FIGS. 4 and 5, there is a control orifice 49 which serves the purpose of matching the flow of the PCV gases to the cubic inch displacement of the engine. Orifice 45 provides this function in FIG. 1.
The reason that the PCV vortex chamber valve systems shown in the various drawings work without moving parts is that the inherent characteristics of the vortex chamber act as a variable impedance flow restricting device. That is, the vortex chamber itself, in its simplest form, provides an impedance to the flow through the vortex chamber which is a square root function of the pressure differential between the inlet and outlet of the vortex chamber (again assuming a simple vortex chamber without any inlet choking or restriction).
The vortex chamber valve of the present invention has been found, by actual installation and testing, to entirely replace existing mechanical valve PCV valve constructions while providing greater flow stabilization of the PCV gases throughout the power operating range of the engine than provided by mechanical, moving part, suction operated existing PCV valves.
The vortex chamber valve construction of the present inventon also has the distinct benefit of being substantially less subject to gumming up than mechanical moving valve type PCV valves.
While I have illustrated and described the preferred embodiments of my invention, it is to be understood that these are capable of variation and modification, and I therefore do not wish to be limited to the precise details set forth, but desire to avail myself of such changes and alterations as fall within the purview of the following claims. | A fluid flow regulator controls the amount of fluid flow or pressure of the fluid flowing through the regulator by producing an impedance to flow through the regulator which varies in relationship to the pressure differential across the regulator and which also varies in relationship to an acceleration in the fluid flowing through the regulator. The regulator has a shape which produces an acceleration in the fluid flowing through the regulator to cause the flow itself to vary the impedance to flow through the regulator. In a specific embodiment the fluid flow regulator is a vortex chamber and can be used as a replacement for existing, mechanical PCV valves for internal combustion engines. The flow regulator of the present invention provides a variable orifice valve function without any moving parts. | 8 |
This application is a continuation of Ser. No. 07/690,949, now abandoned, which is a 371 filing of PCT/EP90/01593, filed Sep. 19, 1990.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates to recombinant polypeptides and peptides, which can be used for the diagnosis of tuberculosis. The invention also relates to a process for preparing the above-said polypeptides and peptides, which are in a state of biological purity such that they can be used as part of the active principle in the preparation of vaccines against tuberculosis.
It also relates to nucleic acids coding for said polypeptides and peptides.
Furthermore, the invention relates to the in vitro diagnostic methods and kits using the above-said polypeptides and peptides and to the vaccines containing the above-said polypeptides and peptides as active principle against tuberculosis.
By "recombinant polypeptides or peptides" it is to be understood that it relates to any molecule having a polypeptidic chain liable to be produced by genetic engineering, through transcription and translation, of a corresponding DNA sequence under the control of appropriate regulation elements within an efficient cellular host. Consequently, the expression "recombinant polypeptides" such as is used herein does not exclude the possibility for the polypeptides to comprise other groups, such as glycosylated groups.
The term "recombinant" indeed involves the fact that the polypeptide has been produced by genetic engineering, particularly because it results from the expression in a cellular host of the corresponding nucleic acid sequences which have previously been introduced into the expression vector used in said host.
Nevertheless, it must be understood that this expression does not exclude the possibility for the polypeptide to be produced by a different process, for instance by classical chemical synthesis according to methods used in the protein synthesis or by proteolytic cleavage of larger molecules.
The expression "biologically pure" or "biological purity" means on the one hand a grade of purity such that the recombinant polypeptide can be used for the production of vaccinating compositions and on the other hand the absence of contaminants, more particularly of natural contaminants.
2. Description of the Prior Art
Tuberculosis remains a major disease in developing countries. The situation is dramatic in some countries, particularly where high incidence of tuberculosis among AIDS patients represents a new source of dissemination of the disease.
Tuberculosis is a chronic infectious disease in which cell-mediated immune mechanisms play an essential role both for protection against and control of the disease.
Despite BCG vaccination, and some effective drugs, tuberculosis remains a major global problem. Skin testing with tuberculin PPD (protein-purified derivative) largely used for screening of the disease is poorly specific, due to cross reactivity with other pathogenic or environmental saprophytic mycobacteria.
Moreover, tuberculin PPD when used in serological tests (ELISA) does not allow to discriminate between patients who have been vaccinated by BCG, or those who have been primo-infected, from those who are developing evolutive tuberculosis and for whom an early and rapid diagnosis would be necessary.
A protein with a molecular weight of 32-kDa has been purified (9) from zinc deficient Mycobacterium bovis BCG culture filtrate (8). This 32-kDa protein of M. bovis BCG has been purified from Sauton zinc deficient culture filtrate of M. bovis BCG using successively hydrophobic chromatography on Phenyl-Sepharose, ion exchange on DEAE-Sephacel and molecular sieving on Sephadex G-100. The final preparation has been found to be homogeneous as based on several analyses. This P 32 protein is a constituent of BCG cells grown in normal conditions. It represents about 3% of the soluble fraction of a cellular extract, and appears as the major protein released in normal Sauton culture filtrate. This protein has been found to have a molecular weight of 32 000 by SDS-polyacrylamide gel electrophoresis and by molecular sieving.
The NH 2 -terminal amino acid sequence of the 32-kDa protein of M. bovis BCG (Phe-Ser-Arg-Pro-Gly-Leu) is identical to that reported for the MPB 59 protein purified from M. bovis BCG substrain Tokyo (34).
Purified P 32 of M. bovis BCG has been tested by various cross immunoelecrophoresis techniques, and has been shown to belong to the antigen 85 complex in the reference system for BCG antigens. It has been more precisely identified as antigen 85A in the Closs reference system for BCG antigens (7).
Increased levels of immunoglobulin G antibodies towards the 32-kDa protein of M. bovis BCG could be detected in 70% of tuberculous patients (30).
Furthermore, the 32-kDa protein of M. bovis BCG induces specific lymphoproliferation and interferon-(IFN-γ) production in peripheral blood leucocytes from patients with active tuberculosis (12) and PPD-positive healthy subjects. Recent findings indicate that the amount of 32-kDa protein of M. bovis BCG-induces IFN-γ in BCG-sensitized mouse spleen cells is under probable H-2 control (13). Finally, the high affinity of mycobacteria for fibronectin is related to proteins of the BCG 85 antigen complex (1).
Matsuo et al. (17) recently cloned the gene encoding the antigen α, a major protein secreted by BCG (substrain Tokyo) and highly homologous to MPB 59 antigen in its NH 2 -terminal amino acid sequence, and even identical for its first 6 amino acids: Phe-Ser-Arg-Pro-Gly-Leu.
This gene was cloned by using a nucleotide probe homologous to the N-terminal amino acid sequence of antigen α, purified from M. tuberculosis as described in Tasaka, H. et al., 1983. "Purification and antigenic specificity of alpha protein (Yoneda and Fukui) from Mycobacterium tuberculosis and Mycobacterium intracellulare". Hiroshima J. Med. Sci. 32, 1-8.
The presence of antigens of around 30-32-kDa, named antigen 85 complex, has been revealed from electrophoretic patterns of proteins originating from culture media of mycobacteria, such as Mycobacterium tuberculosis. By immunoblotting techniques, it has been shown that these antigens cross-react with rabbit sera raised against the 32-kDa protein of BCG (8).
A recent study reported on the preferential humoral response to a 30-kDa and 31-kDa antigen in lepromatous leprosy patients, and to a 32-kDa antigen in tuberculoid leprosy patients (24).
It has also been found that fibronectin (FN)-binding antigens are prominent components of short-term culture supernatants of Mycobacterium tuberculosis. In 3-day-old supernatants, a 30-kilodalton (kDa) protein was identified as the major (FN)-binding molecule. In 21-day-old supernatants, FN was bound to a double protein band of about 30 to 32kDa, as well as to a group of antigens of larger molecular mass (57 to 60 kDa)(1).
In other experiments, recombinant plasmids containing DNA from Mycobacterium tuberculosis were transformed into Escherichia coli, and three colonies were selected by their reactivity with polyclonal antisera to M. tuberculosis. Each recombinant produced 35- and 53-kilodalton proteins (35 K and 53 K proteins, respectively) ("Expression of Proteins of Mycobacterium tuberculosis in Escherichia coli and Potential of Recombinant Genes and Proteins for Development of Diagnostic Reagents", Mitchell L Cohen et al., Journal of Clinical Microbiology, July 1987, p.1176-1180).
Concerning the various results known to date, the physico-chemical characteristics of the antigen P 32 of Mycobacterium tuberculosis are not precise and, furthermore, insufficient to enable its unambiguous identifiability, as well as the characterization of its structural and functional elements.
Moreover, the pathogenicity and the potentially infectious property of M. tuberculosis has hampered research enabling to identify, purify and characterize the constituents as well as the secretion products of this bacteria.
SUMMARY OF THE INVENTION
An aspect of the invention is to provide recombinant polypeptides which can be used as purified antigens for the detection and control of tuberculosis.
Another aspect of the invention is to provide nucleic acids coding for the peptidic chains of biologically pure recombinant polypeptides which enable their preparation on a large scale.
Another aspect of the invention is to provide antigens which can be used in serological tests as an in vitro rapid diagnostic of tuberculosis.
Another aspect of the invention is to provide a rapid in vitro diagnostic means for tuberculosis, enabling it to discriminate between patients suffering from an evolutive tuberculosis from those who have been vaccinated against BCG or who have been primo-infected.
Another aspect of the invention is to provide nucleic probes which can be used as in vitro diagnostic reagent for tuberculosis, as well as in vitro diagnostic reagent for identifying M. tuberculosis from other strains of mycobacteria.
The recombinant polypeptides of the invention contain in their polypeptidic chain one at least of the following amino acid sequences:
the one extending from the extremity constituted by amino acid at position (-29) to the extremity constituted by amino acid as position (-1) represented on FIG. 3a and FIG. 3b, or
the one extending from the extremity constituted by amino acid at position (12) to the extremity constituted by amino acid at position (31) represented on FIG. 3a and FIG. 3b, or
the one extending from the extremity constituted by amino acid at position (36) to the extremity constituted by amino acid at position (55) represented on FIG. 3a and FIG. 3b, or
the one extending from the extremity constituted by amino acid at position (77) to the extremity constituted by amino acid at position (96) represented on FIG. 3a and FIG. 3b, or
the one extending from the extremity constituted by amino acid at position (101) to the extremity constituted by amino acid at position (120) represented on FIG. 3a and FIG. 3b, or
the one extending from the extremity constituted by amino acid at position (175) to the extremity constituted by amino acid at position (194) represented on FIG. 3a and FIG. 3b, or
the one extending from the extremity constituted by amino acid at position (211) to the extremity constituted by amino acid at position (230) represented on FIG. 3a and FIG. 3b, or
the one extending from the extremity constituted by amino acid at position (275) to the extremity constituted by amino acid at position (294) represented on FIG. 3a and FIG. 3b,
and the peptidic sequences resulting from the modification by substitution and/or by addition and/or by deletion of one or several amino acids in so far as this modification does not alter the following properties:
the polypeptides react with rabbit polyclonal antiserum raised against the protein of 32-kDa of M. bovis BCG culture filtrate, and/or
react selectively with human sera from tuberculosis patients and particularly patients developing an evolutive tuberculosis at an early stage,
and/or react with the amino acid sequence extending from the extremity constituted by amino acid at position (1), to the extremity constituted by amino acid at position (294) represented on FIG. 3a and FIG. 3b.
On FIGS. 3a and 3b:
X represents C or GG,
Y represents C or CC,
Z represents C or G,
W represents C or G and is different from Z,
K represents C or CG,
L represents G or CC,
a 1 -b 1 represents ALA-ARG or GLY-ALA-ALA,
a 2 represents arg or gly,
a 3 -b 3 -c 3 -d 3 -e 3 -f 3 -represents his-trp-val-pro-arg-pro or ala-leu-gly-ala,
a 4 represents pro or pro-asn-thr,
a 5 represents pro or ala-pro.
The recombinant polypeptides of the invention contain in their polypeptidic chain one at least of the following amino acid sequences:
the one extending from the extremity constituted by amino acid at position (-29) to the extremity constituted by amino acid at position (-1) represented on FIG. 4a and FIG. 4b, or
the one extending from the extremity constituted by amino acid at position (12) to the extremity constituted by amino acid at position (31) represented on FIG. 4a and FIG. 4b, or
the one extending from the extremity constituted by amino acid at position (36) to the extremity constituted by amino acid at position ((55) represented on FIG. 4a and FIG. 4b, or
the one extending from the extremity constituted by amino acid at position (77) to the extremity constituted by amino acid at position (96) represented on FIG. 4a and FIG. 4b, or
the one extending from the extremity constituted by amino acid at position (101) to the extremity constituted by amino acid at position (120) represented on FIG. 4a and FIG. 4b, or
the one extending from the extremity constituted by amino acid at position (175) to the extremity constituted by amino acid at position (194) represented on FIG. 4a and FIG. 4b, or
the one extending from the extremity constituted by amino acid at position (211) to the extremity constituted by amino acid at position (230) represented on FIG. 4a and FIG. 4b, or
the one extending from the extremity constituted by amino acid at position (275) to the extremity constituted by amino acid at position (294) represented on FIG. 4a and FIG. 4b, or
and the peptidic sequences resulting from the modification by substitution and/or by addition and/or by deletion of one or several amino acids in so far as this modification does not alter the following properties:
the polypeptides react with rabbit polyclonal antiserum raised against the protein of 32-kDa or M. bovis BCG culture filtrate, and/or
react selectively with human sera from tuberculosis patients and particularly patients developing an evolutive tuberculosis at an early stage,
and/or react with the amino acid sequence extending from the extremity constituted by amino acid at position (1), to the extremity constituted by amino acid at position (294) represented on FIG. 4a and FIG. 4b.
The recombinant polypeptides of the invention contain in their polypeptidic chain one at least of the following amino acid sequences:
the one extending from the extremity constituted by amino acid at position (-30) to the extremity constituted by amino acid at position (-1) represented on FIG. 5, or
the one extending from the extremity constituted by amino acid at position (12) to the extremity constituted by amino acid at position (31) represented on FIG. 5, or
the one extending from the extremity constituted by amino acid at position (36) to the extremity constituted by amino acid at position (55) represented on FIG. 5, or
the one extending from the extremity constituted by amino acid at position (77) to the extremity constituted by amino acid at position (96) represented on FIG. 5, or
the one extending from the extremity constituted by amino acid at position (101) to the extremity constituted by amino acid at position (120) represented on FIG. 5, or
the one extending from the extremity constituted by amino acid at position (175) to the extremity constituted by amino acid at position (194) represented on FIG. 5, or
the one extending from the extremity constituted by amino acid at position (211) to the extremity constituted by amino acid at position (230) represented on FIG. 5, or
the one extending from the extremity constituted by amino acid at position (275) to the extremity constituted by amino acid at position (295) represented on FIG. 5,
and the peptidic sequences resulting from the modification by substitution and/or by addition and/or by deletion of one or several amino acids in so far as this modification does not alter the following properties:
the polypeptides react with rabbit polyclonal antiserum raised against the protein of 32-kDa or M. bovis BCG culture filtrate, and/or
react selectively with human sera from tuberculosis patients and particularly patients developing an evolutive tuberculosis at an early stage,
and/or react with the amino acid sequence extending from the extremity constituted by amino acid at position (1), to the extremity constituted by amino acid at position (295) represented on FIG. 5.
Advantageous polypeptides of the invention are characterized by the fact that they react with rabbit polyclonal antiserum raised against the protein of 32-kDa of M. bovis BCG culture filtrate, hereafter designated by "P 32 protein of BCG".
Advantageous polypeptides of the invention are characterized by the fact that they selectively react with human sera from tuberculous patients and particularly patients developing an evolutive tuberculosis at an early stage.
Hereafter is given, in a non limitative way a process for preparing rabbit polyclonal antiserum raised against the P 32 protein of BCG and a test for giving evidence of the reaction between the polypeptides of the invention and said rabbit polyclonal antiserum raised against the P 32 protein of BCG.
1) process for preparing rabbit polyclonal antiserum raised against the P 32 protein of BCG:
Purified P 32 protein of BCG from culture filtrate is used.
a) Purification of protein P 32 of BCG:
P 32 protein can be purified as follows:
The bacterial strains used are M. bovis BCG substrains 1173P2 (Pasteur Institute, Paris) and GL2 (Pasteur Institute, Brussels).
The culture of bacteria is obtained as follows:
Mycobacterium bovis BCG is grown as a pellicle on Sauton medium containing 4 g Aspargine, 57 ml 99% Glycerine (or 60 ml 87% Glycerine), 2 g Citric Acid, 0.5 g K 2 HPO 4 , 0.5 g MgSO 4 , 0.05 g Iron Citrate, 5×10 -6 M Ammonium (17% Fe III) SO 4 Zn.7H 2 O and adjusted to 1 liter distilled water adjusted to pH 7.2 with NH 4 OH, at 37.5° C. for 14 days. As the medium is prepared with distilled water, zinc sulfate is added to the final concentration of 5 μM (normal Sauton medium) (De Bruyn J., Weckx M., Beumer-Jochmans M.-P. Effect of zinc deficiency on Mycobacterium tuberculosis var. bovis (BCG). J. Gen. Microbiol. 1981; 124:353-7). When zinc deficient medium was needed, zinc sulfate is omitted.
The filtrates from zinc deficient cultures are obtained as follows:
The culture medium is clarified by decantation. The remaining bacteria are removed by filtration through Millipak 100 filter unit (Millipore Corp., Bedford, Mass.). When used for purification, the filtrate is adjusted to 20 mM in phosphate, 450 mM in NaCl, 1 mM in EDTA, and the pH is brought to 7.3 with 5 M HCl before sterile filtration.
The protein analysis is carried out by polyacrylamide gel electrophoresis. Sodium dodecyl sulfate polyacrylamide gel electrophoresis (SDS-PAGE) was done on 13% (w/v) acrylamide-containing gels as described by Laemmli UK. (Cleavage of structural proteins during the assembly of the head of bacteriophage T4. Nature 1970; 227:680-5). The gels are stained with Coomassie Brilliant Blue R-250 and for quantitative analysis, scanned at 595 nm with a DU8 Beckman spectrophotometer. For control of purity the gel is revealed with silver stain (Biorad Laboratories, Richmond, Calif.).
The purification step of P 32 is carried out as follows:
Except for hydrophobic chromatography on Phenyl-Sepharose, all buffers contain Tween 80 (0.005% final concentration). The pH is adjusted to 7.3 before sterilization. All purification steps are carried out at +4° C. Elutions are followed by recording the absorbance at 280 nm. The fractions containing proteins are analysed by SDS-PAGE.
(i) The treated filtrate from a 4 liters zinc-deficient culture, usually containing 125 to 150 mg protein per liter, is applied to a column (5.0 by 5.0 cm) of Phenyl-Sepharose CL-4B (Pharmacia Fine Chemicals, Uppsala, Sweden), which is previously equilibrated with 20 mM phosphate buffer (PB) containing 0.45 M NaCl and 1 mM EDTA, at a flow rate of 800 ml per hour. The gel is then washed with one column volume of the same buffer to remove unfixed material and successively with 300 ml of 20 mM and 4 mM PB and 10% ethanol (v/v). The P 32 appears in the fraction eluted with 10% ethanol.
(ii) After the phosphate concentration of this fraction has been brought to 4 mM, it is applied to a column (2.6 by 10 cm) of DEAE-Sephacel (Pharmacia Fine Chemicals), which is equilibrated with 4 mM PB. After washing with the equilibrating buffer the sample is eluted with 25 mM phosphate at a flow rate of 50 ml per hour. The eluate is concentrated in a 202 Amicon stirred cell equipped with a PM 10 membrane (Amicon Corp., Lexington, Mass.).
(iii) The concentrated material is submitted to molecular sieving on a Sehadex G-100 (Pharmacia) column (2.6 by 45 cm) equilibrated with 50 mM PB, at a flow rate of 12 ml per hour. The fractions of the peak giving one band in SDS-PAGE are pooled. The purity of the final preparation obtained is controlled by SDS-PAGE followed by silverstaining and by molecular sieving on a Superose 12 (Pharmcia) column (12.0 by 30 cm) equilibrated with 50 mM PB containing 0.005% Tween 80 at a flow rate of 0.2 ml/min. in the Fast Protein Liquid Chromatography system (Pharmacia). Elution is followed by recording the absorbance at 280 nm and 214 nm.
b) Preparation of rabbit polyclonal antiserum raised against the P 32 protein of BCG:
400 μg of purified P 32 protein of BCG per ml physiological saline are mixed with one volume of incomplete Freund's adjuvant. The material is homogenized and injected intradermally in 50 μl doses delivered at 10 sites in the back of the rabbits, at 0, 4, 7 and 8 weeks (adjuvant is replaced by the diluent for the last injection). One week later, the rabbits are bled and the sera tested for antibody level before being distributed in aliquots and stored at 31 80° C.;
2) test for giving evidence of the reaction between the polypeptides of the invention and said rabbit polyclonal antiserum raised against the P 32 protein of BCG:
the test used was an ELISA test; the ELISA for antibody determination is based on the method of Engvall and Perlmann (Engvall, E., and P. Perlmann. 1971. Enzyme-linked immunosorbent assay (ELISA). Quantitative assay of immunoglobulin G. Immunochemistry 8:871-874)
Immulon Microelisa plates (Dynatech, Kloten, Switzerland) are coated by adding to each well 1 μg of one of the polypeptides of the invention in 100 μl Tris hydrochloride buffer 50 mM (pH 8.2). After incubation for 2 h at 27° C. in a moist chamber, the plates are kept overnight at 4° C. They are washed four times with 0.01 M phosphate-buffered saline (pH 7.2) containing 0.05% Tween 20 by using a Titertek microplate washer (Flow Laboratories. Brussels. Belgium). Blocking is done with 0.5% gelatin in 0.06 M carbonate buffer (pH 9.6) for 1 h. Wells are then washed as before, and 100 μl of above mentioned serum diluted in phosphate-buffered saline containing 0.05% Tween 20 and 0.5% gelatin is added. According to the results obtained in preliminary experiments, the working dilutions are set at 1:200 for IgG, 1:20 for IgA and 1:80 for IgM determinations. Each dilution is run in duplicate. After 2 h of incubation and after the wells are washed, they are filled with 100 μl of peroxidase-conjugated rabbit immunoglobulins directed against human IgG, IgA or IgM (Dakopatts, Copenhagen, Denmark), diluted 1:400, 1:400 and 1:1.200, respectively in phosphate-buffered saline containing 0.5% Tween 20 and 0.5% gelatin and incubated for 90 min. After the wash, the amount of peroxidase bound to the wells is quantified by using a freshly prepared solution of o-phenylenediamine (10 mg/100 ml) and hydrogen peroxide (8 μl of 30% H 2 O 2 per 100 ml) in 0.15 M citrate buffer (pH 5.0) as a substrate. The enzymatic reaction is stopped with 8 N H 2 SO 4 after 15 min. of incubation. The optical density is read at 492 nm with a Titertek Multiskan photometer (Flow Laboratories).
Wells without sera are used as controls for the conjugates. Each experiment is done by including on each plate one negative and two positive reference sera with medium and low antibody levels to correct for plate-to-plate and day-to-day variations. The antibody concentrations are expressed as the optical density values obtained after correction of the readings according to the mean variations of the reference sera.
Hereafter is also given in a non limitative way, a test for giving evidence of the fact that polypeptides of the invention are recognized selectively by human sera from tuberculous patients.
This test is an immunoblotting (Western blotting) analysis, in the case where the polypeptides of the invention are obtained by recombinant techniques. This test can also be used for polypeptides of the invention obtained by a different preparation process. After sodium dodecyl sulfate-polyacrylamide gel electrophoresis, polypeptides of the invention are blotted onto nitrocellulose membranes (Hybond C. (Amersham)) as described by Towbin et al. (29). The expression of polypeptides of the invention fused to β-galactosidase in E. coli Y1089, is visualized by the binding of a polyclonal rabbit anti-32-kDa BCG protein serum (1:1,000) or by using a monoclonal anti-β-galactosidase antibody (Promega). The secondary antibody (alkaline phosphatase anti-rabbit immunoglobulin G and anti-mouse alkaline phosphatase immunoglobulin G conjugates, respectively) is diluted as recommended by the supplier (Promega).
In order to identify selective recognition of polypeptides of the invention and of fusion proteins of the invention by human tuberculous sera, nitrocellulose sheet are incubated overnight with these sera (1:50) (after blocking aspecific protein-binding sites). The human tuberculous sera are selected for their reactivity (high or low) against the purified 32-kDa antigen of BCG tested in a dot blot assay as described in document (31) of the bibliography hereafter. Reactive areas on the nitrocellulose sheets are revealed by incubation with peroxidase conjugated goat anti-human immunoglobulin G antibody (Dakopatts, Copenhagen, Denmark) (1:200) for 4 h, and after repeated washing, color reaction is developed by adding peroxidase substrate (α-chloronaphtol) (Bio-Rad Laboratories, Richmond, Calif.) in the presence of peroxidase and hydrogen peroxide.
It goes without saying that the free reactive functions which are present in some of the amino acids, which are part of the constitution of the polypeptides of the invention, particularly the free carboxyl groups which are carried by the groups Glu or by the C-terminal amino acid on the one hand and/or the free NH 2 groups carried by the N-terminal amino acid or by amino acid inside the peptidic chain, for instance Lys, on the other hand, can be modified in so far as this modification does not alter the above mentioned properties of the polypeptide.
The molecules which are thus modified are naturally part of the invention. The above mentioned carboxyl groups can be acylated or esterified.
Other modifications are also part of the invention. Particularly, the amine or ester functions or both of terminal amino acids can be themselves involved in the bond with other amino acids. For instance, the N-terminal amino acid can be linked to a sequence comprising from 1 to several amino acids corresponding to a part of the C-terminal region of another peptide.
Furthermore, any peptidic sequences resulting from the modification by substitution and/or by addition and/or by deletion of one or several amino acids of the polypeptides according to the invention are part of the invention in so far as this modification does not alter the above mentioned properties of said polypeptides.
The polypeptides according to the invention can be glycosylated or not, particularly in some of their glycosylation sites of the type Asn-X-Ser or Asn-X-Thr, X representing any amino acid.
Advantageous recombinant polypeptides of the invention contain in their polypeptidic chain, one at least of the following amino acid sequences:
the one extending from the extremity constituted by amino acid at position (-42) to the extremity constituted by amino acid at position (-1) represented on FIG. 3a and FIG. 3b,
the one extending from the extremity constituted by amino acid at position (-47) to the extremity constituted by amino acid at position (-1) represented on FIG. 3a and FIG. 3b,
the one extending from the extremity constituted by amino acid at position (-49) to the extremity constituted by amino acid at position (-1) represented on FIG. 3a and FIG. 3b,
the one extending from the extremity constituted by amino acid at position (-55) to the extremity constituted by amino acid at position (-1) represented on FIG. 3a and FIG. 3b,
the one extending from the extremity constituted by amino acid at position (-59) to the extremity constituted by amino acid at position (-1) represented on FIG. 3a and FIG. 3b.
Advantageous recombinant polypeptides of the invention contain in their polypeptidic chain, one at least of the following amino acid sequences:
the one extending from the extremity constituted by amino acid at position (-42) to the extremity constituted by amino acid at position (-1) represented on FIG. 4a and FIG. 4b,
the one extending from the extremity constituted by amino acid at position (-47) to the extremity constituted by amino acid at position (-1) represented on FIG. 4a and FIG. 4b,
the one extending from the extremity constituted by amino acid at position (-49) to the extremity constituted by amino acid at position (-1) represented on FIG. 4a and FIG. 4b,
the one extending from the extremity constituted by amino acid at position (-55) to the extremity constituted by amino acid at position (-1) represented on FIG. 4a and FIG. 4b,
the one extending from the extremity constituted by amino acid at position (-59) to the extremity constituted by amino acid at position (-1) represented on FIG. 4a and FIG. 4b.
Advantageous recombinant polypeptides of the invention contain in their polypeptidic chain, one at least of the following amino acid sequences:
the one extending from the extremity constituted by amino acid at position (-43) to the extremity constituted by amino acid at position (-1) represented on FIG. 5.
Advantageous recombinant polypeptides of the invention contain in their polypeptidic chain, one at least of the following amino acid sequences:
the one extending from the extremity constituted by amino acid at position (1) to the extremity constituted by amino acid at position (294) represented on FIG. 3a and FIG. 3b,
the one extending from the extremity constituted by amino acid at position (-29) to the extremity constituted by amino acid at position (294) represented on FIG. 3a and FIG. 3b,
the one extending from the extremity constituted by amino acid at position (-42) to the extremity constituted by amino acid at position (294) represented on FIG. 3a and FIG. 3b,
the one extending from the extremity constituted by amino acid at position (-47) to the extremity constituted by amino acid at position (294) represented on FIG. 3a and FIG. 3b,
the one extending from the extremity constituted by amino acid at position (-49) to the extremity constituted by amino acid at position (294) represented on FIG. 3a and FIG. 3b,
the one extending from the extremity constituted by amino acid at position (-55) to the extremity constituted by amino acid at position (294) represented on FIG. 3a and FIG. 3b,
the one extending from the extremity constituted by amino acid at position (-59) to the extremity constituted by amino acid at position (294) represented on FIG. 3a and FIG. 3b.
Advantageous recombinant polypeptides of the invention contain in their polypeptidic chain, one at least of the following amino acid sequences:
the one extending from the extremity constituted by amino acid at position (1) to the extremity constituted by amino acid at position (294) represented on FIG. 4a and FIG. 4b,
the one extending from the extremity constituted by amino acid at position (-29) to the extremity constituted by amino acid at position (294) represented on FIG. 4a and FIG. 4b,
the one extending from the extremity constituted by amino acid at position (-42) to the extremity constituted by amino acid at position (294) represented on FIG. 4a and FIG. 4b,
the one extending from the extremity constituted by amino acid at position (-47) to the extremity constituted by amino acid at position (294) represented on FIG. 4a and FIG. 4b,
the one extending from the extremity constituted by amino acid at position (-49) to the extremity constituted by amino acid at position (294) represented on FIG. 4a and FIG. 4b,
the one extending from the extremity constituted by amino acid at position (-55) to the extremity constituted by amino acid at position (294) represented on FIG. 4a and FIG. 4b,
the one extending from the extremity constituted by amino acid at position (-59) to the extremity constituted by amino acid at position (294) represented on FIG. 4a and FIG. 4b.
Advantageous recombinant polypeptides of the invention contain in their polypeptidic chain, one at least of the following amino acid sequences:
the one extending from the extremity constituted by amino acid at position (1) to the extremity constituted by amino acid at position (295) represented on FIG. 5,
the one extending from the extremity constituted by amino acid at position (-30) to the extremity constituted by amino acid at position (295) represented on FIG. 5,
the one extending from the extremity constituted by amino acid at position (-43) to the extremity constituted by amino acid at position (295) represented on FIG. 5.
Other advantageous recombinant polypeptides of the invention consist in one of the following amino acid sequences:
the one extending from the extremity constituted by amino acid at position (-59) to the extremity constituted by amino acid at position (294) represented on FIG. 3a and FIG. 3b,
the one extending from the extremity constituted by amino acid at position (-55) to the extremity constituted by amino acid at position (294) represented on FIG. 3a and FIG. 3b,
the one extending from the extremity constituted by amino acid at position (-49) to the extremity constituted by amino acid at position (294) represented on FIG. 3a and FIG. 3b,
the one extending from the extremity constituted by amino acid at position (-47) to the extremity constituted by amino acid at position (294) represented on FIG. 3a and FIG. 3b,
the one extending from the extremity constituted by amino acid at position (-42) to the extremity constituted by amino acid at position (294) represented on FIG. 3a and FIG. 3b,
the one extending from the extremity constituted by amino acid at position (-29) to the extremity constituted by amino acid at position (294) represented on FIG. 3a and FIG. 3b,
the one extending from the extremity constituted by amino acid at position (1) to the extremity constituted by amino acid at position (294) represented on FIG. 3a and FIG. 3b.
Other advantageous recombinant polypeptides of the invention consist in one of the following amino acid sequences:
the one extending from the extremity constituted by amino acid at position (-59) to the extremity constituted by amino acid at position (294) represented on FIG. 4a and FIG. 4b,
the one extending from the extremity constituted by amino acid at position (-55) to the extremity constituted by amino acid at position (294) represented on FIG. 4a and FIG. 4b,
the one extending from the extremity constituted by amino acid at position (-49) to the extremity constituted by amino acid at position (294) represented on FIG. 4a and FIG. 4b,
the one extending from the extremity constituted by amino acid at position (-47) to the extremity constituted by amino acid at position (294) represented on FIG. 4a and FIG. 4b,
the one extending from the extremity constituted by amino acid at position (-42) to the extremity constituted by amino acid at position (294) represented on FIG. 4a and FIG. 4b,
the one extending from the extremity constituted by amino acid at position (-29) to the extremity constituted by amino acid at position (294) represented on FIG. 4a and FIG. 4b,
the one extending from the extremity constituted by amino acid at position (1) to the extremity constituted by amino acid at position (294) represented on FIG. 4a and FIG. 4b.
Other advantageous recombinant polypeptides of the invention consist in one of the following amino acid sequences:
the one extending from the extremity constituted by amino acid at position (1) to the extremity constituted by amino acid at position (295) represented on FIG. 5,
the one extending from the extremity constituted by amino acid at position (-30) to the extremity constituted by amino acid at position (295) represented on FIG. 5,
the one extending from the extremity constituted by amino acid at position (-43) to the extremity constituted by amino acid at position (295) represented on FIG. 5.
Other advantageous recombinant polypeptides of the invention consist in one of the following amino acid sequences:
the one extending from the extremity constituted by amino acid at position (-59) to the extremity constituted by amino acid at position (-1) represented on FIG. 3a and FIG. 3b,
the one extending from the extremity constituted by amino acid at position (-55) to the extremity constituted by amino acid at position (-1) represented on FIG. 3a and FIG. 3b,
the one extending from the extremity constituted by amino acid at position (-49) to the extremity constituted by amino acid at position (-1) represented on FIG. 3a and FIG. 3b,
the one extending from the extremity constituted by amino acid at position (-47) to the extremity constituted by amino acid at position (-1) represented on FIG. 3a and FIG. 3b,
the one extending from the extremity constituted by amino acid at position (-42) to the extremity constituted by amino acid at position (-1) represented on FIG. 3a and FIG. 3b,
the one extending from the extremity constituted by amino acid at position (-29) to the extremity constituted by amino acid at position (-1) represented on FIG. 3a and FIG. 3b.
Other advantageous recombinant polypeptides of the invention consist in one of the following amino acid sequences:
the one extending from the extremity constituted by amino acid at position (-59) to the extremity constituted by amino acid at position (-1) represented on FIG. 4a and FIG. 4b,
the one extending from the extremity constituted by amino acid at position (-55) to the extremity constituted by amino acid at position (-1) represented on FIG. 4a and FIG. 4b,
the one extending from the extremity constituted by amino acid at position (-49) to the extremity constituted by amino acid at position (-1) represented on FIG. 4a and FIG. 4b,
the one extending from the extremity constituted by amino acid at position (-47) to the extremity constituted by amino acid at position (-1) represented on FIG. 4a and FIG. 4b,
the one extending from the extremity constituted by amino acid at position (-42) to the extremity constituted by amino acid at position (-1) represented on FIG. 4a and FIG. 4b,
the one extending from the extremity constituted by amino acid at position (-29) to the extremity constituted by amino acid at position (-1) represented on FIG. 4a and FIG. 4b.
Other advantageous recombinant polypeptides of the invention consist in one of the following amino acid sequences:
the one extending from the extremity constituted by amino acid at position (-43) to the extremity constituted by amino acid at position (-1) represented on FIG. 5,
the one extending from the extremity constituted by amino acid at position (-30) to the extremity constituted by amino acid at position (-1) represented on FIG. 5.
In eukaryotic cells, these polypeptides can be used as signal peptides, the role of which is to initiate the translocation of a protein from its site of synthesis, but which is excised during translocation.
Other advantageous peptides of the invention consist of one of the following amino acid sequence:
the one extending from the extremity constituted by amino acid at position (12) to the extremity constituted by amino acid at position (31) represented on FIG. 3a and FIG. 3b, or
the one extending from the extremity constituted by amino acid at position (36) to the extremity constituted by amino acid at position (55) represented on FIG. 3a and FIG. 3b, or
the one extending from the extremity constituted by amino acid at position (77) to the extremity constituted by amino acid at position (96) represented on FIG. 3a and FIG. 3b, or
the one extending from the extremity constituted by amino acid at position (101) to the extremity constituted by amino acid at position (120) represented on FIG. 3a and FIG. 3b, or
the one extending from the extremity constituted by amino acid at position (175) to the extremity constituted by amino acid at position (194) represented on FIG. 3a and FIG. 3b, or
the one extending from the extremity constituted by amino acid at position (211) to the extremity constituted by amino acid at position (230) represented on FIG. 3a and FIG. 3b, or
the one extending from the extremity constituted by amino acid at position (275) to the extremity constituted by amino acid at position (294) represented on FIG. 3a and FIG. 3b.
Other advantageous peptides of the invention consist in one of the following amino acid sequence:
the one extending from the extremity constituted by amino acid at position (12) to the extremity constituted by amino acid at position (31) represented on FIG. 4a and FIG. 4b, or
the one extending from the extremity constituted by amino acid at position (36) to the extremity constituted by amino acid at position (55) represented on FIG. 4a and FIG. 4b, or
the one extending from the extremity constituted by amino acid at position (77) to the extremity constituted by amino acid at position (96) represented on FIG. 4a and FIG. 4b, or
the one extending from the extremity constituted by amino acid at position (101) to the extremity constituted by amino acid at position (120) represented on FIG. 4a and FIG. 4b, or
the one extending from the extremity constituted by amino acid at position (175) to the extremity constituted by amino acid at position (194) represented on FIG. 4a and FIG. 4b, or
the one extending from the extremity constituted by amino acid at position (211) to the extremity constituted by amino acid at position (230) represented on FIG. 4a and FIG. 4b, or
the one extending from the extremity constituted by amino acid at position (275) to the extremity constituted by amino acid at position (294) represented on FIG. 4a and FIG. 4b.
Other advantageous peptides of the invention consist in one of the following amino acid sequence:
the one extending from the extremity constituted by amino acid at position (12) to the extremity constituted by amino acid at position (31) represented on FIG. 5, or
the one extending from the extremity constituted by amino acid at position (36) to the extremity constituted by amino acid at position (55) represented on FIG. 5, or
the one extending from the extremity constituted by amino acid at position (77) to the extremity constituted by amino acid at position (96) represented on FIG. 5, or
the one extending from the extremity constituted by amino acid at position (101) to the extremity constituted by amino acid at position (120) represented on FIG. 5, or
the one extending from the extremity constituted by amino acid at position (175) to the extremity constituted by amino acid at position (194) represented on FIG. 5, or
the one extending from the extremity constituted by amino acid at position (211) to the extremity constituted by amino acid at position (230) represented on FIG. 5, or
the one extending from the extremity constituted by amino acid at position (275) to the extremity constituted by amino acid at position (295) represented on FIG. 5.
It is to be noted that the above mentioned polypeptides are derived from the expression products of a DNA derived from the nucleotide sequence coding for a protein of 32-kDa secreted by Mycobacterium tuberculosis as explained hereafter in the examples.
The invention also relates to the amino acid sequences constituted by the above mentioned polypeptides and a protein or an heterologous sequence with respect to said polypeptide, said protein or heterologous sequence comprising for instance from about 1 to about 1000 amino acids. These amino acid sequences will be called fusion proteins.
In an advantageous fusion protein of the invention, the heterologous protein is β-galactosidase.
Other advantageous fusion proteins of the invention are the ones containing an heterologous protein resulting from the expression of one of the following plasmids:
pEX1
pEX2
pEX3
pUEX1 pmTNF MPH
pUEX2
pUEX3
The invention also relates to any nucleotide sequence coding for a polypeptide of the invention.
The invention also relates to nucleic acids comprising nucleotide sequences which hybridize with the nucleotide sequences coding for any of the above mentioned polypeptides under the following hybridization conditions:
hybridization and wash medium: 3×SSC, 20% formamide (1×SSC is 0.15 M NaCl, 0.015 M sodium citrate, pH 7.0),
hybridization temperature (HT) and wash temperature (WT) for the nucleic acids of the invention defined by x-y: i.e. by the sequence extending from the extremity constituted by the nucleotide at position (x) to the extremity constituted by the nucleotide at position (y) represented on FIG. 3a and FIG. 3b.
______________________________________ 1-182 HT = WT = 69° C. 1-194 HT = WT = 69° C. 1-212 HT = WT = 69° C. 1-218 HT = WT = 69° C. 1-272 HT = WT = 69° C. 1-359 HT = WT = 71° C. 1-1241 HT = WT = 73° C. 1-1358 HT = WT = 73° C.183-359 HT = WT = 70° C.183-1241 HT = WT = 73° C.183-1358 HT = WT = 73° C.195-359 HT = WT = 70° C.195-1241 HT = WT = 73° C.195-1358 HT = WT = 73° C.213-359 HT = WT = 70° C.213-1241 HT = WT = 73° C.213-1358 HT = WT = 73° C.219-359 HT = WT = 71° C.219-1241 HT = WT = 73° C.219-1358 HT = WT = 73° C.234-359 HT = WT = 71° C.234-1241 HT = WT = 74° C.234-1358 HT = WT = 73° C.273-359 HT = WT = 71° C.273-1241 HT = WT = 74° C.273-1358 HT = WT = 73° C.360-1241 HT = WT = 73° C.360-1358 HT = WT = 73° C.1242-1358 HT = WT = 62° C.______________________________________
The above mentioned temperatures are to be considered as approximately ±5° C.
The invention also relates to nucleic acids comprising nucleotide sequences which are complementary to the nucleotide sequences coding for any of the above mentioned polypeptides.
It is to be noted that in the above defined nucleic acids, as well as in the hereafter defined nucleic acids, the nucleotide sequences which are brought into play are such that T can be replaced by U.
A group of preferred nucleic acids of the invention comprises one at least of the following nucleotide sequences:
the one extending from the extremity constituted by nucleotide at position (1) to the extremity constituted by nucleotide at position (182) represented in FIG. 3a and FIG. 3b,
the one extending from the extremity constituted by nucleotide at position (273) to the extremity constituted by nucleotide at position (359) represented in FIG. 3a and FIG. 3b,
the one extending from the extremity constituted by nucleotide at position (360) to the extremity constituted by nucleotide at position (1241) represented in FIG. 3a and FIG. 3b,
the one extending from the extremity constituted by nucleotide at position (1242) to the extremity constituted by nucleotide at position (1358), wherein N represents one of the five A, T, C, G or I nucleotides, represented in FIG. 3a and FIG. 3b,
or above said nucleotide sequences wherein T is replaced by U,
or nucleic acids which hybridize with said above mentioned nucleotide sequences or the complementary sequences thereof.
A group of preferred nucleic acids of the invention comprises one at least of the following nucleotide sequences:
the one extending from the extremity constituted by nucleotide at position (1) to the extremity constituted by nucleotide at position (182) represented in FIG. 4a and FIG. 4b,
the one extending from the extremity constituted by nucleotide at position (273) to the extremity constituted by nucleotide at position (359) represented in FIG. 4a and FIG. 4b,
the one extending from the extremity constituted by nucleotide at position (360) to the extremity constituted by nucleotide at position (1241) represented in FIG. 4a and FIG. 4b,
the one extending from the extremity constituted by nucleotide at position (1242) to the extremity constituted by nucleotide at position (1358), wherein N represents one of the five A, T, C, G or I nucleotides, represented in FIG. 4a and FIG. 4b,
or above said nucleotide sequences wherein T is replaced by U,
or nucleic acids which hybridize with said above mentioned nucleotide sequences or the complementary sequences thereof.
A group of preferred nucleic acids of the invention comprises one at least of the following nucleotide sequences:
the one extending from the extremity constituted by nucleotide at position (130) to the extremity constituted by nucleotide at position (219) represented in FIG. 5,
the one extending from the extremity constituted by nucleotide at position (220) to the extremity constituted by nucleotide at position (1104) represented in FIG. 5,
the one extending from the extremity constituted by nucleotide at position (1104) to the extremity constituted by nucleotide at position (1299), wherein N represents one of the five A, T, C, G or I nucleotides, represented in FIG. 5,
or above said nucleotide sequences wherein T is replaced by U,
or nucleic acids which hybridize with said above mentioned nucleotide sequences or the complementary sequences thereof.
Other preferred nucleic acids of the invention comprise one at least of the following nucleotide sequences:
the one extending from the extremity constituted by nucleotide at position (195) to the extremity constituted by nucleotide at position (359) represented in FIG. 3a and FIG. 3b,
the one extending from the extremity constituted by nucleotide at position (213) to the extremity constituted by nucleotide at position (359) represented in FIG. 3a and FIG. 3b,
the one extending from the extremity constituted by nucleotide at position (219) to the extremity constituted by nucleotide at position (359) represented in FIG. 3a and FIG. 3b,
the one extending from the extremity constituted by nucleotide at position (183) to the extremity constituted by nucleotide at position (359) represented in FIG. 3a and FIG. 3b.
Other preferred nucleic acids of the invention comprise one at least of the following nucleotide sequences:
the one extending from the extremity constituted by nucleotide at position (195) to the extremity constituted by nucleotide at position (359) represented in FIG. 4a and FIG. 4b,
the one extending from the extremity constituted by nucleotide at position (213) to the extremity constituted by nucleotide at position (359) represented in FIG. 4a and FIG. 4b,
the one extending from the extremity constituted by nucleotide at position (219) to the extremity constituted by nucleotide at position (359) represented in FIG. 4a and FIG. 4b,
the one extending from the extremity constituted by nucleotide at position (183) to the extremity constituted by nucleotide at position (359) represented in FIG. 4a and FIG. 4b.
Another preferred group of nucleic acids of the invention comprises the following nucleotide sequences:
the one extending from the extremity constituted by nucleotide at position (360) to the extremity constituted by nucleotide at position (1358) represented in FIG. 3a and FIG. 3b.
Another preferred group of nucleic acids of the invention comprises the following nucleotide sequences:
the one extending from the extremity constituted by nucleotide at position (360) to the extremity constituted by nucleotide at position (1358) represented in FIG. 4a and FIG. 4b.
According to another advantageous embodiment, nucleic acids of the invention comprises one of the following sequences:
the one extending from the extremity constituted by nucleotide at position (1) to the extremity constituted by nucleotide at position (194) represented in FIG. 3a and FIG. 3b,
the one extending from the extremity constituted by nucleotide at position (1) to the extremity constituted by nucleotide at position (212) represented in FIG. 3a and FIG. 3b,
the one extending from the extremity constituted by nucleotide at position (1) to the extremity constituted by nucleotide at position (218) represented in FIG. 3a and FIG. 3b,
the one extending from the extremity constituted by nucleotide at position (1) to the extremity constituted by nucleotide at position (272) represented in FIG. 3a and FIG. 3b,
the one extending from the extremity constituted by nucleotide at position (1) to the extremity constituted by nucleotide at position (359) represented in FIG. 3a and FIG. 3b,
the one extending from the extremity constituted by nucleotide at position (1) to the extremity constituted by nucleotide at position (1358) represented in FIG. 3a and FIG. 3b,
the one extending from the extremity constituted by nucleotide at position (1) to the extremity constituted by nucleotide at position (1241) represented in FIG. 3a and FIG. 3b,
the one extending from the extremity constituted by nucleotide at position (183) to the extremity constituted by nucleotide at position (1358) represented in FIG. 3a and FIG. 3b,
the one extending from the extremity constituted by nucleotide at position (183) to the extremity constituted by nucleotide at position (1241) represented in FIG. 3a and FIG. 3b,
the one extending from the extremity constituted by nucleotide at position (195) to the extremity constituted by nucleotide at position (1358) represented in FIG. 3a and FIG. 3b,
the one extending from the extremity constituted by nucleotide at position (195) to the extremity constituted by nucleotide at position (1241) represented in FIG. 3a and FIG. 3b,
the one extending from the extremity constituted by nucleotide at position (213) to the extremity constituted by nucleotide at position (1358) represented in FIG. 3a and FIG. 3b,
the one extending from the extremity constituted by nucleotide at position (213) to the extremity constituted by nucleotide at position (1241) represented in FIG. 3a and FIG. 3b,
the one extending from the extremity constituted by nucleotide at position (219) to the extremity constituted by nucleotide at position (1358) represented in FIG. 3a and FIG. 3b,
the one extending from the extremity constituted by nucleotide at position (219) to the extremity constituted by nucleotide at position (1241) represented in FIG. 3a and FIG. 3b,
the one extending from the extremity constituted by nucleotide at position (234) to the extremity constituted by nucleotide at position (1358) represented in FIG. 3a and FIG. 3b,
the one extending from the extremity constituted by nucleotide at position (234) to the extremity constituted by nucleotide at position (1241) represented in FIG. 3a and FIG. 3b,
the one extending from the extremity constituted by nucleotide at position (273) to the extremity constituted by nucleotide at position (1241) represented in FIG. 3a and FIG. 3b,
the one extending from the extremity constituted by nucleotide at position (273) to the extremity constituted by nucleotide at position (1358) represented in FIG. 3a and FIG. 3b.
According to another advantageous embodiment, nucleic acids of the invention comprises one of the following sequences:
the one extending from the extremity constituted by nucleotide at position (1) to the extremity constituted by nucleotide at position (194) represented in FIG. 4a and FIG. 4b,
the one extending from the extremity constituted by nucleotide at position (1) to the extremity constituted by nucleotide at position (212) represented in FIG. 4a and FIG. 4b,
the one extending from the extremity constituted by nucleotide at position (1) to the extremity constituted by nucleotide at position (218) represented in FIG. 4a and FIG. 4b,
the one extending from the extremity constituted by nucleotide at position (1) to the extremity constituted by nucleotide at position (272) represented in FIG. 4a and FIG. 4b,
the one extending from the extremity constituted by nucleotide at position (1) to the extremity constituted by nucleotide at position (359) represented in FIG. 4a and FIG. 4b,
the one extending from the extremity constituted by nucleotide at position (1) to the extremity constituted by nucleotide at position (1358) represented in FIG. 4a and FIG. 4b,
the one extending from the extremity constituted by nucleotide at position (1) to the extremity constituted by nucleotide at position (1241) represented in FIG. 4a and FIG. 4b,
the one extending from the extremity constituted by nucleotide at position (183) to the extremity constituted by nucleotide at position (1358) represented in FIG. 4a and FIG. 4b,
the one extending from the extremity constituted by nucleotide at position (183) to the extremity constituted by nucleotide at position (1241) represented in FIG. 4a and FIG. 4b,
the one extending from the extremity constituted by nucleotide at position (195) to the extremity constituted by nucleotide at position (1358) represented in FIG. 4a and FIG. 4b,
the one extending from the extremity constituted by nucleotide at position (195) to the extremity constituted by nucleotide at position (1241) represented in FIG. 4a and FIG. 4b,
the one extending from the extremity constituted by nucleotide at position (213) to the extremity constituted by nucleotide at position (1358) represented in FIG. 4a and FIG. 4b,
the one extending from the extremity constituted by nucleotide at position (213) to the extremity constituted by nucleotide at position (1241) represented in FIG. 4a and FIG. 4b,
the one extending from the extremity constituted by nucleotide at position (219) to the extremity constituted by nucleotide at position (1358) represented in FIG. 4a and FIG. 4b,
the one extending from the extremity constituted by nucleotide at position (219) to the extremity constituted by nucleotide at position (1241) represented in FIG. 4a and FIG. 4b,
the one extending from the extremity constituted by nucleotide at position (234) to the extremity constituted by nucleotide at position (1358) represented in FIG. 4a and FIG. 4b,
the one extending from the extremity constituted by nucleotide at position (234) to the extremity constituted by nucleotide at position (1241) represented in FIG. 4a and FIG. 4b,
the one extending from the extremity constituted by nucleotide at position (273) to the extremity constituted by nucleotide at position (1241) represented in FIG. 4a and FIG. 4b,
the one extending from the extremity constituted by nucleotide at position (273) to the extremity constituted by nucleotide at position (1358) represented in FIG. 4a and FIG. 4b.
Preferred nucleic acids of the invention consist in one of the following nucleotide sequences:
the one extending from the extremity constituted by nucleotide at position (183) to the extremity constituted by nucleotide at position (359) represented in FIG. 3a and FIG. 3b,
the one extending from the extremity constituted by nucleotide at position (195) to the extremity constituted by nucleotide at position (359) represented in FIG. 3a and FIG. 3b,
the one extending from the extremity constituted by nucleotide at position (213) to the extremity constituted by nucleotide at position (359) represented in FIG. 3a and FIG. 3b,
the one extending from the extremity constituted by nucleotide at position (219) to the extremity constituted by nucleotide at position (359) represented in FIG. 3a and FIG. 3b,
the one extending from the extremity constituted by nucleotide at position (234) to the extremity constituted by nucleotide at position (359) represented in FIG. 3a and FIG. 3b,
the one extending from the extremity constituted by nucleotide at position (273) to the extremity constituted by nucleotide at position (359) represented in FIG. 3a and FIG. 3b.
Preferred nucleic acids of the invention consist in one of the following nucleotide sequences:
the one extending from the extremity constituted by nucleotide at position (183) to the extremity constituted by nucleotide at position (359) represented in FIG. 4a and FIG. 4b,
the one extending from the extremity constituted by nucleotide at position (195) to the extremity constituted by nucleotide at position (359) represented in FIG. 4a and FIG. 4b,
the one extending from the extremity constituted by nucleotide at position (213) to the extremity constituted by nucleotide at position (359) represented in FIG. 4a and FIG. 4b,
the one extending from the extremity constituted by nucleotide at position (219) to the extremity constituted by nucleotide at position (359) represented in FIG. 4a and FIG. 4b,
the one extending from the extremity constituted by nucleotide at position (234) to the extremity constituted by nucleotide at position (359) represented in FIG. 4a and FIG. 4b,
the one extending from the extremity constituted by nucleotide at position (273) to the extremity constituted by nucleotide at position (359) represented in FIG. 4a and FIG. 4b.
These nucleotide sequence can be used as nucleotide signal sequences, coding for the corresponding signal peptide.
Preferred nucleic acids of the invention consist in one of the following nucleotide sequences:
the one extending from the extremity constituted by nucleotide at position (360) to the extremity constituted by nucleotide at position (1241) represented in FIG. 3a and FIG. 3b,
the one extending from the extremity constituted by nucleotide at position (360) to the extremity constituted by nucleotide at position (1358) represented in FIG. 3a and FIG. 3b.
Preferred nucleic acids of the invention consist in one of the following nucleotide sequences:
the one extending from the extremity constituted by nucleotide at position (1) to the extremity constituted by nucleotide at position (182) represented in FIG. 3a and FIG. 3b,
the one extending from the extremity constituted by nucleotide at position (1) to the extremity constituted by nucleotide at position (194) represented in FIG. 3a and FIG. 3b,
the one extending from the extremity constituted by nucleotide at position (1) to the extremity constituted by nucleotide at position (212) represented in FIG. 3a and FIG. 3b,
the one extending from the extremity constituted by nucleotide at position (1) to the extremity constituted by nucleotide at position (218) represented in FIG. 3a and FIG. 3b,
the one extending from the extremity constituted by nucleotide at position (1) to the extremity constituted by nucleotide at position (272) represented in FIG. 3a and FIG. 3b,
the one extending from the extremity constituted by nucleotide at position (1) to the extremity constituted by nucleotide at position (359) represented in FIG. 3a and FIG. 3b,
the one extending from the extremity constituted by nucleotide at position (1) to the extremity constituted by nucleotide at position (1241) represented in FIG. 3a and FIG. 3b,
the one extending from the extremity constituted by nucleotide at position (1) to the extremity constituted by nucleotide at position (1358) represented in FIG. 3a and FIG. 3b,
the one extending from the extremity constituted by nucleotide at position (183) to the extremity constituted by nucleotide at position (1241) represented in FIG. 3a and FIG. 3b,
the one extending from the extremity constituted by nucleotide at position (183) to the extremity constituted by nucleotide at position (1358) represented in FIG. 3a and FIG. 3b,
the one extending from the extremity constituted by nucleotide at position (195) to the extremity constituted by nucleotide at position (1241) represented in FIG. 3a and FIG. 3b,
the one extending from the extremity constituted by nucleotide at position (195) to the extremity constituted by nucleotide at position (1358) represented in FIG. 3a and FIG. 3b,
the one extending from the extremity constituted by nucleotide at position (213) to the extremity constituted by nucleotide at position (1241) represented in FIG. 3a and FIG. 3b,
the one extending from the extremity constituted by nucleotide at position (213) to the extremity constituted by nucleotide at position (1358) represented in FIG. 3a and FIG. 3b,
the one extending from the extremity constituted by nucleotide at position (219) to the extremity constituted by nucleotide at position (1241) represented in FIG. 3a and FIG. 3b,
the one extending from the extremity constituted by nucleotide at position (219) to the extremity constituted by nucleotide at position (1358) represented in FIG. 3a and FIG. 3b,
the one extending from the extremity constituted by nucleotide at position (234) to the extremity constituted by nucleotide at position (1241) represented in FIG. 3a and FIG. 3b,
the one extending from the extremity constituted by nucleotide at position (234) to the extremity constituted by nucleotide at position (1358) represented in FIG. 3a and FIG. 3b,
the one extending from the extremity constituted by nucleotide at position (273) to the extremity constituted by nucleotide at position (1241) represented in FIG. 3a and FIG. 3b,
the one extending from the extremity constituted by nucleotide at position (273) to the extremity constituted by nucleotide at position (1358) represented in FIG. 3a and FIG. 3b,
the one extending from the extremity constituted by nucleotide at position (1242) to the extremity constituted by nucleotide at position (1358) represented in FIG. 3a and FIG. 3b.
Preferred nucleic acids of the invention consist in one of the following nucleotide sequences:
the one extending from the extremity constituted by nucleotide at position (360) to the extremity constituted by nucleotide at position (1241) represented in FIG. 4a and FIG. 4b,
the one extending from the extremity constituted by nucleotide at position (360) to the extremity constituted by nucleotide at position (1358) represented in FIG. 4a and FIG. 4b.
Preferred nucleic acids of the invention consist in one of the following nucleotide sequences:
the one extending from the extremity constituted by nucleotide at position (1) to the extremity constituted by nucleotide at position (182) represented in FIG. 4a and FIG. 4b,
the one extending from the extremity constituted by nucleotide at position (1) to the extremity constituted by nucleotide at position (194) represented in FIG. 4a and FIG. 4b,
the one extending from the extremity constituted by nucleotide at position (1) to the extremity constituted by nucleotide at position (212) represented in FIG. 4a and FIG. 4b,
the one extending from the extremity constituted by nucleotide at position (1) to the extremity constituted by nucleotide at position (218) represented in FIG. 4a and FIG. 4b,
the one extending from the extremity constituted by nucleotide at position (1) to the extremity constituted by nucleotide at position (272) represented in FIG. 4a and FIG. 4b,
the one extending from the extremity constituted by nucleotide at position (1) to the extremity constituted by nucleotide at position (359) represented in FIG. 4a and FIG. 4b,
the one extending from the extremity constituted by nucleotide at position (1) to the extremity constituted by nucleotide at position (1241) represented in FIG. 4a and FIG. 4b,
the one extending from the extremity constituted by nucleotide at position (1) to the extremity constituted by nucleotide at position (1358) represented in FIG. 4a and FIG. 4b,
the one extending from the extremity constituted by nucleotide at position (183) to the extremity constituted by nucleotide at position (1241) represented in FIG. 4a and FIG. 4b,
the one extending from the extremity constituted by nucleotide at position (183) to the extremity constituted by nucleotide at position (1358) represented in FIG. 4a and FIG. 4b,
the one extending from the extremity constituted by nucleotide at position (195) to the extremity constituted by nucleotide at position (1241) represented in FIG. 4a and FIG. 4b,
the one extending from the extremity constituted by nucleotide at position (195) to the extremity constituted by nucleotide at position (1358) represented in FIG. 4a and FIG. 4b,
the one extending from the extremity constituted by nucleotide at position (213) to the extremity constituted by nucleotide at position (1241) represented in FIG. 4a and FIG. 4b,
the one extending from the extremity constituted by nucleotide at position (213) to the extremity constituted by nucleotide at position (1358) represented in FIG. 4a and FIG. 4b,
the one extending from the extremity constituted by nucleotide at position (219) to the extremity constituted by nucleotide at position (1241) represented in FIG. 4a and FIG. 4b,
the one extending from the extremity constituted by nucleotide at position (219) to the extremity constituted by nucleotide at position (1358) represented in FIG. 4a and FIG. 4b,
the one extending from the extremity constituted by nucleotide at position (234) to the extremity constituted by nucleotide at position (1241) represented in FIG. 4a and FIG. 4b,
the one extending from the extremity constituted by nucleotide at position (234) to the extremity constituted by nucleotide at position (1358) represented in FIG. 4a and FIG. 4b,
the one extending from the extremity constituted by nucleotide at position (273) to the extremity constituted by nucleotide at position (1241) represented in FIG. 4a and FIG. 4b,
the one extending from the extremity constituted by nucleotide at position (273) to the extremity constituted by nucleotide at position (1358) represented in FIG. 4a and FIG. 4b,
the one extending from the extremity constituted by nucleotide at position (1242) to the extremity constituted by nucleotide at position (1358) represented in FIG. 4a and FIG. 4b.
Preferred nucleic acids of the invention consist in one of the following nucleotide sequences:
the one extending from the extremity constituted by nucleotide at position (1) to the extremity constituted by nucleotide at position (129) represented in FIG. 5,
the one extending from the extremity constituted by nucleotide at position (1) to the extremity constituted by nucleotide at position (219) represented in FIG. 5,
the one extending from the extremity constituted by nucleotide at position (1) to the extremity constituted by nucleotide at position (1104) represented in FIG. 5,
the one extending from the extremity constituted by nucleotide at position (1) to the extremity constituted by nucleotide at position (1299) represented in FIG. 5,
the one extending from the extremity constituted by nucleotide at position (90) to the extremity constituted by nucleotide at position (219) represented in FIG. 5,
the one extending from the extremity constituted by nucleotide at position (90) to the extremity constituted by nucleotide at position (1299) represented in FIG. 5,
the one extending from the extremity constituted by nucleotide at position (90) to the extremity constituted by nucleotide at position (1104) represented in FIG. 5,
the one extending from the extremity constituted by nucleotide at position (130) to the extremity constituted by nucleotide at position (1104) represented in FIG. 5,
the one extending from the extremity constituted by nucleotide at position (130) to the extremity constituted by nucleotide at position (1299) represented in FIG. 5,
the one extending from the extremity constituted by nucleotide at position (220) to the extremity constituted by nucleotide at position (1299) represented in FIG. 5.
Preferred nucleic acids of the invention consist in one of the following nucleotide sequences:
the one extending from the extremity constituted by nucleotide at position (1) to the extremity constituted by nucleotide at position (129) represented in FIG. 5,
the one extending from the extremity constituted by nucleotide at position (1) to the extremity constituted by nucleotide at position (219) represented in FIG. 5,
the one extending from the extremity constituted by nucleotide at position (1) to the extremity constituted by nucleotide at position (1104) represented in FIG. 5,
the one extending from the extremity constituted by nucleotide at position (1) to the extremity constituted by nucleotide at position (1299) represented in FIG. 5,
the one extending from the extremity constituted by nucleotide at position (90) to the extremity constituted by nucleotide at position (219) represented in FIG. 5,
the one extending from the extremity constituted by nucleotide at position (90) to the extremity constituted by nucleotide at position (1104) represented in FIG. 5,
the one extending from the extremity constituted by nucleotide at position (90) to the extremity constituted by nucleotide at position (1299) represented in FIG. 5,
the one extending from the extremity constituted by nucleotide at position (130) to the extremity constituted by nucleotide at position (219) represented in FIG. 5,
the one extending from the extremity constituted by nucleotide at position (130) to the extremity constituted by nucleotide at position (1104) represented in FIG. 5,
the one extending from the extremity constituted by nucleotide at position (130) to the extremity constituted by nucleotide at position (1299) represented in FIG. 5,
the one extending from the extremity constituted by nucleotide at position (220) to the extremity constituted by nucleotide at position (1104) represented in FIG. 5,
the one extending from the extremity constituted by nucleotide at position (220) to the extremity constituted by nucleotide at position (1299) represented in FIG. 5,
the one extending from the extremity constituted by nucleotide at position (1104) to the extremity constituted by nucleotide at position (1299) represented in FIG. 5.
The invention also relates to any recombinant nucleic acids containing at least a nucleic acid of the invention inserted in an heterologous nucleic acid.
The invention relates more particularly to recombinant nucleic acid such as defined, in which the nucleotide sequence of the invention is preceded by a promoter (particularly an inducible promoter) under the control of which the transcription of said sequence is liable to be processed and possibly followed by a sequence coding for transcription termination signals.
The invention also relates to the recombinant nucleic acids in which the nucleic acid sequences coding for the polypeptide of the invention and possibly the signal peptide, are recombined with control elements which are heterologous with respect to the ones to which they are normally associated within the bacteria gene and, more particularly, the regulation elements adapted to control their expression in the cellular host which has been chosen for their production.
The invention also relates to recombinant vectors, particularly for cloning and/or expression, comprising a vector sequence, notably of the type plasmid, cosmid or phage, and a recombinant nucleic acid of the invention, in one of the non essential sites for its replication.
Appropriate vectors for expression of the recombinant antigen are the following one:
pEX1 pmTNF MPH
pEX2 pIGRI
pEX3
pUEX1
pUEX2
pUEX3
The pEX1, pEX2 and pEX3 vectors are commercially available and can be obtained from Boehringer Mannheim.
The pUEX1, pUEX2 and pUEX3 vectors are also commercially available and can be obtained from Amersham.
According to an advantageous embodiment of the invention, the recombinant vector contains, in one of its non essential sites for its replication, necessary elements to promote the expression of polypeptides according to the invention in a cellular host and possibly a promoter recognized by the polymerase of the cellular host, particularly an inducible promoter and possibly a signal sequence and/or an anchor sequence.
According to another additional embodiment of the invention, the recombinant vector contains the elements enabling the expression by E. coli of a nucleic acid according to the invention inserted in the vector, and particularly the elements enabling the expression of the gene or part thereof of β-galactosidase.
The invention also relates to a cellular host which is transformed by a recombinant vector according to the invention, and comprising the regulation elements enabling the expression of the nucleotide sequence coding for the polypeptide according to the invention in this host.
The invention also relates to a cellular host chosen from among bacteria such as E. coli, transformed by a vector as above defined, and defined hereafter in the examples, or chosen from among eukaryotic organism, such as CHO cells, insect cells, Sf9 cells Spodoptera frugiperda! infected by the virus Ac NPV (Autographa californica nuclear polyhydrosis virus) containing suitable vectors such as pAc 373 pYM1 or pVC3, BmN Bombyx mori! infected by the virus BmNPV containing suitable vectors such as pBE520 or p89B310.
The invention relates to an expression product of a nucleic acid expressed by a transformed cellular host according to the invention.
The invention also relates to nucleotidic probes, hybridizing with anyone of the nucleic acids or with their complementary sequences, and particularly the probes chosen among the following nucleotidic sequences gathered in Table 1, and represented in FIG. 9.
TABLE 1______________________________________Probes A (i), A (ii), A (iii), A (iv) and A (v)A (i) CAGCTTGTTGACAGGGTTCGTGGCA (ii) GGTTCGTGGCGCCGTCACGA (iii) CGTCGCGCGCCTAGTGTCGGA (iv) CGGCGCCGTCGGTGGCACGGCGAA (v) CGTCGGCGCGGCCCTAGTGTCGGProbe B TCGCCCGCCCTGTACCTGProbe C GCGCTGACGCTGGCGATCTATCProbe D CCGCTGTTGAACGTCGGGAAGProbe E AAGCCGTCGGATCTGGGTGGCAAC Probes F (i), F (ii), F (iii) and F (iv)F (i) ACGGCACTGGGTGCCACGCCCAACF (ii) ACGCCCAACACCGGGCCCGCCGCAF (iii) ACGGGCACTGGGTGCCACGCCCAACF (iv) ACGCCCCAACACCGGGCCCGCGCCCCAor their complementary nucleotidic sequences.______________________________________The hybridization conditions can be the following ones:hybridization and wash medium: 3 X SSC, 29% formamide(1 X SSC is 0.15M NaCl, 0.015M sodium citrate, pH 7.0),hybridization temperature (HT) and wash temperature (WT):(WT) °C.: HT and WT (°C.)______________________________________A (i) 50A (ii) 50A (iii) 52A (iv) 60A (v) 52B 48C 50D 45E 52F (i) 55F (ii) 59F (iii) 55F (iv) 59______________________________________
These probes might enable to differentiate M. tuberculosis from other bacterial strains and in particular from the following mycobacteria species:
Mycobacterium marinum, Mycobacterium scrofulaceum, Mycobacterium gordonae, Mycobacterium szulgai, Mycobacterium intracellulare, Mycobacterium xenopi, Mycobacterium gastri, Mycobacterium nonchromogenicum, Mycobacterium terrae and Mycobacterium triviale, and more particularly from M. bovis, Mycobacterium kansasii, Mycobacterium avium, Mycobacterium phlei and Mycobacterium fortuitum.
The invention also relates to DNA or RNA primers which can be used for the synthesis of nucleotidic sequences according to the invention by PCR (polymerase chain reaction technique), such as described in U.S. Pat. Nos. 4,683,202 and 4,683,195 and European Patent n° 200362.
The invention also relates to any DNA or RNA primer constituted by about 15 to about 25 nucleotides of a nucleotide sequence coding for a polypeptide according to the invention.
The invention also relates to any DNA or RNA primer constituted by about 15 to about 25 nucleotides liable to hybridize with a nucleotide sequence coding for a polypeptide according to the invention.
The invention also relates to any DNA or RNA primer constituted by about 15 to about 25 nucleotides complementary to a nucleotide sequence coding for a polypeptide according to the invention.
The sequences which can be used as primers are given in Table 2 hereafter (sequences P1 to P6 or their complement) and illustrated in FIG. 9:
TABLE 2______________________________________P1 GAGTACCTGCAGGTGCCGTCGCCGTCGATGGGCCGP2 ATCAACACCCCGGCGTTCGAGTGGTACP2 compl. GTACCACTCGAACGCCGGGGTGTTGATP3 TGCCAGACTTACAAGTGGGAP3 compl. TCCCACTTGTAAGTCTGGCAP4 TCCTGACCAGCGAGCTGCCGP4 compl. CGGCAGCTCGCTGGTCAGGAP5 CCTGATCGGCCTGGCGATGGGTGACGCP5 compl. GCGTCACCCATCGCCAGGCCGATCAGGP6 compl. GCGCCCCAGTACTCCCAGCTGTGCGT______________________________________ compl. = complement
The sequences can be combined in twelve different primer-sets (given in Table 3) which allow enzymatical amplification by the polymerase chain reaction (PCR) technique of any of the nucleotide sequences of the invention, and more particularly the one extending from the extremity constituted by nucleotide at position 1 to the extremity constituted by nucleotide at position 1358, as well as the nucleotide sequence of antigen α of BCG (17).
The detection of the PCR amplified product can be achieved by a hybridization reaction with an oligonucleotide sequence of at least 10 nucleotides which is located between PCR primers which have been used to amplify the DNA.
The PCR products of the nucleotide sequences of the invention can be distinguished from the α-antigen gene of BCG or part thereof by hybridization techniques (dot-spot, Southern blotting, etc.) with the probes indicated in Table 3. The sequences of these probes can be found in Table 1 hereabove.
TABLE 3______________________________________Primer set Detection with probe______________________________________1. P1 and the complement of P2 B2. P1 and the complement of P3 B3. P1 and the complement of P4 B4. P1 and the complement of P5 B or C5 P1 and the complement of P6 B, C, D or E6. P2 and the complement of P5 C7. P2 and the complement of P6 C, D or E8. P3 and the complement of P5 C9. P3 and the complement of P6 C, D or E10. P4 and the complement of P5 C11. P4 and the complement of P6 C, D or E12. P5 and the complement of P6 D or E______________________________________
It is to be noted that enzymatic amplification can also be achieved with all oligonucleotides with sequences of about 15 consecutive bases of the primers given in Table 2. Primers with elongation at the 5'-end or with a small degree of mismatch may not considerably affect the outcome of the enzymatic amplification if the mismatches do not interfere with the base-pairing at the 3'-end of the primers.
Specific enzymatic amplification of the nucleotide sequences of the invention and not of the BCG gene can be achieved when the probes (given in Table 1) or their complements are used as amplification primers.
When the above mentioned probes of Table 1 are used as primers, the primer sets are constituted by any of the nucleotide sequences (A, B, C, D, E, F) of Table 1 in association with the complement of any other nucleotide sequence, chosen from A, B, C, D, E or F, it being understood that sequence A means any of the sequences A(i), A(ii), A(iii), A(i), A(v) and sequence F, any of the sequences F(i), F(ii), F(iii) and F(iv).
Advantageous primer sets for enzymatic amplification of the nucleotide sequence of the invention can be one of the following primer sets given in Table 3bis hereafter:
TABLE 3BIS______________________________________ A (i)or A (ii)or A (iii) and the complement of Bor A (iv)or A (v) A (i)or A (ii)or A (iii) and the complement of Cor A (iv)or A (v) B and the complement of C A (i)or A (ii)or A (iii) and the complement of For A (iv)or A (v) A (i)or A (ii)or A (iii) and the complement of Dor A (iv)or A (v) A (i)or A (ii)or A (iii) and the complement of Eor A (iv)or A (v) B and the complement of D B and the complement of E B and the complement of F C and the complement of D C and the complement of E C and the complement of F D and the complement of E D and the complement of F E and the complement of F______________________________________
A(i), A(ii), A(iii), A(iv), A(v), B, C, D, E and F having the nucleotide sequence indicated in Table 1.
In the case of amplification of a nucleotide sequence of the invention with any of the above mentioned primer sets defined in Table 3bis hereabove, the detection of the amplified nucleotide sequence can be achieved by a hybridization reaction with an oligonucleotide sequence of at least 10 nucleotides, said sequence being located between the PCR primers which have been used to amplify the nucleotide sequence. An oligonucleotide sequence located between said two primers can be determined from FIG. 9 where the primers A, B, C, D, E and F are represented by the boxed sequences respectively named probe region A, probe region B, probe region C, probe region D, probe region E and probe region F.
The invention also relates to a kit for enzymatic amplification of a nucleotide sequence by PCR technique and detection of the amplified nucleotide sequence containing
one of the PCR primer sets defined in Table 3 and one of the detection probes of the invention, advantageously the probes defined in Table 1,
or one of the PCR primer sets defined in Table 3bis, and a detection sequence consisting for instance in an oligonucleotide sequence of at least 10 nucleotides, said sequence being located (FIG. 9) between the two PCR primers constituting the primer set which has been used for amplifying said nucleotide sequence.
The invention also relates to a process for preparing a polypeptide according to the invention comprising the following steps:
the culture in an appropriate medium of a cellular host which has previously been transformed by an appropriate vector containing a nucleic acid according to the invention,
the recovery of the polypeptide produced by the above said transformed cellular host from the above said culture medium, and
the purification of the polypeptide produced, eventually be means of immobilized metal ion affinity chromatography (IMAC).
The polypeptides of the invention can be prepared according to the classical techniques in the field of peptide synthesis.
The synthesis can be carried out in homogeneous solution or in solid phase.
For instance, the synthesis technique in homogeneous solution which can be used is the one described by Houbenweyl in the book titled "Methode der organischen chemie" (Method of organic chemistry) edited by E. Wunsh, vol. 15-I et II. THIEME, Stuttgart 1974.
The polypeptides of the invention can also be prepared according to the method described by R. D. MERRIFIELD in the article titled "Solid phase peptide synthesis" (J. Am. Chem. Soc, 45, 2149-2154 1964).
The invention also relates to a process for preparing the nucleic acids according to the invention.
A suitable method for chemically preparing the single-stranded nucleic acids (containing at most 100 nucleotides of the invention) comprises the following steps:
DNA synthesis using the automatic β-cyanoethyl phosphoramidite method described in Bioorganic Chemistry 4; 274-325, 1986.
In the case of single-stranded DNA, the material which is obtained at the end of the DNA synthesis can be used as such.
A suitable method for chemically preparing the double-stranded nucleic acids (containing at most 100 bp of the invention) comprises the following steps:
DNA synthesis of one sense oligonucleotide using the automatic β-cyanoethyl phosphoramidite method described in Bioorganic Chemistry 4; 274-325, 1986, and DNA synthesis of one anti-sense oligonucleotide using said above-mentioned automatic β-cyanoethyl phosphoramidite method,
combining the sense and anti-sense oligonucleotides by hybridization in order to form a DNA duplex,
cloning the DNA duplex obtained into a suitable plasmid vector and recovery of the DNA according to classical methods, such as restriction enzyme digestion and agarose gel electrophoresis.
A method for the chemical preparation of nucleic acids of length greater than 100 nucleotides--or bp, in the case of double-stranded nucleic acids--comprises the following steps:
assembling of chemically synthesized oligonucleotides, provided at their ends with different restriction sites, the sequences of which are compatible with the succession of amino acids in the natural peptide, according to the principle described in Proc. Nat. Acad. Sci. USA 80; 7461-7465, 1983,
cloning the DNA thereby obtained into a suitable plasmid vector and recovery of the desired nucleic acid according to classical methods, such as restriction enzyme digestion and agarose gel electrophoresis.
The invention also relates to antibodies themselves formed against the polypeptides according to the invention.
It goes without saying that this production is not limited to polyclonal antibodies.
It also relates to any monoclonal antibody produced by any hybridoma liable to be formed according to classical methods from splenic cells of an animal, particularly of a mouse or rat, immunized against the purified polypeptide of the invention on the one hand, and of cells of a myeloma cell line on the other hand, and to be selected by its ability to produce the monoclonal antibodies recognizing the polypeptide which has been initially used for the immunization of the animals.
The invention also relates to any antibody of the invention labeled by an appropriate label of the enzymatic, fluorescent or radioactive type.
The peptides which are advantageously used to produce antibodies, particularly monoclonal antibodies, are the following one gathered in Tables 4a and 4b:
TABLE 4a______________________________________(see FIG. 4a and 4b)Amino acid Amino acidposition position(NH.sub.2 -terminal) (COOH-terminal)______________________________________12 QVPSPSMGRDIKVQFQSGGA 3136 LYLLDGLRAQDDFSGWDINT 5577 SFYSDWYQPACRKAGCQTYK 96101 LTSELPGWLQANRHVKPTGS 120175 KASDMWGPKEDPAWQRNDPL 194211 CGNGKPSDLGGNNLPAKFLE 230275 KPDLQRHWVPRPTPGPPQGA 294______________________________________
TABLE 4b______________________________________(see FIG. 5)Amino acid Amino acidposition position(NH.sub.2 -terminal) (COOH-terminal)______________________________________77 SFYSDWYQPACGKAGCQTYK 96276 PDLQRALGATPNTGPAPQGA 295______________________________________
The amino acid sequences are given in the 1-letter code.
Variations of the peptides listed in Tables 4a and 4b are also possible depending on their intended use. For example, if the peptides are to be used to raise antisera, the peptides may be synthesized with an extra cysteine residue added. This extra cysteine residue is preferably added to the amino terminus and facilitates the coupling of the peptide to a carrier protein which is necessary to render the small peptide immunogenic. If the peptide is to be labeled for use in radioimmune assays, it may be advantageous to synthesize the protein with a tyrosine attached to either the amino or carboxyl terminus to facilitate iodination. These peptides possess therefore the primary sequence of the peptides listed in Tables 4a and 4b but with additional amino acids which do not appear in the primary sequence of the protein and whose sole function is to confer the desired chemical properties to the peptides.
The invention also relates to a process for detecting in vitro antibodies related to tuberculosis in a human biological sample liable to contain them, this process comprising
contacting the biological sample with a polypeptide or a peptide according to the invention under conditions enabling an in vitro immunological reaction between said polypeptide and the antibodies which are possibly present in the biological sample and
the in vitro detection of the antigen/antibody complex which may be formed.
Preferably, the biological medium is constituted by a human serum.
The detection can be carried out according to any classical process.
By way of example a preferred method brings into play an immunoenzymatic process according to ELISA technique or immunofluorescent or radioimmunological (RIA) or the equivalent ones.
Thus the invention also relates to any polypeptide according to the invention labeled by an appropriate label of the enzymatic, fluorescent, radioactive . . . type.
Such a method for detecting in vitro antibodies related to tuberculosis comprises for instance the following steps:
deposit of determined amounts of a polypeptidic composition according to the invention in the wells of a titration microplate,
introduction into said wells of increasing dilutions of the serum to be diagnosed,
incubation of the microplate,
repeated rinsing of the microplate,
introduction into the wells of the microplate of labeled antibodies against the blood immunoglobulins,
the labeling of these antibodies being carried out by means of an enzyme which is selected from among the ones which are able to hydrolyze a substrate by modifying the absorption of the radiation of this latter at least at a given wave length,
detection by comparing with a control standard of the amount of hydrolyzed substrate.
The invention also relates to a process for detecting and identifying in vitro antigens of M. tuberculosis in a human biological sample liable to contain them, this process comprising:
contacting the biological sample with an appropriate antibody of the invention under conditions enabling an in vitro immunological reaction between said antibody and the antigens of M. tuberculosis which are possible present in the biological sample and the in vitro detection of the antigen/antibody complex which may be formed.
Preferably, the biological medium is constituted by sputum, plural effusion liquid, broncho-alveolar washing liquid, urine, biopsy or autopsy material.
Appropriate antibodies are advantageously monoclonal antibodies directed against the peptides which have been mentioned in Table 4.
The invention also relates to an additional method for the in vitro diagnostic of tuberculosis in a patient liable to be infected by Mycobacterium tuberculosis comprising the following steps:
the possible previous amplification of the amount of the nucleotide sequences according to the invention, liable to be contained in a biological sample taken from said patient by means of a DNA primer set as above defined,
contacting the above mentioned biological sample with a nucleotide probe of the invention, under conditions enabling the production of an hybridization complex formed between said probe and said nucleotide sequence,
detecting the above said hybridization complex which has possible been formed.
To carry out the in vitro diagnostic method for tuberculosis in a patient liable to be infected by Mycobacterium tuberculosis as above defined, the following necessary or kit can be used, said necessary or kit comprising:
a determined amount of a nucleotide probe of the invention,
advantageously the appropriate medium for creating an hybridization reaction between the sequence to be detected and the above mentioned probe,
advantageously, reagents enabling the detection of the hybridization complex which has been formed between the nucleotide sequence and the probe during the hybridization reaction.
The invention also relates to an additional method for the in vitro diagnostic of tuberculosis in a patient liable to be infected by Mycobacterium tuberculosis comprising:
contacting a biological sample taken from a patient with a polypeptide or a peptide of the invention, under conditions enabling an in vitro immunological reaction between said polypeptide or peptide and the antibodies which are possibly present in the biological sample and
the in vitro detection of the antigen/antibody complex which has possibly been formed.
To carry out the in vitro diagnostic method for tuberculosis in a patient liable to be infected by Mycobacterium tuberculosis, the following necessary or kit can be used, said necessary or kit comprising:
a polypeptide or a peptide according to the invention,
reagents for making a medium appropriate for the immunological reaction to occur,
reagents enabling to detect the antigen/antibody complex which has been produced by the immunological reaction, said reagents possible having a label, or being liable to be recognized by a labeled reagent,
more particularly in the case where the above mentioned polypeptide or peptide is not labeled.
The invention also relates to an additional method for the in vitro diagnostic of tuberculosis in a patient liable to be infected by M. tuberculosis, comprising the following steps:
contacting the biological sample with an appropriate antibody of the invention under conditions enabling an in vitro immunological reaction between said antibody and the antigens of M. tuberculosis which are possibly present in the biological sample and--the in vitro detection of the antigen/antibody complex which may be formed.
Appropriate antibodies are advantageously monoclonal antibodies directed against the peptides which have been mentioned in Table 4.
To carry out the in vitro diagnostic method for tuberculosis in a patient liable to be infected by Mycobacterium tuberculosis, the following necessary or kit can be used, said necessary or kit comprising:
an antibody of the invention,
reagents for making a medium appropriate for the immunological reaction to occur,
reagents enabling to detect the antigen/antibody complexes which have been produced by the immunological reaction, said reagent possibly having a label or being liable to be recognized by a label reagent, more particularly in the case where the above mentioned antibody is not labeled.
An advantageous kit for the diagnostic in vitro of tuberculosis comprises:
at least a suitable solid phase system, e.g. a microtiter-plate for deposition thereon of the biological sample to be diagnosed in vitro,
a preparation containing one of the monoclonal antibodies of the invention,
a specific detection system for said monoclonal antibody,
appropriate buffer solutions for carrying out the immunological reaction between a test sample and said monoclonal antibody on the one hand, and the bonded monoclonal antibodies and the detection system on the other hand.
The invention also relates to a kit, as described above, also containing a preparation of one of the polypeptides or peptides of the invention, said antigen of the invention being either a standard (for quantitative determination of the antigen of M. tuberculosis which is sought) or a competitor, with respect to the antigen which is sought, for the kit to be used in a competition dosage process.
The invention also relates to an immunogenic composition comprising a polypeptide or a peptide according to the invention, in association with a pharmaceutically acceptable vehicle.
The invention also relates to a vaccine composition comprising among other immunogenic principles anyone of the polypeptides or peptides of the invention or the expression product of the invention, possible coupled to a natural protein or to a synthetic polypeptide having a sufficient molecular weight so that the conjugate is able to induce in vivo the production of antibodies neutralizing Mycobacterium tuberculosis, or induce in vivo a cellular immune response by activating M. tuberculosis antigen-responsive T cells.
The peptides of the invention which are advantageously used as immunogenic principle have one of the following sequences:
TABLE 4a______________________________________(see FIG. 4a and 4b)Amino acid Amino acidposition position(NH.sub.2 -terminal) (COOH-terminal)______________________________________12 QVPSPSMGRDIKVQFQSGGA 3136 LYLLDGLRAQDDFSGWDINT 5577 SFYSDWYQPACRKAGCQTYK 96101 LTSELPGWLQANRHVKPTGS 120175 KASDMWGPKEDPAWQRNDPL 194211 CGNGKPSDLGGNNLPAKFLE 230275 KPDLQRHWVPRPTPGPPQGA 294______________________________________
TABLE 4b______________________________________(see FIG. 5)Amino acid Amino acidposition position(NH.sub.2 -terminal) (COOH-terminal)______________________________________77 SFYSDWYQPACGKAGCQTYK 96276 PDLQRALGATPNTGPAPQGA 295______________________________________
The amino acid sequences are given in the l-letter code.
Other characteristics and advantages of the invention will appear in the following examples and the figures illustrating the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
FIGS. 1A and 1B correspond to the identification of six purified λgt11 M. tuberculosis recombinant clones. FIG. 1A corresponds to the EcoRI restriction analysis of clone 15, clone 16, clone 17, clone 19, clone 24 and EcoRI-HindIII digested lambda DNA-molecular weight marker lane (in kilobase pairs) (M) (Boehringer).
FIG. 1B corresponds to the immunoblotting analysis of crude lysates of E. coli lysogenized with clone 15, clone 16, clone 17, clone 19, clone 23 and clone 24.
Arrow (←) indicates fusion protein produced by recombinant λgt11-M-tuberculosis clones. Expression and immunoblotting were as described above. Molecular weight (indicated in kDa) were estimated by comparison with molecular weight marker (High molecular weight-SDS calibration kit, Pharmacia).
FIG. 2 corresponds to the restriction map of the DNA inserts in the λgt11 M. tuberculosis recombinant clones 17 and 24 identified with polyclonal anti-32-kDa (BDG) antiserum as above defined and of clones By1, By2 and By5 selected by hybridization with a 120 bp EcoRI-Kpn I restriction fragment of clone 17.
DNA was isolated from λgt11 phase stocks by using the Lambda Sorb Phage Immunoadsorbent, as described by the manufacturer (Promega). Restriction sites were located as described above. Some restriction sites (*) were deduced from a computer analysis of the nucleotide sequence.
The short vertical bars () represent linker derived EcoRI sites surrounding the DNA inserts of recombinant clones. The lower part represents a magnification of the DNA region containing the antigen of molecular weight of 32-kDa, that has been sequenced. Arrows indicate strategies and direction of dideoxy-sequencing. (→) fragment subcloned in Bluescribe M13; (⃡) fragment subclone in mp10 and mp11 M13 vectors; (▪→) sequence determined with the use of a synthetic oligonucleotide.
FIGS. 3A and 3B correspond to the nucleotide and amino acid sequences of the general formula of the antigens of the invention.
FIGS. 4A and 4B correspond to the nucleotide and amino acid sequences of one of the antigens of the invention.
Two groups of sequences resembling the E. coli consensus promoter sequences are boxed and the homology to the consensus is indicated by italic bold letters. Roman bold letters represent a putative Shine-Dalgarno matif.
The NH 2 -terminal amino acid sequence of the mature protein which is underlined with a double line happens to be very homologous--29/32 amino acids--with the one of MPB 59 antigen (34). Five additional ATG codons, upstream of the ATG at position 273 are shown (dotted underlined). Vertical arrows (↓) indicate the presumed NH 2 end of clone 17 and clone 24. The option taken here arbitrarily represents the 59 amino acid signal peptide corresponding to ATG 183 .
FIGS. 5A, 5B, and 5C correspond to the nucleotide and amino acid sequences of the antigen of 32-kDa of the invention.
The NH 2 -terminal amino acid sequence of the mature protein which is underlined with a double line happens to be very homologous--29/32 amino acids--with the one of MPB 59 antigen (34). Vertical arrows (↓) indicate the presumed NH 2 end of clone 17 and clone 24.
FIG. 6 is the hydropathy pattern of the antigen of the invention of a molecular weight of 32-kDa and of the antigen α of BCG (17).
FIGS. 7A and 7B represent the homology between the amino acid sequences of the antigen of 32-kDa of the invention and of antigen α of BCG (revised version).
Identical amino acids; (:) evolutionarily conserved replacement of an amino acid (.), and absence of homology () are indicated. Underlined sequence (=) represents the signal peptide, the option taken here arbitrarily representing the 43-amino acid signal peptide corresponding to ATG 91 . Dashes in the sequences indicate breaks necessary for obtaining the optimal alignment.
FIG. 8 illustrates the fact that the protein of 32-kDa of the invention is selectively recognized by human tuberculous sera.
FIG. 8 represents the immunoblotting with human tuberculous sera, and anti-β-galactosidase monoclonal antibody. Lanes 1 to 6: E. coli lysate expressing fusion protein (140 kDa); lanes 7 to 12:unfused β-galactosidase (114 kDa). The DNA insert of clone 17 (2.7 kb) was subcloned into pUEX 2 and expression of fusion protein was induced as described by Bresson and Stanley (4). Lanes 1 and 7 were probed with the anti-β-galactosidase monoclonal antibody: lanes 4, 5, 6 and 10, 11, 12 with 3 different human tuberculous sera highly responding towards purified protein of the invention of 32-kDa; lanes 2 and 3 and 8 and 9 were probed with 2 different low responding sera.
FIGS. 9A-D represent the nucleic acid sequence alignment of the 32-kDa protein gene of M. tuberculosis of the invention (upper line), corresponding to the sequence in FIG. 5, of the gene of FIGS. 4A and 4B of the invention (middle line), and of the gene for antigen α of BCG (lower line).
Dashes in the sequence indicate breaks necessary for obtaining optimal alignment of the nucleic acid sequence.
FIG. 9a represents part of the nucleic acid sequence of the 32-kDA protein including probe region A and probe region B as well as primer region P1.
FIG. 9b represents part of the nucleic acid sequence of the 32-kDA protein including Primer regions P2, P3 and P4 and part of probe region C.
FIG. 9c represents part of the nucleic acid sequence of the 32-kDA protein including part of probe region C, probe regions D and E and primer region P5.
FIG. 9d represents part of the nucleic acid sequence of the 32 KDA protein including probe region F and primer region P6.
The primer regions for enzymatical amplification are boxed (P1 to P6).
The specific probe regions are boxed and respectively defined by probe region A, probe region B, probe region C, probe region D, probe region E and probe region F.
It is to be noted that the numbering of nucleotides is different from the numbering of FIGS. 3A and FIG. 3B, and of FIG. 5, because nucleotide at position 1 (on FIG. 9) corresponds to nucleotide 234 on FIG. 3A, and corresponds to nucleotide 91 on FIG. 5.
FIG. 10A corresponds to the restriction and genetic map of the pIGRI plasmid use din Example IV for the expression of the P 32 antigen of the invention in E. coli.
On this figure, underlined restriction sites are unique.
FIGS. 10B-M correspond to the pIGRI nucleic acid sequence.
On this figure, the origin of nucleotide stretches used to construct plasmid pIGRI are specified hereafter.
Position
3422-206: lambda PL containing EcoRI blunt-MboII blunt fragment of pPL(λ) (Pharmacia)
207-384: synthetic DNA sequence
228-230: initiation codon ATG of first cistron
234-305: DNA encoding amino acids 2 to 25 of mature mouse TNF
306-308: stop codon (TAA) first cistron
311-312: initiation codon (ATG) second cistron
385-890: rrnBT 1 T 2 containing HindIII-SspI fragment from pKK223 (Pharmacia)
891-3421: DraI-EcoRI blunt fragment of pAT 153 (Bioexcellence) containing the tetracycline resistance gene and the origin of replication.
Table 5 hereafter corresponds to the complete restriction site analysis of pIGRI.
TABLE 5__________________________________________________________________________RESTRICTION-SITE ANALYSIS__________________________________________________________________________ Name of the plasmid : pIGRI Total number of bases is: 3423. Analysis done on the complete sequence.__________________________________________________________________________List of cuts by enzyme.__________________________________________________________________________Acc I: 370 2765Acy I: 735 2211 2868 2982 3003Afl III: 1645Aha III: 222Alu I: 386 1088 1345 1481 1707 2329 2732 3388 3403Alw NI: 1236Apa LI: 1331Asp 718I: 208Asu I: 329 494 623 713 1935 1977 2156 2280 2529 2617 289 3244Ava I: 1990Ava II: 329 494 1935 1977 2280 2529 2617Bal I: 1973Bam HI: 3040Bbe I: 2214 2871 2985 3006Bbv I: 389 1316 1735 1753 1866 1869 2813 3202Bbv I*: 1017 1223 1226 1973 1997 2630Bbv II: 1822 2685Bgl I: 2253 2487Bin I: 15 903 1001 1087 3048Bin I*: 902 999 2313 3035Bsp HI: 855 925 2926Bsp MI: 382 2361Bst NI: 213 475 585 753 1486 1499 1620 1975 2358 3287Cau II: 4 683 716 1268 1933 2159 2883 3247Cfr 10I: 2132 2486 2646 3005 3014 3255Cfr I: 1971 2476 2884 3016 3120Cla I: 3393Cvi JI: 190 263 270 380 386 391 421 607 625 714 77 791 1088 1117 1160 1171 1236 1315 1340 1345 1481 157 1605 1623 1634 1707 1726 1926 1931 1973 2010 2092 213 2157 2162 2300 2310 2329 2370 2427 2435 2465 2478 249 2544 2588 2732 2748 2804 2822 2886 2894 2932 2946 301 3087 3122 3245 3269 3388 3403Cvi QI: 209 3253Dde I: 133 336 343 518 608 664 962 1371 1835Dpn I: 9 236 897 909 987 995 1006 1081 1957 2274 228 2320 2592 2951 3042 3069Dra II: 1935 1977 2892Dra III: 293Dsa I: 309 1968 2887Eco 31I: 562Eco 47III: 341 1773 2642 2923 3185Eco 57I: 214Eco 57I*: 1103Eco 78I: 2212 2869 2983 3004Eco NI: 196 2792Eco RII: 211 473 583 751 1484 1497 1618 1973 2356 3285Eco RV: 3232Fnu 4H1: 378 479 1031 1237 1240 1305 1448 1603 1721 1724 174 1855 1858 1987 2001 2008 2011 2130 2209 2254 2311 239 2479 2644 2695 2802 2836 2839 3117 3120 3191Fnu DII: 489 1021 1602 1784 1881 2003 2029 2174 2184 2313 237 2440 2445 2472 2601 2716 3072Fok I: 415 799 3317Fok I*: 763 2370 2415 3269Gsu I: 339 2035Gsu I*: 2589Hae I: 775 791 1171 1623 1634 1973 2370 2427 2499Hae II: 343 541 1405 1775 2214 2644 2871 2925 2985 3006 318Hae III: 625 714 775 791 1171 1605 1623 1634 1973 2157 237 2427 2478 2499 2588 2822 2886 2894 3018 3122 3245Hga I: 158 181 743 2035 2185 2776Hga I*: 955 1533 2429 2461 3015Hgi AI: 139 1335 1954 2245 2832 3143Hgi CI: 208 2126 2210 2649 2867 2981 3002 3296 3339Hgi JII: 2934 2948Hha I: 342 489 540 1021 1130 1304 1404 1471 1741 1774 196 2000 2062 2213 2472 2603 2643 2718 2870 2924 2984 300 3158 3186 3318Hin P1I: 340 487 538 1019 1128 1302 1402 1469 1739 1772 196 1998 2060 2211 2470 2601 2641 2716 2868 2922 2982 300 3156 3184 3316Hind II: 107 371 2766Hind III: 384 3386Hinf I: 367 1275 1671 1746 1891 2112 2410 2564 2784Hpa II: 3 682 716 1077 1267 1293 1440 1932 2133 2159 239 2487 2647 2723 2883 3006 3015 3030 3247 3256Hph I: 94 138 181 663 914 1900 2121 2975 3020 3302Hph I*: 6Kpn I: 212Mae I: 364 899 1152 1928 3187Mae II: 274 698 944 1847 1871 2460 2516Mae III: 169 255 304 313 1109 1225 1288 2267 2534 3202 329Mbo I: 7 234 895 907 985 993 1004 1079 1955 2272 228Mbo II: 2318 2590 2949 3040 3067Mbo II*: 988 2944Mme I*: 1252 1436 3112 3199Mnl I: 1218 1542 1948 2446 2630Mnl I*: 208 289 337 711 1467 1750 2116 2143 2181 2242 254Mse I: 179 186 221 433 764 941 3361 3383 3420Mst I: 1963 2061 3157Nae I: 2134 2488 2648 3016Nar I: 2211 2868 2982 3003Nco I: 309Nhe I: 3186Nla III: 166 230 313 512 567 859 929 1649 1828 1962 216 2226 2241 2369 2486 2672 2711 2857 2930 3068 3415Nla IV: 210 330 496 1578 1617 1936 1979 2093 2128 2163 221 2530 2651 2869 2893 2983 3004 3042 3088 3298 3341Nru I: 2445Nsp BII: 1062 1307 2278Nsp HI: 1649 2857Pfl MI: 293 2052 2101Ple I: 375 1754Ple I*: 1269 2778Ppu MI: 1935 1977Pss I: 1938 1980 2895Pst I: 379Rsa I: 210 3254Sal I: 369 2764Scr FI: 4 213 475 585 683 716 753 1268 1486 1499 162 1933 1975 2159 2358 2883 3247 3287Sdu I: 139 1335 1954 2245 2832 2934 2948 3143Sec I: 3 309 1485 1968 2046 2248 2881 2887 3286 3300Sfa NI: 597 765 2392 2767 3178 3291Sfa NI*: 1548 1985 2380 3001 3013 3202Sph I: 2857Sso II: 2 211 473 583 681 714 751 1266 1484 1497 161 1931 1973 2157 2356 2881 3245 3285Sty I: 309 2046Taq I: 252 370 613 1547 2149 2290 2765 3078 3393Taq IIB: 1749Taq IIB*: 2751Tth111II: 38 1054Tth111II*: 633 1022 1061Xba I: 363Xho II: 7 895 907 993 1004 3040Xma III: 2476Xmn I: 414__________________________________________________________________________ Total number of cuts is: 705.Sorted list of enzymes by n* of cuts.__________________________________________________________________________Cvi JI: 61 Sdu I : 8 Tth111II* : 3 Ava I : 1Fnu 4HI: 31 Cau II : 8 Nsp BII : 3 Taq IIB : 1Hha I: 25 Bbv I : 8 Fok I : 3 Alw NI : 1Hin P1I: 25 Mbo II : 7 Pfl MI : 3 Dra III : 1Hae III: 21 Ava II : 7 Hind II : 3 Afl III : 1Nla IV: 21 Mae II : 7 Dsa I : 3 Cla I : 1Nla III: 21 Sfa NI : 6 Bsp HI : 3 Eco 57I* : 1Hpa II: 20 Xho II : 6 Pss I : 3 Nhe I : 1Scr FI: 18 Hgi AI : 6 Mst I : 3 Gsu I* : 1Sso II: 18 Sfa NI* : 6 Hgi JII : 2 Bal I : 1Fnu DII: 17 Bbv I* : 6 Ple I : 2 Eco RV : 1Mbo I: 16 Cfr 10I : 6 Mbo II* : 2 Sph I : 1Dpn I: 16 Hga I : 6 Cvi QI : 2 Xma III : 1Mnl I*: 15 Acy I : 5 Acc I : 2 Hph I* : 1Asu I: 12 Bin I : 5 Bgl I : 2 Taq IIB* : 1Hae II: 11 Cfr I : 5 Ple I* : 2 Eco 57I : 1Mae III: 11 Hga I* : 5 Gsu I : 2 Kpn I : 1Hph I: 10 Mae I : 5 Ppu MI : 2 Xba I : 1Bst NI: 10 Eco 47III : 5 Tth111II : 2 Aha III : 1Eco RII: 10 Mnl I : 5 Hind III : 2 Nru I : 1Sec I: 10 Mme I* : 4 Nsp HI : 2 Bam HI : 1Dde I: 9 Eco 78I : 4 Rsa I : 2 Apa LI : 1Hinf I: 9 Nae I : 4 Sal I : 2 Asp 718I : 1Hae I: 9 Bbe I : 4 Bbv II : 2 Eco 31I : 1Alu I: 9 Bin I* : 4 Bsp MI : 2 Nco I : 1Hgi CI: 9 Nar I : 4 Sty I : 2 Pst I : 1Mse I: 9 Fok I* : 4 Eco NI : 2Taq I: 9 Dra II : 3 Xmn I : 2__________________________________________________________________________List of non cutting selected enzymes.__________________________________________________________________________Aat II, Afl II, Apa I, Asu II, Avr II, Bbv II*, Bcl IBql II, Bsp MI*, Bsp MII, Bss HII, Bst EII, Bst XI, Eco 31I*Eco RI, Esp I, Hpa I, Mlu I Mme I, Nde I Not INsi I, Pma CI, Pvu I, Pvu II, Rsr II, Sac I, Sac IISau I, Sca I, Sci I, Sfi I, Sma I, Sna BI, Spe ISpl I, Ssp I, Stu I, Tag IIA, Tag IIA*, Tth 111I, VspIXca I, Xho I, Xma I__________________________________________________________________________ Total number of selected enzymes which do not cut: 45
FIG. 11A corresponds to the restriction and genetic map of the pmTNF MPH plasmid used in Example V for the expression of the P 32 antigen of the invention in E. coli.
FIGS. 11B-M correspond to the pmTNF-MPH nucleic acid sequence.
On this figure, the origin of nucleotide stretches used to construct plasmid pmTNF-MPH is specified hereafter.
Position
1-208: lambda PL containing EcoRI blunt-MboII blunt fragment of pPL(λ) (Pharmacia)
209-436: synthetic DNA fragment
230-232: initiation codon (ATG) of mTNF fusion protein
236-307: sequence encoding AA 2 to 25 of mature mouse TNF
308-384: multiple cloning site containing His 6 encoding sequence at position 315-332
385-436: HindIII fragment containing E. coli trp terminator
437-943: rrnBT 1 T 2 containing HindIII-SspI fragment from pKK223 (Pharmacia)
944-3474: DraI-EcoRI blunt fragment of pAT 153 (bioexcellence) containing the tetracycline resistance gene and the origin of replication.
Table 6 hereafter corresponds to the complete restriction site analysis of pmTNF-MPH.
TABLE 6__________________________________________________________________________RESTRICTION-SITE ANALYSIS__________________________________________________________________________ Done on DNA sequence PMTNFMPH. Total number of bases is: 3474. Analysis done on the complete sequence.__________________________________________________________________________List of cuts by enzyme.__________________________________________________________________________Acc I: 371 2818Acy I: 788 2264 2921 3035 3056Afl II: 387Afl III: 1698Aha III: 224Alu I: 386 439 1141 1398 1534 1760 2382 2785 3441 3456Alw NI: 1289Apa I: 345Apa LI: 1384Asp 718I: 210Asu I: 341 342 547 676 766 1988 2030 2209 2333 2582 267 2945 3297Ava I: 338 2043Ava II: 547 1988 2030 2333 2582 2670Bal I: 2026Bam HI: 334 3093Bbe I: 2267 2924 3038 3059Bbv I: 1369 1788 1806 1919 1922 2866 3255Bbv I*: 1070 1276 1279 2026 2050 2683Bbv II: 1875 2738Bgl I: 2306 2540Bin I: 17 342 956 1054 1140 3101Bin I*: 329 955 1052 2366 3088Bsp HI: 908 978 2979Bsp MI: 2414Bsp MII: 354Bst NI: 215 528 638 806 1539 1552 1673 2028 2411 3340Cau II: 6 339 340 736 769 1321 1986 2212 2936 3300Cfr 10I: 374 2185 2539 2699 3058 3067 3308Cfr I: 2024 2529 2937 3069 3173Cla I: 3446Cvi JI: 192 265 272 343 350 361 386 400 439 444 47 660 678 767 828 844 1141 1170 1213 1224 1289 136 1393 1398 1534 1632 1658 1676 1687 1760 1779 1979 198 2026 2063 2145 2189 2210 2215 2353 2363 2382 2423 248 2488 2518 2531 2552 2597 2641 2785 2801 2857 2875 293 2947 2985 2999 3071 3140 3175 3298 3322 3441 3456Cvi QI: 211 3306Dde I: 135 571 661 717 1015 1424 1888Dpn I: 11 238 336 950 962 1040 1048 1059 1134 2010 232 2342 2373 2645 3004 3095 3122Dra II: 1988 2030 2945Dra III: 295 331Dsa I: 345 2021 2940Eco 31I: 615Eco 47III: 1826 2695 2976 3238Eco 57I: 216Eco 57I*: 1156Eco 78I: 2265 2922 3036 3057Eco NI: 198 2845Eco RI: 309Eco RII: 213 526 636 804 1537 1550 1671 2026 2409 3338Eco RV: 3285Fnu 4H1: 401 417 532 1084 1290 1293 1358 1501 1656 1774 177 1795 1908 1911 2040 2054 2061 2064 2183 2262 2307 236 2447 2532 2697 2748 2855 2889 2892 3170 3173 3244Fnu DII: 542 1074 1655 1837 1934 2056 2082 2227 2237 2366 243 2493 2498 2525 2654 2769 3125Fok I: 468 852 3370Fok I*: 816 2423 2468 3322Gsu I: 2088Gsu I*: 2642Hae I: 361 828 844 1224 1676 1687 2026 2423 2480 2552Hae II: 594 1458 1828 2267 2697 2924 2978 3038 3059 3240Hae III: 343 361 678 767 828 844 1224 1658 1676 1687 202 2210 2423 2480 2531 2552 2641 2875 2939 2947 3071 317 3298Hga I: 160 183 796 2088 2238 2829Hga I*: 1008 1586 2482 2514 3068Hgi AI: 141 1388 2007 2298 2885 3196Hgi CI: 210 2179 2263 2702 2920 3034 3055 3349 3392Hgi JII: 345 2987 3001Hha I: 542 593 1074 1183 1357 1457 1524 1794 1827 2017 205 2115 2266 2525 2656 2696 2771 2923 2977 3037 3058 321 3239 3371Hin P1I: 540 591 1072 1181 1355 1455 1522 1792 1825 2015 205 2113 2264 2523 2654 2694 2769 2921 2975 3035 3056 320 3237 3369Hind II: 109 372 2819Hind III: 384 437 3439Hinf I: 368 1328 1724 1799 1944 2165 2463 2617 2837Hpa II: 5 339 355 375 735 769 1130 1320 1346 1493 198 2186 2212 2450 2540 2700 2776 2936 3059 3068 3083 330 3309Hph I: 96 140 183 716 967 1953 2174 3028 3073 3355Hph I*: 8 305 311 317Kpn I: 214Mae I: 365 952 1205 1981 3240Mae II: 276 330 751 997 1900 1924 2513 2569Mae III: 171 257 1162 1278 1341 2320 2587 3255 3343Mbo I: 9 236 334 948 960 1038 1046 1057 1132 2008 232 2340 2371 2643 3002 3093 3120Mbo II: 209 475 970 1832 1880 2472 2743Mbo II*: 1041 2997Mme I*: 1305 1489 3165 3252Mnl I: 372 1271 1595 2001 2499 2683Mnl I*: 210 291 350 764 1520 1803 2169 2196 2234 2295 259 2864 3083 3287 3347Mse I: 181 188 223 388 486 817 994 3414 3436Mst I: 2016 2114 3210Nae I: 2187 2541 2701 3069Nar I: 2264 2921 3035 3056Nco I: 345Nhe I: 3239Nla III: 168 232 349 382 565 620 912 982 1702 1881 201 2222 2279 2294 2422 2539 2725 2764 2910 2983 3121 346Nla IV: 212 336 343 549 1631 1670 1989 2032 2146 2181 221 2265 2583 2704 2922 2946 3036 3057 3095 3141 3351 339Nru I: 2498Nsp BII: 412 1115 1360 2331Nsp HI: 382 1702 2910Pf1 MI: 295 2105 2154Ple I: 376 1807Ple I*: 1322 2831Pma CI: 331Ppu MI: 1988 2030Pss I: 1991 2033 2948Rsa I: 212 3307Sal I: 370 2817Scr FI: 6 215 339 340 528 638 736 769 806 1321 153 1552 1673 1986 2028 2212 2411 2936 3300 3340Sdu I: 141 345 1388 2007 2298 2885 2987 3001 3196Sec I: 5 338 345 1538 2021 2099 2301 2934 2940 3339 335Sfa NI: 650 818 2445 2820 3231 3344Sfa NI*: 420 1601 2038 2433 3054 3066 3255Sma I: 340Sph I: 382 2910Sso II: 4 213 337 338 526 636 734 767 804 1319 153 1550 1671 1984 2026 2210 2409 2934 3298 3338Stu I: 361Sty I: 345 2099Taq I: 254 371 666 1600 2202 2343 2818 3131 3446Taq IIB: 1802Taq IIB*: 2804Tth111II: 40 1107Tth111II*: 686 1075 1114Xba I: 364Xho II: 9 334 948 960 1046 1057 3093Xma I: 339Xma III: 2529Xmn I: 467__________________________________________________________________________ Total number of cuts is: 743.List of non cutting selected enzymes.__________________________________________________________________________Aat II, Asu II, Avr II, Bbv II*, Bcl I, Bgl II, Bsp MI*Bss HII, Bst EII, Bst XI, Eco 31I*, Esp I, Hpa I, Mlu IMme I, Nde I, Not I, Nsi I, Pst I, Pvu I, Pvu IIRsr II, Sac I, Sac II, Sau I, Sca I, Sci I, Sfi ISna BI, Spe I, Spl I, Ssp I, Taq IIA, Taq IIA*, Tth 111IVsp I, Xca I, Xho I__________________________________________________________________________ Total number of selected enzymes which do not cut: 38
FIG. 12A corresponds to the restriction and genetic map of the plasmid pIG2 used to make the intermediary construct pIG2 Mt32 as described in Example IV for the subcloning of the P 32 antigen in plasmid pIGRI.
FIGS. 12B-L correspond to the pIG2 nucleic acid sequence.
On this figure, the origin of nucleotide stretches used to construct plasmid pIG2 is specified hereafter.
Position
3300-206: lambda PL containing EcoRI-MboII blunt fragment of pPL(λ) (Pharmacia)
207-266: synthetic sequence containing multiple cloning site and ribosome binding site of which the ATG initiation codon is located at position 232-234
267-772: rrnBT 1 T 2 containing HindIII-SspI fragment from pKK223 (Pharmacia)
773-3300: tetracycline resistance gene and origin of replication containing EcoRI-DraI fragment of pAT 153 (Bioexcellence)
Table 7 corresponds to the complete restriction site analysis of pIG2.
TABLE 7__________________________________________________________________________RESTRICTION-SITE ANALYSIS__________________________________________________________________________ Done on DNA sequence pIG2 Total number of bases is: 3301. Analysis done on the complete sequence.__________________________________________________________________________List of cuts by enzyme.__________________________________________________________________________Acc I: 252 2647Acy I: 617 2093 2750 2864 2885Afl III: 1527Aha III: 222Alu I: 268 970 1227 1363 1589 2211 2614 3270 3285Alw NI: 1118Apa LI: 1213Asp 718I: 208Asu I: 376 505 595 1817 1859 2038 2162 2411 2499 2774 312Ava I: 1872Ava II: 376 1817 1859 2162 2411 2499Bal I: 1855Bam HI: 239 2922Bbe I: 2096 2753 2867 2888Bbv I: 271 1198 1617 1635 1748 1751 2695 3084Bbv I*: 899 1105 1108 1855 1879 2512Bbv II: 1704 2567Bgl I: 2135 2369Bin I: 15 247 785 883 969 2930Bin I*: 234 784 881 2195 2917Bsp HI: 737 807 2808Bsp MI: 264 2243Bst NI: 213 357 467 635 1368 1381 1502 1857 2240 3169Cau II: 4 565 598 1150 1815 2041 2765 3129Cfr 10I: 2014 2368 2528 2887 2896 3137Cfr I: 1853 2358 2766 2898 3002Cla I: 3275Cvi JI: 190 262 268 273 303 489 507 596 657 673 97 999 1042 1053 1118 1197 1222 1227 1363 1461 1487 150 1516 1589 1608 1808 1813 1855 1892 1974 2018 2039 204 2182 2192 2211 2252 2309 2317 2347 2360 2381 2426 247 2614 2630 2686 2704 2768 2776 2814 2828 2900 2969 300 3127 3151 3270 3285Cvi QI: 209 3135Dde I: 133 400 490 546 844 1253 1717Dpn I: 9 241 779 791 869 877 888 963 1839 2156 217 2202 2474 2833 2924 2951Dra II: 1817 1859 2774Dsa I: 230 1850 2769Eco 31I: 444Eco 47III: 1655 2524 2805 3067Eco 57I: 214Eco 57I*: 985Eco 78I: 2094 2751 2865 2886Eco NI: 196 2674Eco RII: 211 355 465 633 1366 1379 1500 1855 2238 3167Eco RV: 3114Fnu 4HI: 260 361 913 1119 1122 1187 1330 1485 1603 1606 162 1737 1740 1869 1883 1890 1893 2012 2091 2136 2193 227 2361 2526 2577 2684 2718 2721 2999 3002 3073Fnu DII: 371 903 1484 1666 1763 1885 1911 2056 2066 2195 226 2322 2327 2354 2483 2598 2954Fok I: 297 681 3199Fok I*: 645 2252 2297 3151Gsu I: 1917Gsu I*: 2471Hae I: 657 673 1053 1505 1516 1855 2252 2309 2381Hae II: 423 1287 1657 2096 2526 2753 2807 2867 2888 3069Hae III: 507 596 657 673 1053 1487 1505 1516 1855 2039 225 2309 2360 2381 2470 2704 2768 2776 2900 3004 3127Hga I: 158 181 625 1917 2067 2658Hga I*: 837 1415 2311 2343 2897Hgi AI: 139 1217 1836 2127 2714 3025Hgi CI: 208 2008 2092 2531 2749 2863 2884 3178 3221Hgi JII: 2816 2830Hha I: 371 422 903 1012 1186 1286 1353 1623 1656 1846 188 1944 2095 2354 2485 2525 2600 2752 2806 2866 2887 304 3068 3200Hin P1I: 369 420 901 1010 1184 1284 1351 1621 1654 1844 188 1942 2093 2352 2483 2523 2598 2750 2804 2864 2885 303 3066 3198Hind II: 107 253 2648Hind III: 266 3268Hinf I: 249 1157 1553 1628 1773 1994 2292 2446 2666Hpa II: 3 564 598 959 1149 1175 1322 1814 2015 2041 227 2369 2529 2605 2765 2888 2897 2912 3129 3138Hph I: 94 138 181 545 796 1782 2003 2857 2902 3184Hph I*: 6Kpn I: 212Mae I: 246 781 1034 1810 3069Mae II: 580 826 1729 1753 2342 2398Mae III: 169 991 1107 1170 2149 2416 3084 3172Mbo I: 7 239 777 789 867 875 886 961 1837 2154 216 2200 2472 2831 2922 2949Mbo II: 207 304 799 1661 1709 2301 2572Mbo II*: 870 2826Mme I*: 1134 1318 2994 3081Mnl I: 253 1100 1424 1830 2328 2512Mnl I*: 208 593 1349 1632 1998 2025 2063 2124 2426 2693 291 3116 3176Mse I: 179 186 221 315 646 823 3243 3265Mst I: 1845 1943 3039Nae I: 2016 2370 2530 2898Nar I: 2093 2750 2864 2885Nco I: 230Nhe I: 3068Nla III: 166 234 394 449 741 811 1531 1710 1844 2051 210 2123 2251 2368 2554 2593 2739 2812 2950 3297Nla IV: 210 241 378 1460 1499 1818 1861 1975 2010 2045 209 2412 2533 2751 2775 2865 2886 2924 2970 3180 3223Nru I: 2327Nsp BII: 944 1189 2160Nsp HI: 1531 2739Pfl MI: 1934 1983Ple I: 257 1636Ple I*: 1151 2660Ppu MI: 1817 1859Pss I: 1820 1862 2777Pst I: 261Rsa I: 210 3136Sal I: 251 2646Scr FI: 4 213 357 467 565 598 635 1150 1368 1381 150 1815 1857 2041 2240 2765 3129 3169Sdu I: 139 1217 1836 2127 2714 2816 2830 3025Sec I: 3 230 1367 1850 1928 2130 2763 2769 3168 3182Sfa NI: 479 647 2274 2649 3060 3173Sfa NI*: 1430 1867 2262 2883 2895 3084Sph I: 2739Sso II: 2 211 355 465 563 596 633 1148 1366 1379 150 1813 1855 2039 2238 2763 3127 3167Ssp I: 226Sty I: 230 1928Taq I: 252 495 1429 2031 2172 2647 2960 3275Taq IIB: 1631Taq IIB*: 2633Tth111II: 38 936Tth111II*: 515 904 943Xba I: 245Xho II: 7 239 777 789 875 886 2922Xma III: 2358Xmn I: 296Eco RI: 3300__________________________________________________________________________ Total number of cuts is: 689.List of non cuttings elected enzymes.__________________________________________________________________________Aat II, Afl II, Apa I, Asu II, Avr II, Bbv II*, Bcl IBgl II, Bsp MI*, Bsp MII, Bss HII, Bst EII, Bst XI, Dra IIIEco 31I*, Esp I, Hpa I, Mlu I, Mme I, Nde I, Not INsi I, Pma CI, Pvu I, Pvu II, Rsr II, Sac I, Sac IISau I, Sca I, Sci I, Sfi I, Sma I, Sna BI, Spe ISpl I, Stu I, Taq IIA, Taq IIA*, Tth 111I, Vsp I, Xca IXho I, Xma I__________________________________________________________________________ Total number of selected enzymes which do not cut: 44
FIG. 13 corresponds to the amino acid sequence of the total fusion protein mTNF-His 6 -P 32 .
On this figure:
the continuous underlined sequence ( ) represents the mTNF sequence (first 25 amino acids),
the dotted underlined sequence (---) represents the polylinker sequence, the double underlined sequence (--) represents the extra amino acids created at cloning site, and
the amino acid marked with nothing is the antigen sequence starting from the amino acid at position 4 of FIG. 5.
FIGS. 14A and 14B correspond to the expression of the mTNF-His 6 -P 32 fusion protein in K12ΔH, given in Example VI, with FIG. 14A representing the Coomassie Brilliant Blue stained SDS-PAGE and 14B representing immunoblots of the gel with anti-32-kDa and anti-mTNF-antibody.
On FIG. 14A, the lanes correspond to the following:
Lanes______________________________________1. protein molecular weight markers2. pmTNF-MPH-Mt32 28° C. 1 h induction3. " 42° C. 1 h induction4. " 42° C. 2 h induction5. " 42° C. 3 h induction6. " 28° C. 4 h induction7. " 42° C. 4 h induction8. " 28° C. 5 h induction9. " 42° C. 5 h induction______________________________________
On FIG. 14B, the lanes correspond to the following:
Lanes______________________________________1. pmTNF-MPH-Mt32 28° C. 1 h induction2. " 42° C. 1 h induction3. " 28° C. 4 h induction4. " 42° C. 4 h induction______________________________________
FIG. 15 corresponds to the IMAC elution profile of the recombinant antigen with decreasing pH as presented in Example VII.
FIG. 16 corresponds to the IMAC elution profile of the recombinant antigen with increasing imidazole concentrations as presented in Example VII.
FIG. 17 corresponds to the IMAC elution profile of the recombinant antigen with a step gradient of increasing imidazole concentrations as presented in Example VII.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
EXAMPLE I
MATERIAL AND METHODS
Screening of the λgt11 M. tuberculosis recombinant DNA library with anti-32-kDa antiserum
A λgt11 recombinant library constructed from genomic DNA of M. tuberculosis (Erdman strain), was obtained from R. Young (35). Screening was performed as described (14,35) with some modifications hereafter mentioned. λgt11 infected E. coli Y1090 (10 5 pfu per 150 mm plate) were seeded on NZYM plates (Gibco) (16) and incubated at 42° C. for 24 hrs. To induce expression of the β-galactosidase-fusion proteins the plate were overlaid with isopropyl β-D-thiogalactoside (IPTG)-saturated filters (Hybond C extra, Amersham), and incubated for 2 hrs at 37° C. Screening was done with a polyclonal rabbit anti-32-kDa antiserum. Said polyclonal antiserum rabbit anti-32-kDa antiserum was obtained by raising antiserum against the P 32 M. bovis BCG (strain 1173P2--Institut Pasteur Paris) as follows: 400 μg (purified P 32 protein of M. bovis BCG) per ml physiological saline were mixed with one volume of incomplete Freund's adjuvant. The material was homogenized and injected intradermally in 50 μl doses, delivered at 10 sites in the back of the rabbits, at 0, 4, 7 and 8 weeks (adjuvant was replaced by the diluent for the last injection). One week later, the rabbits were bled and the sera tested for antibody level before being distributed in aliquots and stored at -80° C.
The polyclonal rabbit anti-32-kDa antiserum was pre-absorbed on E. coli lysate (14) and used at a final dilution of 1:300. A secondary alkaline-phosphatase anti-rabbit IgG conjugate (Promega), diluted at 1:5000 was used to detect the β-galactosidase fusion proteins. For color development nitro blue tetrazolium (NBT) and 5-bromo-4-chloro-3-indolyl phosphate (BCIP) were used. Reactive areas on the filter turned deep purple within 30 min. Usually three consecutive purification steps were performed to obtain pure clones. IPTG, BCIP and NBT were from Promega corp. (Madison, Wis.).
Plaque screening by hybridization for obtaining the secondary clones BY1, By2 and By5 hereafter defined
The procedure used was as described by Maniatis et al. (14).
Preparation of crude lysates from λgt11 recombinant lysogens
Colonies of E. coli Y1089 were lysogenized with appropriate λgt11 recombinants as described by Hyunh et al. (14). Single colonies of lysogenized E. coli Y1089 were inoculated into LB medium and grown to an optical density of 0.5 at 600 nm at 30 ° C. After a heat shock at 45° C. for 20 min., the production of β-galactosidase-fusion protein was induced by the addition of IPTG to a final concentration of 10 mM. Incubation was continued for 60 min. at 37° C. and cells were quickly harvested by centrifugation. Cells were concentrated 50 times in buffer (10 mM Tris pH 8.0, 2 mM EDTA) and rapidly frozen into liquid nitrogen. The samples were lysed by thawing and treated with 100 μg/ml DNase I in EcoRI restriction buffer, for 5-10 minutes at 37° C.
Immunoblotting (Western blotting) analysis
After SDS-PAGE electrophoresis, recombinant lysogen proteins were blotted onto nitrocellulose membranes (Hybond C, Amersham) as described by Towbin et al. (29). The expression of mycobacterial antigens, fused to β-galactosidase in E. coli Y1089 was visualized by the binding of a polyclonal rabbit anti-32-kDa antiserum (1:1000) obtained as described in the above paragraph "Screening of the λgt11 M. tuberculosis recombinant DNA library with anti-32-kDa antiserum" and using a monoclonal anti-β-galactosidase antibody (Promega). A secondary alkaline-phosphatase anti-rabbit IgG conjugate (Promega) diluted at 1:5000, was used to detect the fusion proteins.
The use of these various antibodies enables to detect the β-galactosidase fusion protein. This reaction is due to the M. tuberculosis protein because of the fact that non fused-β-galactosidase is also present on the same gel and is not recognized by the serum from tuberculous patients.
In order to identify selective recognition of recombinant fusion proteins by human tuberculous sera, nitrocellulose sheets were incubated overnight with these sera (1:50) (after blocking a specific protein binding sites). The human tuberculous sera were selected for their reactivity (high or low) against the purified 32-dKa antigen of M. bovis BCG tested in a Dot blot assay as previously described (31). Reactive areas on the nitrocellulose sheets were revealed by incubation with peroxidase conjugated goat anti-human IgG antibody (Dakopatts, Copenhagen, Denmark) (1:200) for 4 hrs and after repeated washings color reaction was developed by adding peroxidase substrate (α-chloronaphthol) (Bio-Rad) in the presence of peroxidase and hydrogen peroxide.
Recombinant DNA analysis
Initial identification of M. tuberculosis DNA inserts in purified λgt11 clones was performed by EcoRI restriction. After digestion, the excised inserts were run on agarose gels and submitted to Southern hybridization. Probes were labeled with α 32 P-dCTP by random priming (10). Other restriction sites were located by single and double digestions of recombinant λgt11 phage DNA or their subcloned EcoRI fragments by HindIII, PstI, KpnI, AccI and SphI.
Sequencing
Sequence analysis was done by the primer extension dideoxy termination method of Sanger et al. (25) after subcloning of specific fragments in Bluescribe-M13 (6) or in mp10 and mp11 M13 vectors (Methods in Enzymology, vol. 101, 1983, p. 20-89, Joachim Messing, New M13 vectors for cloning, Academic Press). Sequence analysis was greatly hampered by the high GC content of the M. tuberculosis DNA (65%). Sequencing reactions were therefore performed with several DNA polymerases: T7 DNA polymerase ("Sequenase" USB), Klenow fragment of DNA polymerase I (Amersham) and in some cases with AMV reverse transcriptase (Super RT, Anglian Biotechnology Ltd.) and sometimes with dITP instead of dGTP. Several oligodeoxynucleotides were synthesized and used to focus ambiguous regions of the sequence. The sequencing strategy is summarized in FIG. 2. In order to trace possible artefactual frameshifts in some ambiguous regions, a special program was used to define the most probably open reading frame in sequences containing a high proportion of GC (3). Several regions particularly prone to sequencing artefacts were confirmed or corrected by chemical sequencing (18). For this purpose, fragments were subcloned in the chemical sequencing vector pGV462 (21) and analysed as described previously. Selected restriction fragments of about 250-350 bp were isolated, made blunt-ended by treatment with either Klenow polymerase or Mung bean nuclease, and subcloned in the SmaI or HincII site of pGV462. Both strands of the inserted DNA were sequenced by single-end labeling at Tth 111I or BstEII (32) and a modified chemical degradation strategy (33).
Routine computer aided analysis of the nucleic acid and deduced amino acid sequences were performed with the LGBC program from Bellon (2). Homology searches used the FASTA programs from Pearson and Lipman (23) and the Protein Identification Resource (PIR) from the National Biomedical Research Fundation--Washington (NBRF) (NBRF/PIR data bank), release 16 (March 1988).
RESULTS
Screening of the λgt11M, M. tuberculosis recombinant DNA library with polyclonal anti-32-kDa antiserum
Ten filters representing 1.5×10 6 plaques were probed with a polyclonal rabbit anti-32-kDa antiserum (8). Following purification, six independent positive clones were obtained.
Analysis of recombinant clones
EcoRI restriction analysis of these 6 purified λgt11 recombinant clones DNA, (FIG. 1A) revealed 4 different types of insert. Clone 15 had an insert with a total length of 3.8 kb with two additional internal EcoRI sites resulting in three DNA fragments of 1.8 kb, 1.5 kb and 0.5 kb. The DNA Insert of clone 16 was 1.7 kb long. Clones 17 and 19 had a DNA insert of almost identical length being 2.7 kb and 2.8 kb respectively.
Finally, clone 23 (not shown) and clone 24 both contained an insert of 4 kb with one additional EcoRI restriction site giving two fragments of 2.3 kb and 1.7 kb. Southern analysis (data not shown) showed that the DNA inserts of clones 15, 16, 19 and the small fragment (1.7 kb) of clone 24 only hybridized with themselves whereas clone 17 (2.7 kb) hybridized with itself but also equally well with the 2.3 kb DNA fragment of clone 24. Clones 15, 16 and 19 are thus distinct and unrelated to the 17, 23, 24 group. This interpretation was further confirmed by analysis of crude lysates of E. coli Y1089 lysogenized with the appropriate λgt11 recombinants and induced with IPTG. Western blot analysis (FIG. 1B), showed no fusion protein, either mature or incomplete, reactive with the polyclonal anti-32-kDa antiserum in cells expressing clones 15, 16 and 19. Clones 15, 16 and 19, were thus considered as false positives and were not further studied. On the contrary, cells lysogenized with clone 23 and 24 produced an immunoreactive fusion protein containing about 10 kDa of the 32-kDa protein. Clone 17 finally expressed a fusion protein of which the foreign polypeptide part is about 25 kDa long. The restriction endonuclease maps of the 2.3 kb insert of clone 24 and of the 2.7 kb fragment of clone 17 (FIG. 2) allowed us to align and orient the two inserts suggesting that the latter corresponds to a ±0.5 kb 5' extension of the first.
As clone 17 was incomplete, the same λgt11 recombinant M. tuberculosis DNA library was screened by hybridization with a 120 bp EcoRI-Kpnl restriction fragment corresponding to the very 5' end of the DNA insert of clone 17 (previously subcloned in a Blue Scribe vector commercialized by Vector cloning Systems (Stratagene Cloning System) (FIG. 2). Three 5'-extended clones By1, By2 and By5 were isolated, analyzed by restriction and aligned. The largest insert, By5 contained the information for the entire coding region (see below) flanked by 3.1 kb upstream and 1.1 kb downstream (FIG. 2).
DNA sequencing
The 1358 base pairs nucleotide sequence derived from the various λgt11 overlapping clones is represented in FIGS. 3a and 3b. The DNA sequence contains a 1059 base pair open reading frame starting at position 183 and ending with a TAG codon at position 1242. It occurs that the NH 2 -terminal amino-acid sequence, (phe-ser-arg-pro-gly-leu-pro-val-glu-tyr-leu-gln-val-pro-ser-pro-ser-met-gly-arg-asp-ile-lys-val-gln-phe-gln-ser-gly-gly-ala-asn) which can be located within this open reading frame from the nucleotide sequence beginning with a TTT codon at position 360 corresponds to the same NH 2 -terminal amino acid sequence of the MPB 59 antigen except for the amino acids at position 20, 21, 31, which are respectively gly, cys and asn in the MPB 59 (34). Therefore, the DNA region upstream of this sequence is expected to encode a signal peptide required for the secretion of a protein of 32-dKa. The mature protein thus presumably consists of 295 amino acid residues from the N-terminal Phe (TTT codon) to the C-terminal Ala (GCC codon) (FIG. 5).
Six ATG codons were found to precede the TTT at position 360 in the same reading frame. Usage of any of these ATGs in the same reading frame would lead to the synthesis of signal peptides of 29, 42, 47, 49, 55 and 59 residues.
Hydropathy pattern
The hydropathy pattern coding sequence of the protein of 32-kDa of the invention and that of the antigen α of BCG (17) were determined by the method of Kyte and Doolittle (15). The nonapeptide profiles are shown in FIG. 6. Besides the initial hydrophobic signal peptide region, several hydrophilic domains could be identified. It is interesting to note that the overall hydrophilicity pattern of the protein of 32-kDa of the invention is comparable to that of the BCG antigen α. For both proteins, a domain of highest hydrophilicity could be identified between amino acid residues 200 and 250.
Homology
Matsuo et al. (17) recently published the sequence of a 1095 nucleotide cloned DNA corresponding to the gene coding for the antigen α of BCG. The 978 bp coding region of M. bovis antigen α as revised in Infection and Immunity, vol. 58, p. 550-556, 1990, and 1017 bp coding regions of the protein of 32-kDa of the invention show a 77.5% homology, in an aligned region of 942 bp. At the amino acid level both precursor protein sequences share 75.6% identical residues. In addition, 17.6% of the amino acids correspond to evolutionary conserved replacements as defined in the algorithm used for the comparison (PAM250 matrix, ref 23). FIG. 7 shows sequence divergences in the N-terminal of the signal peptide. The amino terminal sequence--32 amino acids--of both mature proteins is identical except for position 31.
Human sera recognize the recombinant 32-kDa protein
FIG. 8 shows that serum samples from tuberculous patients when immunoblotted with a crude E. coli extract expressing clone 17 distinctly react with the 140 kDa fusion protein (lanes 4 to 6) contain the protein of 32-kDa of the invention, but not with unfused β-galactosidase expressed in a parallel extract (lanes 10 to 12). Serum samples from two negative controls selected as responding very little to the purified protein of 32-kDa of the invention does neither recognize the 140 kDa fused protein containing the protein of 32-dKa of the invention, nor the unfused β-galactosidase (lanes 2, 3 and 8 and 9). The 140 k-Da fused protein and the unfused β-galactosidase were easily localized reacting with the anti-β-galactosidase monoclonal antibody (lanes 1 to 7).
The invention has enabled to prepare a DNA region coding particularly for a protein of 32-kDa (cf. FIG. 5); said DNA region containing an open reading frame of 338 codons (stop codon non included). At position 220 a TTT encoding the first amino acid of the mature protein is followed by the 295 triplets coding for the mature protein of 32-kDa. The size of this open reading frame, the immunoreactivity of the derived fusion proteins, the presence of a signal peptide and, especially, the identification within this gene of a NH 2 -terminal region highly homologous to that found in the MPB 59 antigen (31/32 amino acids homology) and in the BCG antigen α (31/32 amino acids homology) (see FIG. 7), strongly suggest that the DNA fragment described contains the complete cistron encoding the protein of 32-kDa secreted by M. tuberculosis, and which had never been so far identified in a non ambiguous way.
Six ATG codons were found to precede this TTT at position 220 in the same reading frame. Usage of any of these ATGs in the same reading frame would lead to the synthesis of signal peptides of 43, 48, 50, 56 or 60 residues. Among these various possibilities, initiation is more likely to take place either at ATG 91 or ATG 52 because both are preceded by a plausible E. coli-like promoter and a Shine-Dalgarno motif.
If initiation takes place at ATG 91 , the corresponding signal peptide would code for a rather long peptide signal of 43 residues. This length however is not uncommon among secreted proteins from Gram positive bacteria (5). It would be preceded by a typical E. coli Shine-Dalgarno motif (4/6 residues homologous to AGGAGG) at a suitable distance.
If initiation takes place at ATG 52 , the corresponding signal peptide would code for a peptide signal of 56 residues but would have a less stringent Shine-Dalgarno ribosome binding site sequence.
The region encompassing the translation termination triplet was particularly sensitive to secondary structure effects which lead to so-called compressions on the sequencing gels. In front of the TAG termination codon at position 1105, 22 out of 23 residues are G-C base pairs, of which 9 are G's.
Upstream ATG 130 , a sequence resembling an E. coli promoter (11) comprising an hexanucleotide (TTGAGA) (homology 5/6 to TTGACA) and a AAGAAT box (homology 4/6 to TATAAT) separated by 16 nucleotides was observed. Upstream the potential initiating codon ATG 91 , one could detect several sequences homologous to the E. coli "-35 hexanucleotide box", followed by a sequence resembling a TATAAT box. Among these, the most suggestive is illustrated on FIGS. 3a and 3b. It comprises a TTGGCC at position 59 (FIGS. 3a and 3b) (homology 4/6 to TTGACA) separated by 14 nucleotides from a GATAAG (homology 4/6 to TATAAT). Interestingly this putative promoter region shares no extensive sequence homology with the promoter region described for the BCG protein α-gene (17) nor with that described for the 65 kDa protein gene (26, 28).
Searching the NBRF data bank (issue 16.0) any significant homology between the protein of 32-kDa of the invention and any other completely known protein sequence could not be detected. In particular no significant homology was observed between the 32-kDa protein and α and β subunits of the human fibronectin receptor (1). The NH 2 -terminal sequence of the 32-kDa protein of the invention is highly homologous--29/32 amino acids--to that previously published for BCG MPB 59 antigen (34) and to that of BCG α-antigen--31/32 amino acids--(Matsuo, 17) and is identical in its first 6 amino acids with the 32-kDa protein of M. bovis BCG (9). However, the presumed initiating methionine precedes an additional 29 or 42 amino acid hydrophobic sequence which differs from the one of α-antigen (cf. FIG. 7), but displaying all the characteristics attributed to signal sequences of secreted polypeptides in prokaryotes (22).
Interestingly, no significant homology between the nucleic acid (1-1358) of the invention (cf. FIGS. 3a and 3b) and the DNA of the antigen α of Matsuo exists within their putative promoter regions.
EXAMPLE II
CONSTRUCTION OF A BACTERIAL PLASMID CONTAINING THE ENTIRE CODING SEQUENCE OF THE 32-kDa PROTEIN OF M. TUBERCULOSIS
In the previous example, in FIG. 2, the various overlapping λgt11 isolates covering the 32-kDa protein gene region from M. tuberculosis were described. Several DNA fragments were subcloned from these λgt11 phages in the Blue Scribe M13+ plasmid (Stratagene). Since none of these plasmids contained the entire coding sequence of the 32-kDa protein gene, a plasmid containing this sequence was reconstructed.
Step 1
Preparation of the DNA fragments
1) The plasmid BS-Buy5-800 obtained by subcloning HindIII fragments of By5 (cf. FIG. 2) into the Blue Scribe M13 + plasmid (Stratagene), was digested with HindIII and a fragment of 800 bp was obtained and isolated from a 1% agarose gel by electroelution.
2) The plasmid BS-4.1 obtained by subcloning the 2,7 kb EcoRI insert from λgt11-17) into the Blue Scribe M13 + plasmid (Stratagene) (see FIG. 2 of patent application) was digested with HindIII and SphI and a fragment of 1500 bp was obtained and isolated from a 1% agarose gel by electroelution.
3) Blue Scribe M13 + was digested with HindIII and SphI, and treated with calf intestine alkaline phosphatase (special quality for molecular biology, Boehringer Mannheim) as indicated by the manufacturer.
Step 2
ligation
The ligation reaction contained
125 ng of the 800 bp HindIII fragment (1)
125 ng of the 1500 bp SphI-HindIII insert (2)
50 ng of the HindIII-SphI digested BSM13 + vector (3)
2 μl of 10 ligation buffer (Maniatis et al., 1982)
1 μl of (=2,5 U) of T4 DNA ligase (Amersham)
4 μl PEG 6000, 25% (w/v)
8 μl H 2 O
The incubation was for 4 hours at 16° C.
Step 3
Transformation
100 μl of DH5α E. coli (Gibco BRL) were transformed with 10 μl of the ligation reaction (step 2) and plated on IPTG, X-Gal ampicillin plates, as indicated by the manufacturer. About 70 white colonies were obtained.
Step 4
As the 800 bp fragment could have been inserted in both orientations, plasmidic DNA from several clones were analyzed by digestion with PstI in order to select one clone (different from clone 11), characterized by the presence of 2 small fragments of 229 and 294 bp. This construction contains the HindIII-HindIII-SphI complex in the correct orientation. The plasmid containing this new construction was called: "BS.BK.P 32 .complet".
EXAMPLE III
EXPRESSION OF A POLYPEPTIDE OF THE INVENTION IN E. COLI
The DNA sequence coding for a polypeptide, or part of it, can be linked to a ribosome binding site which is part of the expression vector, or can be fused to the information of another protein or peptide already present on the expression vector.
In the former case the information is expressed as such and hence devoid of any foreign sequences (except maybe for the aminoterminal methionine which is not always removed by E. coli).
In the latter case the expressed protein is a hybrid or a fusion protein.
The gene, coding for the polypeptide, and the expression vector are treated with the appropriate restriction enzyme(s) or manipulated otherwise as to create termini allowing ligation. The resulting recombinant vector is used to transform a host. The transformants are analyzed for the presence and proper orientation of the inserted gene. In addition, the cloning vector may be used to transform other strains of a chosen host. Various methods and materials for preparing recombinant vectors, transforming them to host cells and expressing polypeptides and proteins are described by Panayatatos, N., in "Plasmids, a practical approach" (ed. K. G. Hardy, IRL Press) pp. 163-176, by Old and Primrose, principals of gene manipulation (2d Ed, 1981) and are well known by those skilled in the art.
Various cloning vectors may be utilized for expression. Although a plasmid is preferably, the vector may be a bacteriophage or cosmid. The vector chosen should be compatible with the host cell chosen.
Moreover, the plasmid should have a phenotypic property that will enable the transformed host cells to be readily identified and separated from those which are not transformed. Such selection genes can be a gene providing resistance to an antibiotic like for instance, tetracyclin, carbenicillin, kanamycin, chloramphenicaol, streptomycin, etc.
In order to express the coding sequence of a gene in E. coli the expression vector should also contain the necessary signals for transcription and translation.
Hence it should contain a promoter, synthetic or derived from a natural source, which is functional in E. coli. Preferably, although usually not absolutely necessary, the promoter should be controllable by the manipulator. Examples of widely used controllable promoters for expression in E. coli are the lac, the trp, the tac and the lambda PL and PR promoter.
Preferably, the expression vector should also contain a terminator of transcription functional in E. coli. Examples of used terminators of transcription are the trp and the rrnB terminators.
Furthermore, the expression vector should contain a ribosome binding site, synthetic or from a natural source, allowing translation and hence expression of a downstream coding sequence. Moreover, when expression devoid of foreign sequences is desired, a unique restriction site, positioned in such a way that it allows ligation of the sequence directly to the initiation codon of the ribosome binding site, should be present.
A suitable plasmid for performing this type of expression is pKK233-2 (Pharmacia). This plasmid contains the trc promoter, the lac Z ribosome binding site and the rrnB transcription terminator.
Also suitable is plasmid pIGRI (Innogenetics, Ghent, Belgium). This plasmid contains the tetracycline resistance gene and the origin of replication of pAT 153 (available from Bioexcellence, Biores B.V., Woerden, The Netherlands), the lambda PL promoter up to the MboII site in the 5' untranslated region of the lambda N gene (originating from pPL(λ); Pharmacia).
Downstream from the PL promoter, a synthetic sequence was introduced which encodes a "two cistron" translation cassette whereby the stop codon of the first cistron (being the first 25 amino acids of TNF, except for Leu at position 1 which is converted to Val) is situated between the Shine-Dalgarno sequence and the initiation codon of the second ribosome binding site. The restriction and genetic map of pIGRI is represented in FIG. 10a.
FIG. 10b and Table 5 represent respectively the nucleic acid sequence and complete restriction site analysis of pIGRI.
However, when expression as a hybrid protein is desired, then the expression vector should also contain the coding sequence of a peptide or polypeptide which is (preferably highly) expressed by this vector in the appropriate host.
In this case the expression vector should contain a unique cleavage site for one or more restriction endonucleases downstream of the coding sequence.
Plasmids pEX1, 2 and 3 (Boehringer, Mannheim) and pUEX1, 2 and 2 (Amersham) are useful for this purpose.
They contain an ampicillin resistance gene and the origin of replication of pBR322 (Bolivar at al. (1977) Gene 2, 95-113), the lac Z gene fused at its 5' end to the lambda PR promoter together with the coding sequence for the 9 first amino acids of its natural gene cro, and a multiple cloning site at the 3' end of the lac Z coding sequence allowing production of a beta galactosidase fused polypeptide.
The pUEX vectors also contain the CI857 allele of the bacteriophage lambda CI repressor gene.
Also useful is plasmid pmTNF MPH (Innogenetics). It contains the tetracycline resistance gene and the origin of replication of pAT 153 (obtainable from Bioexcellence, Biores B.V., Woerden. The Netherlands), the lambda PL promoter up to the MboII site in the N gene 5' untranslated region (originating from pPL(λ); Pharmacia), followed by a synthetic ribosome binding site (see sequence data), and the information encoding the first 25 AA of mTNF (except for the initial Leu which is converted to Val). This sequence is, in turn, followed by a synthetic polylinker sequence which encodes six consecutive histidines followed by several proteolytic sites (a formic acid, CNBr, kallikrein, and E. coli protease VII sensitive site, respectively), each accessible via a different restriction enzyme which is unique for the plasmid (SmaI, NcoI, BspMII and StuI, respectively; see restriction and genetic map, FIG. 11a). Downstream from the polylinker, several transcription terminators are present including the E. coli trp terminator (synthetic) and the rrnBT 1 T 2 (originating from pKK223-3; Pharmacia). The total nucleic acid sequence of this plasmid is represented in FIG. 11b.
Table 6 gives a complete restriction site analysis of pmTNF MPH.
The presence of 6 successive histidines allows purification of the fusion protein by Immobilized Metal Ion Affinity Chromatography (IMAC).
After purification, the foreign part of the hybrid protein can be removed by a suitable protein cleavage method and the cleaved product can then be separated from the uncleaved molecules using the same IMAC based purification procedure.
In all the above-mentioned plasmids where the lambda PL or PR promoter is used, the promoter is temperature-controlled by means of the expression of the lambda cI ts 857 allele which is either present on a defective prophage incorporated in the chromosome of the host (K12ΔH, ATCC n° 33767) or on a second compatible plasmid (pACYC derivative). Only in the pUEX vectors is this cI allele present on the vector itself.
It is to be understood that the plasmids presented above are exemplary and other plasmids or types of expression vectors maybe employed without departing from the spirit or scope of the present invention.
If a bacteriophage or phagemid is used, instead of plasmid, it should have substantially the same characteristics used to select a plasmid as described above.
EXAMPLE IV
SUBCLONING OF THE P32 ANTIGEN IN PLASMID pIGRI
Fifteen μg of plasmid "BS-BK-P 32 complet" (see Example II) was digested with EclXI and BstEII (Boehringer, Mannheim) according to the conditions recommended by the supplier except that at least 3 units of enzyme were used per μg of DNA. EclXI cuts at position 226 (FIG. 5) and BstEII at position 1136, thus approaching very closely the start and stop codon of the mature P 32 antigen. This DNA is hereafter called DNA coding for the "P 32 antigen fragment".
The DNA coding for the "P 32 antigen fragment" (as defined above) is subcloned in pIGRI (see FIG. 10a) for expression of a polypeptide devoid of any foreign sequences. To bring the ATG codon of the expression vector in frame with the P 32 reading frame, an intermediary construct is made in pIG2 (for restriction and genetic map, see FIG. 12a; DNA sequences, see FIG. 12b; complete restriction site analysis, see Table 7).
Five μg of plasmid pIG2 is digested with NcoI. Its 5' sticky ends are filled in prior to dephosphorylation.
Therefore, the DNA was incubated in 40 μl NB buffer (0.05M Tris-Cl pH 7.4; 10 mM MgCl 2 ; 0.05% β-mercaptoethanol) containing 0.5 mM of all four dXTP (X=A,T,C,G) and 2 μl of Klenow fragment of E. coli DNA polymerase I (5 U/μl, Boehringer, Mannheim) for at least 3 h at 15° C.
After blunting, the DNA was once extracted with one volume of phenol equilibrated against 200 mM Tris-Cl pH 8, twice with at least two volumes of diethylether and finally collected using the "gene clean kit™" (Bio101) as recommended by the supplier. The DNA was then dephosphorylated at the 5' ends in 30 μl of CIP buffer (50 mM TrisCl pH 8, 1 mM ZnCl 2 ) and 20 to 25 units of calf intestine phosphatase (high concentration, Boehringer, Mannheim). The mixture was incubated at 37° C. for 30 min, then EGTA (ethyleneglycol bis (β-aminoethylether)-N,N,N',N' tetraacetic acid) pH 8 is added to a final concentration of 10 mM. The mixture was then extracted with phenol followed by diethylether as described above, and the DNA was precipitated by addition of 1/10 volume of 3M KAc (Ac=CH 3 COO) pH 4.8 and 2 volumes of ethanol followed by storage at -20° C. for at least one hour.
After centrifugation at 13000 rpm in a Biofuge A (Hereaus) for 5 min the pelleted DNA was dissolved in H 2 O to a final concentration of 0.2 μg/μl.
The EclXI-BstEII fragment, coding for the "P 32 antigen fragment" (see above) was electrophoresed on a 1% agarose gel (BRL) to separate it from the rest of the plasmid and was isolated from the gel by centrifugation over a Millipore HVLP filter (φ 2 cm) (2 min,, 13000 rpm, Biofuge at room temperature) and extracted with Tris equilibrated phenol followed by diethylether as described above.
The DNA was subsequently collected using the "Gene clean kit™" (Bio101) as recommended by the supplier.
After that, the 5' sticky ends were blunted by treatment with the Klenow fragment of E. coli DNA polymerase I as described above and the DNA was then again collected using the "Gene clean kit™" in order to dissolve it in 7 μl of H 2 O.
One μl of vector DNA is added together with one μl of 10×ligase buffer (0.5M TrisCl pH 7.4, 100 mM MgCl 2 , 5 mM ATP, 50 mM DTT (dithiothreitol)) and 1 μl of T4 DNA ligase (1 unit/μl, Boehringer, Mannheim). Ligatin was performed for 6 h at 13° C. and 5 μl of the mixture is then used to transform strain DH1 (lambda) strain DH1--ATCC N° 33849--lysogenized with wild type bacteriophage λ! using standard transformation techniques as described for instance by Maniatis et al. in "Molecular cloning, a laboratory manual", Cold Spring Harbor Laboratory (1982).
Individual transformants are grown and lysed for plasmid DNA preparation using standard procedures (Experiments with gene fusion, Cold Spring Harbor Laboratory (1984) (T. J. Silhavy, H. L Berman and L. W. Enquist, eds) and the DNA preparations are checked for the correct orientation of the gene within the plasmid by restriction enzyme analysis.
A check for correct blunting is done by verifying the restoration of the NcoI site at the 5' and 3' end of the antigen coding sequence. One of the clones containing the P 32 antigen fragment in the correct orientation is kept for further work and designated pIG 2 -Mt32. In this intermediary construct, the DNA encoding the antigen is not in frame with the ATG codon. However, it can now be moved as a NcoI fragment to another expression vector.
15 μg of pIG 2 -Mt32 id digested with NcoI. The NcoI fragment encoding the P 32 antigen is gel purified and blunted as described above. After purification, using "gene clear kit™" it is dissolved in 7 μl of H 2 O.
5 μg of plasmid pIGRI is digested with NcoI, blunted and dephosphorylated as described above. After phenol extraction, followed by diethylether and ethanol precipitation, the pellet is dissolved in H 2 O to a final concentration of 0.2 μg/μl.
Ligation of vector and "antigen fragment" DNA is carried out as described above. The ligation mixture is then transformed into strain DH1 (lambda) and individual transformants are analysed for the correct orientation of the gene within the plasmid by restriction enzyme analysis. A check for correct blunting is done by verifying the creation of a new NsiI site at the 5' and 3' ends of the antigen coding sequence. One of the clones containing the P 32 antigen fragment in the correct orientation is kept for further work and designated pIGRI.Mt32.
EXAMPLE V
SUBCLONING OF THE P32 ANTIGEN IN pmTNF MPS
Fifteen μg of the plasmid pIG2 Mt32 (see example IV) was digested with the restriction enzyme NcoI (Boehringer, Mannheim), according to the conditions recommended by the supplier except that at least 3 units of enzyme were used per μg of DNA.
After digestion, the reaction mixture is extracted with phenol equilibrated against 200 mM TrisCl pH 8, (one volume), twice with diethylether (2 volumes) and precipitated by addition of 1/10 volume of 3M KAc (Ac═CH 3 COO) pH 4.8 and 2 volumes of ethanol followed by storage at -20° C. for at least one hour.
After centrifugation for 5 minutes at 13000 rpm in a Biofuge A (Hereaus) the DNA is electrophoresed on a 1% agarose gel (BRL).
The DNA coding for the "P 32 antigen fragment" as described above, is isolated by centrifugation over a Millipore HVLP filter (φ 2 cm) (2 minutes, 13000 rpm, Biofuges at room temperature) and extracted one with trisCl equilibrated phenol and twice with diethylether. The DNA is subsequently collected using "Gene clean kit™" (Bio 101) and dissolved in 7 μl of H 2 O.
The 5' overhanging ends of the DNA fragment generated by digestion with NcoI were filled in by incubating the DNA in 40 μl NB buffer (0.05M Tris-HCl, pH 7.4; 10 mM MgCl 2 ; 0.05% β-mercaptoethanol) containing 0.5 mM of all four dXTPS (X=A, T, C, G) and 2 μl of Klenow fragment of E. coli DNA polymerase I (5 units/μl Boehringer Mannheim) for at least 3 h at 15° C. After blunting, the DNA was extracted with phenol, followed by diethylether, and collected using a "gene clean kit™" as described above.
Five μg of plasmid pmTNF MPH is digested with StuI, subsequently extracted with phenol, followed by diethylether, and precipitated as described above. The restriction digest is verified by electrophoresis of a 0.5 μg sample on an analytical 1,2% agarose gel.
The plasmid DNA is then desphosphorylated at the 5' ends to prevent self-ligation in 30 μl of CIP buffer (50 mM TrisCl pH 8, 1 mM ZnC12) and 20 to 25 units of calf intestine phosphatase (high concentration, Boehringer Mannheim). The mixture is incubated at 37° C. for 30 minutes, then EGTA (ethyleneglycol bis (β-aminoethylether)-N,N,N',N' tetraacetic acid) pH 8 is added to a final concentration of 10 mM. The mixture is extracted with phenol followed by diethylether and the DNA is precipitated as described above. The precipitate is pelleted by centrifugation in a Biofuge A (Hereaus) at 13000 rpm for 10 min at 4° C. and the pellet is dissolved in H 2 O to a final DNA concentration of 0.2 μg/μl.
One μl of this vector DNA is mixed with the 7 μl solution containing the DNA fragment coding for the "P32antigen fragment" (as defined above) and 1 μl 10×ligase buffer (0.5M TrisCl pH 7.4, 100 mM MgCl2, 5 mM ATP, 50 mM DTT (dithiothreitol)) plus 1 μl T 4 DNA ligase (1 unit/μl, Boehringer Mannheim) is added. The mixture is incubated at 13° C. for 6 hours and 5 μl of the mixture is then used for transformation into strain DH1(lambda) using standard transformation techniques are described by for instance Maniatis et al. in "Molecular cloning, a laboratory manual", Cold Spring Harbor Laboratory (1982).
Individual transformants are grown and then lysed for plasmid DNA preparation using standard procedures (Experiments with gene fusions, Cold Spring Harbor Laboratory 1984 (T. J. Silhavy, M. L. Berman and L. W. Enquist eds.)) and are checked for the correct orientation of the gene within the plasmid by restriction enzyme analysis.
One of the clones containing the DNA sequence encoding the antigen fragment in the correct orientation was retained for further work and designated pmTNF-MPH-Mt32. It encodes all information of the P 32 antigen starting from position +4 in the amino acid sequence (see FIG. 5). The amino acid sequence of the total fusion protein is represented in FIG. 13.
EXAMPLE VI
INDUCTION OF ANTIGEN EXPRESSION FROM pmTNF MPH Mt32
A- MATERIAL AND METHODS
DNA of pmTNF-MPH-Mt32 is transformed into E. coli strain K12ΔH (ATCC 33767) using standard transformation procedures except that the growth temperature of the cultures is reduced to 28° C. and the heat shock temperature to 34° C.
A culture of K12ΔH harboring pmTNF-MPH-Mt32, grown overnight in Luria broth at 28° C. with vigorous shaking in the presence of 10 μg/ml tetracycline, is inoculated into fresh Luria broth containing tetracycline (10 μg/ml) and grown to an optical density at 600 nanometers of 0.2 in the same conditions as for the overnight culture.
When the optical density at 600 nanometers has reached 0.2 half of the culture is shifted to 42° C. to induce expression while the other half remains at 28° C. as a control. At several time interfaces aliquotes are taken which are extracted with one volume of phenol equilibrated against M9 salts (0.1% ammonium chloride, 0.3% potassium dihydrogenium phosphate, 1.5% disodium hydrogenium phosphate, 12 molecules of water) and 1% SDS. At the same time, the optical density (600 nm) of the culture is checked. The proteins are precipitated from the phenol phase by addition of two volumes of acetone and storage overnight at -20° C. The precipitate is pelleted (Biofuge A, 5 min., 13000 rpm, room temperature) dried at the air, dissolved in a volume of Laemmli (Nature (1970) 227:680) sample buffer (+β mercapto ethanol) according to the optical density and boiled for 3 min.
Samples are then run on a SDS polyacrylamide gel (15%) according to Laemmli (1970). Temperature induction of mTNF-His 6 -P 32 is monitored by both Coomassie Brilliant Blue (CBB) staining and immunoblotting. CBB staining is performed by immersing the gel in a 1/10 diluted CBB staining solution (0.5 g CBB-R250 (Serva) in 90 ml methanol:H 2 O (1:1 v/v) and 10 ml glacial acetic acid) and left for about one hour on a gently rotating platform. After destaining for a few hours in destaining solution (30% methanol, 7% glacial acetic acid) protein bands are visualised and can be scanned with a densitometer (Ultroscan XL Enhanced Laser Densitometer, LKB).
For immunoblotting the proteins are blotted onto Hybond C membranes (Amersham) as described by Townbin et al (1979). After blotting, proteins on the membrane are temporarily visualised with Ponceau S (Serva) and the position of the molecular weight markers is indicated. The stain is then removed by washing in H 2 O. Aspecific protein binding sites are blocked by incubating the blots in 10% non-fat dried milk for about 1 hour on a gently rotating platform. After washing twice with NT buffer (25 mM Tris-HCl, pH 8.0; 150 mM NaCl) blots are incubated with polyclonal rabbit anti-32-kDa antiserum (1:1000), obtained as described in example I ("screening of the λgt11 M. tuberculosis recombinant DNA library with anti-32-kDa antiserum") in the presence of E. coli lysate or with monoclonal anti-hTNF-antibody which crossreacts with mTNF (Innogenetics, n° 17F5D10) for at least 2 hours on a rotating platform. After washing twice with NT buffer+0.02% Triton.X.100, blots are incubated for at least 1 hour with the secondary antiserum:alkaline phosphatase-conjugated swine anti-rabbit immunoglobulins (1/500; Prosan) in the first case, and alkaline phosphatase conjugated rabbit anti-mouse immunoglobulins (1/500; Sigma) in the second case.
Blots are washed again twice with NT buffer+0.02% Triton X100 and visualisation is then performed with nitro blue tetrazolium (NBT) and 5-bromo-4-chloro-3-indolyl-phosphate (BCIP) from Promega using conditions recommended by the supplier.
B. RESULTS
Upon induction of K12ΔH cells containing pmTNF-MPH-Mt32, a clearly visible band of about 35-kDa appears on CBB stained gels, already one hour after start of induction (FIG. 14a). This band, corresponding to roughly 25% of total protein contents of the cell, reacts strongly with anti-32-kDa and anti-mTNF antisera on immunoblots (FIG. 14b). However, this band represents a cleavage product of the original fusion protein, since a minor band, around 37 kDa, is also visible on immunoblots, reacting specifically with both antisera as well. This suggests that extensive cleavage of the recombinant mTNF-His 6 -P 32 takes place about 2-3 kDa from its carboxyterminal end.
EXAMPLE VII
PURIFICATION OF RECOMBINANT ANTIGEN ON IMMOBILIZED METAL ION AFFINITY CHROMATOGRAPHY (IMAC)
The hybrid protein mTNF-His 6 -P 32 (amino acid sequence, see FIG. 13) expressed by K12ΔH cells containing pmTNF.MPH.Mt32, is especially designed to facilitate purification by IMAC, since the 6 successive histidines in the polylinker sequence bring about a strong affinity for metal ions (HOCHULI et al, 1988).
a. Preparation of the crude cell extract
12 l of E. coli cells K12ΔH containing plasmid pmTNF-MPH-Mt32 were grown in Luria Broth containing tetracycline (10 μg/ml) at 28° C. to an optical density (600 nm) of 0.2 and then induced by shifting the temperature to 42° C. After 3 hours of induction, cells were harvested by centrifugation (Beckman, JA 10 rotor, 7.500 rpm, 10 min). The cell paste was resuspended in lysis buffer (10 mM KCl, 10 mM Tris-HCl pH 6.8, 5 mM EDTA) to a final concentration of 50% (w/v) cells.
ε-NH 2 -capronic acid and dithiotreitol (DTT) were added to a final concentration of resp. 20 mM and 1 mM, to prevent proteolytic degradation. This concentrated cell suspension was stored overnight at -70° C.
Cells were lysed by passing them three times through a French press (SLM-Aminco) at a working pressure of 800-1000 psi. During and after lysis, cells were kept systematically on ice.
The cell lysate was cleared by centrifugation (Beckman, JA 20, 18.000 rpm, 20 min, 4° C.). The supernatant (SN) was carefully taken off and the pellet, containing membranes and inclusion bodies, was kept for further work since preliminary experiments had shown that the protein was mainly localised in the membrane fraction.
7M guanidinium hydrochloride (GuHCl, marketed by ICN) in 100 mM phosphate buffer pH 7.2 was added to the pellet volume to a final concentration of 6M GuHCl. The pellet was resuspended and extracted in a bounce tissue homogenizer (10 cycles).
After clearing (Beckman, JA 20, 18.000 rpm, 20 min, 4° C.), about 100 ml of supernatant was collected (=extract 1) and the removing pellet was extracted again as described above (=extract 2, 40 ml).
The different fractions (SN,EX1,EX2) were analysed on SDS-PAGE (Laemmli, Nature 1970; 227:680) together with control samples of the induced culture. Scanning of the gel revealed that the recombinant protein makes up roughly 25% of the total protein content of the induced cell culture. After fractionation most of the protein was found back in the extracts. No difference was noticed between reducing and non-reducing conditions (plus and minus β-mercaptoethanol).
b. Preparation of the Ni ++ IDA (Imino diacetic acid) column
5 ml of the chelating gel, Chelating Sepharose 6B (Pharmacia) is washed extensively with water to remove the ethanol in which it is stored and then packed in a "Econo-column" (1×10 cm, Biorad). The top of the column is connected with the incoming fluid (sample, buffer, etc) while the end goes to the UV 280 detector via a peristaltic jump. Fractions are collected using a fraction collector and, when appropriate, pH of the fractions is measured manually.
The column is loaded with Ni ++ (6 ml NiCl 2 .6H 2 O; 5 μg/μl) and equilibrated with starting buffer (6M guanidinium hydrochloride, 100 mM phosphate buffer, pH 7.2).
After having applied the sample, the column is washed extensively with starting buffer to remove unbound material.
To elute the bound material, 2 different elution procedures are feasible
1) elution by decreasing pH,
2) elution by increasing imidazol concentration.
Both will be discussed here.
To regenerate the column, which has to be done after every 2-3 runs, 20 ml (about 5 column volumes) of the following solutions are pumped successively through the column
0.05M EDTA--0.5M NaCl
0.1M NaOH
H 2 O
6 ml NiCl 2 6H 2 O (5 mg/ml).
After equilibrating with starting buffer the column is ready to use again.
c. Chromatography
All buffers contained 6M guanidinium hydrochloride throughout the chromatography. The column was developed at a flow rate of 0.5 ml/min at ambient temperature. Fractions of 2 ml were collected and, when appropriate, further analysed by SDS-PAGE and immunoblotting. Gels were stained with Coomassie Brilliant Blue R250 and silver stain, as described by ANSORGE (1985). Immunoblotting was carried out as described in example I. The primary antiserum used was either polyclonal anti-32kDa-antiserum (1/1000) obtained as described in example I ("screening of the λgt11 M. tuberculosis recombinant DNA library with anti-32kDa-antiserum") or anti-E. coli-immunoglobulines (1/500; PROSAN), or monoclonal anti-hTNF-antibody which cross-reacts with mTNF (Innogenetics, N° 17F5D10). The secondary antiserum was alkaline phosphatase conjugated swine anti-rabbit immunoglobulines (1/500, PROSAN), or alkaline phosphatase conjugated rabbit-anti-mouse immunoglobulines (1/500, Sigma).
C1. Elution with decreasing pH
Solutions used
A: 6M GuHCl 100 mM phosphate pH 7.2
B: 6M GuHCl 25 mM phosphate pH 7.2
C; 6M GuHCl 50 mM phosphate pH 4.2
After applying 3 ml of extract 1 (OD 280 =32.0) and extensively washing with solution A, the column is equilibrated with solution B and then developed with a linear pH gradient from 7.2 to 4.2 (25 ml of solution B and 25 ml of solution C were mixed in a gradient former). The elution profile is shown in FIG. 15.
From SDS-PAGE analysis (Coomassie and silverstain) it was clear that most of the originally bound recombinant protein was eluted in the fractions between pH 5.3 and 4.7.
Screening of these fractions on immunoblot with anti-32-kDa and the 17F5D10 monoclonal antibody showed that, together with the intact recombinant protein, also some degradation products and higher aggregation forms of the protein were present, although in much lower amount. Blotting with anti-E. coli antibody revealed that these fractions (pH 5.3-4.7) still contained immunodetectable contaminating E. coli proteins (75, 65, 43, 35 and 31 kDa bands) and lipopolysaccharides.
C2. Elution with increasing imidazol concentration
Solutions used
A: 6M GuHCl 100 mM phosphate pH 7.2
B: 6M GuHCl 50 mM imidazol pH 7.2
C: 6M GuHCl 100 mM imidazol pH 7.2
D: 6M GuHCl 15 mM imidazol pH 7.2
E: 6M GuHCl 25 mM imidazol pH 7.2
F: 6M GuHCl 35 mM imidazol pH 7.2
Sample application and washing was carried out as in C1, except that after washing, no equilibration was necessary with 6M GuHCl 25 mM phosphate. The column was first developed with a linear gradient of imidazol going from 0 to 50 mM (25 ml of solution A and 25 ml of solution B were mixed in a gradient former) followed by a step elution to 100 mM imidazol (solution C). During the linear gradient, proteins were gradually eluted in a broad smear, while the step to 100 mM gave rise to a clear peak (FIG. 16).
SDS-PAGE analysis of the fractions revealed that in the first part of the linear gradient (fr 1-24) most contaminating E. coli proteins were washed out, while the latter part of the gradient (fr 25-50) and the 100 mM peak contained more than 90% of the recombinant protein.
As in C1, these fractions showed, besides a major band of intact recombinant protein, some minor bands of degradation and aggregation products. However, in this case, the region below 24-kDa seemed nearly devoid of protein bands, which suggests that less degradation procuts co-elute with the intact protein. Also, the same contaminating E. coli proteins were detected by immunoblotting, as in C1, although the 31-kDa band seems less intense and even absent in some fractions.
In a second stage, we developed the column with a step gradient of increasing imidazol concentrations. After having applied the sample and washed the column, 2 column volumes (about 8 ml) of the following solutions were brought successively onto the column: solution D, E, F and finally 4 column volumes of solution C. The step gradient resulted in a more concentrated elution profile (FIG. 17) which makes it more suitable for scaling up purposes.
In conclusion, the mTNF-His 6 -P 32 protein has been purified to at least 90% by IMAC. Further purification can be achieved through a combination of the following purification steps:
IMAC on chelating superose (Pharmacia)
ion exchange chromatography (anion or cation)
reversed phase chromatography
gel filtration chromatography
immunoaffinity chromatography
elution from polyacrylamide gel.
These chromatographic methods are commonly used for protein purification.
The plasmids of FIGS. 10b, 11b and 12b are new. contaminating E. coli proteins were washed out, while the latter part of the gradient (fr 25-50) and the 100 mM peak contained more than 90% of the recombinant protein.
As in C1, these fractions showed, besides a major band of intact recombinant protein, some minor bands of degradation and aggregation products. However, in this case, the region below 24-kDa seemed nearly devoid of protein bands, which suggests that less degradation products co-elute with the intact protein. Also, the same contaminating E. coli proteins were detected by immunoblotting, as in C1, although the 31-kDa band seems less intense and even absent in some fractions.
In a second stage, we developed the column with a step gradient of increasing imidazol concentrations. After having applied the sample and washed the column, 2 column volumes (about 8 ml) of the following solutions were brought successively onto the column: solution D, E, F and finally 4 column volumes of solution C. The stepgradient resulted in a more concentrated elution profile (FIG. 17) which makes it more suitable for scaling up purposes.
In conclusion, the mTNF-His 6 -P 32 protein has been purified to at least 90% by IMAC. Further purification can be achieved through a combination of the following purification steps:
IMAC on chelating superose (Pharmacia)
ion exchange chromatography (anion or cation)
reversed phase chromatography
gel filtration chromatography
immunoaffinity chromatography
elution from polyacrylamide gel.
These chromatographic methods are commonly used for protein purification.
The plasmids of FIGS. 10b, 11b and 12b are new.
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DESCRIPTION: SEQ ID NO:# 20 TCGG- (2) INFORMATION FOR SEQ ID NO: 4:- (i) SEQUENCE CHARACTERISTICS:#pairs (A) LENGTH: 23 base (B) TYPE: nucleic acid (C) STRANDEDNESS: single (D) TOPOLOGY: linear- (ii) MOLECULE TYPE: DNA (genomic)- (iii) HYPOTHETICAL: NO- (iii) ANTI-SENSE: NO#4: (xi) SEQUENCE DESCRIPTION: SEQ ID NO:# 23ACGG CGA- (2) INFORMATION FOR SEQ ID NO: 5:- (i) SEQUENCE CHARACTERISTICS:#pairs (A) LENGTH: 23 base (B) TYPE: nucleic acid (C) STRANDEDNESS: single (D) TOPOLOGY: linear- (ii) MOLECULE TYPE: DNA (genomic)- (iii) HYPOTHETICAL: NO- (iii) ANTI-SENSE: NO#5: (xi) SEQUENCE DESCRIPTION: SEQ ID NO:# 23GTGT CGG- (2) INFORMATION FOR SEQ ID NO: 6:- (i) SEQUENCE CHARACTERISTICS:#pairs (A) LENGTH: 18 base (B) TYPE: nucleic acid (C) STRANDEDNESS: single (D) TOPOLOGY: linear- (ii) MOLECULE TYPE: DNA (genomic)- (iii) HYPOTHETICAL: NO- (iii) ANTI-SENSE: NO#6: (xi) SEQUENCE DESCRIPTION: SEQ ID NO:# 18 TG- (2) INFORMATION FOR SEQ ID NO: 7:- (i) SEQUENCE CHARACTERISTICS:#pairs (A) LENGTH: 22 base (B) TYPE: nucleic acid (C) STRANDEDNESS: single (D) TOPOLOGY: linear- (ii) MOLECULE TYPE: DNA (genomic)- (iii) HYPOTHETICAL: NO- (iii) ANTI-SENSE: NO#7: (xi) SEQUENCE DESCRIPTION: SEQ ID NO:# 22CTA TC- (2) INFORMATION FOR SEQ ID NO: 8:- (i) SEQUENCE CHARACTERISTICS:#pairs (A) LENGTH: 21 base (B) TYPE: nucleic acid (C) STRANDEDNESS: single (D) TOPOLOGY: linear- (ii) MOLECULE TYPE: DNA (genomic)- (iii) HYPOTHETICAL: NO- (iii) ANTI-SENSE: NO#8: (xi) SEQUENCE DESCRIPTION: SEQ ID NO:#21 GGAA G- (2) INFORMATION FOR SEQ ID NO: 9:- (i) SEQUENCE CHARACTERISTICS:#pairs (A) LENGTH: 24 base (B) TYPE: nucleic acid (C) STRANDEDNESS: single (D) TOPOLOGY: linear- (ii) MOLECULE TYPE: DNA (genomic)- (iii) HYPOTHETICAL: NO- (iii) ANTI-SENSE: NO#9: (xi) SEQUENCE DESCRIPTION: SEQ ID NO:# 24GTGG CAAC- (2) INFORMATION FOR SEQ ID NO: 10:- (i) SEQUENCE CHARACTERISTICS:#pairs (A) LENGTH: 24 base (B) TYPE: nucleic acid (C) STRANDEDNESS: single (D) TOPOLOGY: linear- (ii) MOLECULE TYPE: DNA (genomic)- (iii) HYPOTHETICAL: NO- (iii) ANTI-SENSE: NO#10: (xi) SEQUENCE DESCRIPTION: SEQ ID NO:# 24CGCC CAAC- (2) INFORMATION FOR SEQ ID NO: 11:- (i) SEQUENCE CHARACTERISTICS:#pairs (A) LENGTH: 24 base (B) TYPE: nucleic acid (C) STRANDEDNESS: single (D) TOPOLOGY: linear- (ii) MOLECULE TYPE: DNA (genomic)- (iii) HYPOTHETICAL: NO- (iii) ANTI-SENSE: NO#11: (xi) SEQUENCE DESCRIPTION: SEQ ID NO:# 24CCGC CGCA- (2) INFORMATION FOR SEQ ID NO: 12:- (i) SEQUENCE CHARACTERISTICS:#pairs (A) LENGTH: 25 base (B) TYPE: nucleic acid (C) STRANDEDNESS: single (D) TOPOLOGY: linear- (ii) MOLECULE TYPE: DNA (genomic)- (iii) HYPOTHETICAL: NO- (iii) ANTI-SENSE: NO#12: (xi) SEQUENCE DESCRIPTION: SEQ ID NO:# 25 ACGC CCAAC- (2) INFORMATION FOR SEQ ID NO: 13:- (i) SEQUENCE CHARACTERISTICS:#pairs (A) LENGTH: 27 base (B) TYPE: nucleic acid (C) STRANDEDNESS: single (D) TOPOLOGY: linear- (ii) MOLECULE TYPE: DNA (genomic)- (iii) HYPOTHETICAL: NO- (iii) ANTI-SENSE: NO#13: (xi) SEQUENCE DESCRIPTION: SEQ ID NO:# 27 CCCG CGCCCCA- (2) INFORMATION FOR SEQ ID NO: 14:- (i) SEQUENCE CHARACTERISTICS:#pairs (A) LENGTH: 35 base (B) TYPE: nucleic acid (C) STRANDEDNESS: single (D) TOPOLOGY: linear- (ii) MOLECULE TYPE: DNA (genomic)- (iii) HYPOTHETICAL: NO- (iii) ANTI-SENSE: NO#14: (xi) SEQUENCE DESCRIPTION: SEQ ID NO:# 35 CGTC GCCGTCGATG GGCCG- (2) INFORMATION FOR SEQ ID NO: 15:- (i) SEQUENCE CHARACTERISTICS:#pairs (A) LENGTH: 27 base (B) TYPE: nucleic acid (C) STRANDEDNESS: single (D) TOPOLOGY: linear- (ii) MOLECULE TYPE: DNA (genomic)- (iii) HYPOTHETICAL: NO- (iii) ANTI-SENSE: NO#15: (xi) SEQUENCE DESCRIPTION: SEQ ID NO:# 27 TCGA GTGGTAC- (2) INFORMATION FOR SEQ ID NO: 16:- (i) SEQUENCE CHARACTERISTICS:#pairs (A) LENGTH: 27 base (B) TYPE: nucleic acid (C) STRANDEDNESS: single (D) TOPOLOGY: linear- (ii) MOLECULE TYPE: DNA (genomic)- (iii) HYPOTHETICAL: NO- (iii) ANTI-SENSE: NO#16: (xi) SEQUENCE DESCRIPTION: SEQ ID NO:# 27 GGGG TGTTGAT- (2) INFORMATION FOR SEQ ID NO: 17:- (i) SEQUENCE CHARACTERISTICS:#pairs (A) LENGTH: 20 base (B) TYPE: nucleic acid (C) STRANDEDNESS: single (D) TOPOLOGY: linear- (ii) MOLECULE TYPE: DNA (genomic)- (iii) HYPOTHETICAL: NO- (iii) ANTI-SENSE: NO#17: (xi) SEQUENCE DESCRIPTION: SEQ ID NO:# 20 GGGA- (2) INFORMATION FOR SEQ ID NO: 18:- (i) SEQUENCE CHARACTERISTICS:#pairs (A) LENGTH: 20 base (B) TYPE: nucleic acid (C) STRANDEDNESS: single (D) TOPOLOGY: linear- (ii) MOLECULE TYPE: DNA (genomic)- (iii) HYPOTHETICAL: NO- (iii) ANTI-SENSE: NO#18: (xi) SEQUENCE DESCRIPTION: SEQ ID NO:# 20 GGCA- (2) INFORMATION FOR SEQ ID NO: 19:- (i) SEQUENCE CHARACTERISTICS:#pairs (A) LENGTH: 20 base (B) TYPE: nucleic acid (C) STRANDEDNESS: single (D) TOPOLOGY: linear- (ii) MOLECULE TYPE: DNA (genomic)- (iii) HYPOTHETICAL: NO- (iii) ANTI-SENSE: NO#19: (xi) SEQUENCE DESCRIPTION: SEQ ID NO:# 20 GCCG- (2) INFORMATION FOR SEQ ID NO: 20:- (i) SEQUENCE CHARACTERISTICS:#pairs (A) LENGTH: 20 base (B) TYPE: nucleic acid (C) STRANDEDNESS: single (D) TOPOLOGY: linear- (ii) MOLECULE TYPE: DNA (genomic)- (iii) HYPOTHETICAL: NO- (iii) ANTI-SENSE: NO#20: (xi) SEQUENCE DESCRIPTION: SEQ ID NO:# 20 AGGA- (2) INFORMATION FOR SEQ ID NO: 21:- (i) SEQUENCE CHARACTERISTICS:#pairs (A) LENGTH: 27 base (B) TYPE: nucleic acid (C) STRANDEDNESS: single (D) TOPOLOGY: linear- (ii) MOLECULE TYPE: DNA (genomic)- (iii) HYPOTHETICAL: NO- (iii) ANTI-SENSE: NO#21: (xi) SEQUENCE DESCRIPTION: SEQ ID NO:# 27 ATGG GTGACGC- (2) INFORMATION FOR SEQ ID NO: 22:- (i) SEQUENCE CHARACTERISTICS:#pairs (A) LENGTH: 27 base (B) TYPE: nucleic acid (C) STRANDEDNESS: single (D) TOPOLOGY: linear- (ii) MOLECULE TYPE: DNA (genomic)- (iii) HYPOTHETICAL: NO- (iii) ANTI-SENSE: NO#22: (xi) SEQUENCE DESCRIPTION: SEQ ID NO:# 27 GGCC GATCAGG- (2) INFORMATION FOR SEQ ID NO: 23:- (i) SEQUENCE CHARACTERISTICS:#pairs (A) LENGTH: 26 base (B) TYPE: nucleic acid (C) STRANDEDNESS: single (D) TOPOLOGY: linear- (ii) MOLECULE TYPE: DNA (genomic)- (iii) HYPOTHETICAL: NO- (iii) ANTI-SENSE: NO#23: (xi) SEQUENCE DESCRIPTION: SEQ ID NO:# 26 AGCT GTGCGT- (2) INFORMATION FOR SEQ ID NO: 24:- (i) SEQUENCE CHARACTERISTICS:#acids (A) LENGTH: 20 amino (B) TYPE: amino acid (D) TOPOLOGY: linear- (ii) MOLECULE TYPE: peptide- (iii) HYPOTHETICAL: NO#24: (xi) SEQUENCE DESCRIPTION: SEQ ID NO:- Gln Val Pro Ser Pro Ser Met Gly - # Arg Asp Ile Lys Val Gln PheGln# 15- Ser Gly Gly Ala 20- (2) INFORMATION FOR SEQ ID NO: 25:- (i) SEQUENCE CHARACTERISTICS:#acids (A) LENGTH: 20 amino (B) TYPE: amino acid (D) TOPOLOGY: linear- (ii) MOLECULE TYPE: peptide- (iii) HYPOTHETICAL: NO#25: (xi) SEQUENCE DESCRIPTION: SEQ ID NO:- Leu Tyr Leu Leu Asp Gly Leu Arg - # Ala Gln Asp Asp Phe Ser GlyTrp# 15- Asp Ile Asn Thr 20- (2) INFORMATION FOR SEQ ID NO: 26:- (i) SEQUENCE CHARACTERISTICS:#acids (A) LENGTH: 20 amino (B) TYPE: amino acid (D) TOPOLOGY: linear- (ii) MOLECULE TYPE: peptide- (iii) HYPOTHETICAL: NO#26: (xi) SEQUENCE DESCRIPTION: SEQ ID NO:- Ser Phe Tyr Ser Asp Trp Tyr Gln - # Pro Ala Cys Arg Lys Ala GlyCys# 15- Gln Thr Tyr Lys 20- (2) INFORMATION FOR SEQ ID NO: 27:- (i) SEQUENCE CHARACTERISTICS:#acids (A) LENGTH: 20 amino (B) TYPE: amino acid (D) TOPOLOGY: linear- (ii) MOLECULE TYPE: peptide- (iii) HYPOTHETICAL: NO#27: (xi) SEQUENCE DESCRIPTION: SEQ ID NO:- Leu Thr Ser Glu Leu Pro Gly Trp - # Leu Gln Ala Asn Arg His ValLys# 15- Pro Thr Gly Ser 20- (2) INFORMATION FOR SEQ ID NO: 28:- (i) SEQUENCE CHARACTERISTICS:#acids (A) LENGTH: 20 amino (B) TYPE: amino acid (D) TOPOLOGY: linear- (ii) MOLECULE TYPE: peptide- (iii) HYPOTHETICAL: NO#28: (xi) SEQUENCE DESCRIPTION: SEQ ID NO:- Lys Ala Ser Asp Met Trp Gly Pro - # Lys Glu Asp Pro Ala Trp GlnArg# 15- Asn Asp Pro Leu 20- (2) INFORMATION FOR SEQ ID NO: 29:- (i) SEQUENCE CHARACTERISTICS:#acids (A) LENGTH: 20 amino (B) TYPE: amino acid (D) TOPOLOGY: linear- (ii) MOLECULE TYPE: peptide- (iii) HYPOTHETICAL: NO#29: (xi) SEQUENCE DESCRIPTION: SEQ ID NO:- Cys Gly Asn Gly Lys Pro Ser Asp - # Leu Gly Gly Asn Asn Leu ProAla# 15- Lys Phe Leu Glu 20- (2) INFORMATION FOR SEQ ID NO: 30:- (i) SEQUENCE CHARACTERISTICS:#acids (A) LENGTH: 20 amino (B) TYPE: amino acid (D) TOPOLOGY: linear- (ii) MOLECULE TYPE: peptide- (iii) HYPOTHETICAL: NO#30: (xi) SEQUENCE DESCRIPTION: SEQ ID NO:- Lys Pro Asp Leu Gln Arg His Trp - # Val Pro Arg Pro Thr Pro GlyPro# 15- Pro Gln Gly Ala 20- (2) INFORMATION FOR SEQ ID NO: 31:- (i) SEQUENCE CHARACTERISTICS:#acids (A) LENGTH: 20 amino (B) TYPE: amino acid (D) TOPOLOGY: linear- (ii) MOLECULE TYPE: peptide- (iii) HYPOTHETICAL: NO#31: (xi) SEQUENCE DESCRIPTION: SEQ ID NO:- Ser Phe Tyr Ser Asp Trp Tyr Gln - # Pro Ala Cys Gly Lys Ala GlyCys# 15- Gln Thr Tyr Lys 20- (2) INFORMATION FOR SEQ ID NO: 32:- (i) SEQUENCE CHARACTERISTICS:#acids (A) LENGTH: 20 amino (B) TYPE: amino acid (D) TOPOLOGY: linear- (ii) MOLECULE TYPE: peptide- (iii) HYPOTHETICAL: NO#32: (xi) SEQUENCE DESCRIPTION: SEQ ID NO:- Pro Asp Leu Gln Arg Ala Leu Gly - # Ala Thr Pro Asn Thr Gly ProAla# 15- Pro Gln Gly Ala 20- (2) INFORMATION FOR SEQ ID NO: 33:- (i) SEQUENCE CHARACTERISTICS:#acids (A) LENGTH: 32 amino (B) TYPE: amino acid (D) TOPOLOGY: linear- (ii) MOLECULE TYPE: peptide- (iii) HYPOTHETICAL: NO#33: (xi) SEQUENCE DESCRIPTION: SEQ ID NO:- Phe Ser Arg Pro Gly Leu Pro Val - # Glu Tyr Leu Gln Val Pro SerPro# 15- Ser Met Gly Arg Asp Ile Lys Val - # Gln Phe Gln Ser Gly Gly AlaAsn# 30- (2) INFORMATION FOR SEQ ID NO: 34:- (i) SEQUENCE CHARACTERISTICS:#pairs (A) LENGTH: 1357 base (B) TYPE: nucleic acid (C) STRANDEDNESS: single (D) TOPOLOGY: linear- (ii) MOLECULE TYPE: DNA (genomic)- (iii) HYPOTHETICAL: YES- (iii) ANTI-SENSE: NO- (ix) FEATURE: (A) NAME/KEY: misc-feature (B) LOCATION: 302#N is G or GG OTHER INFORMATION:- (ix) FEATURE: (A) NAME/KEY: misc-feature (B) LOCATION: 306#N is G or GG and the same as position 302- (ix) FEATURE: (A) NAME/KEY: misc-feature (B) LOCATION: 308#N is C or CC OTHER INFORMATION:- (ix) FEATURE: (A) NAME/KEY: misc-feature (B) LOCATION: 620#N is C or G) OTHER INFORMATION:- (ix) FEATURE: (A) NAME/KEY: misc-feature (B) LOCATION: 1102#N is C or G and different from position 620- (ix) FEATURE: (A) NAME/KEY: misc-feature (B) LOCATION: 1103#N is C or G and the same as position 620- (ix) FEATURE: (A) NAME/KEY: misc-feature (B) LOCATION: 1198#N is G or GG and the same as position 302- (ix) FEATURE: (A) NAME/KEY: misc-feature (B) LOCATION: 1229#N is C or CG OTHER INFORMATION:- (ix) FEATURE: (A) NAME/KEY: misc-feature (B) LOCATION: 1231#N is G or CC OTHER INFORMATION:#34: (xi) SEQUENCE DESCRIPTION: SEQ ID NO:- CGACACATGC CCAGACACTG CGGAAATGCC ACCTTCAGGC CGTCGCGTCG GT - #CCCGAATT 60- GGCCGTGAAC GACCGCCGGA TAAGGGTTTC GGCGGTGCGC TTGATGCGGG TG - #GACGCCCA 120- AGTTGTGGTT GACTACACGA GCACTGCCGG GCCCAGCGCC TGCAGTCTGA CC - #TAATTCAG 180- GATGCGCCCA AACATGCATG GATGCGTTGA GATGAGGATG AGGGAAGCAA GA - #ATGCAGCT 240- TGTTGACAGG GTTCGTGGCG CCGTCACGGG TATGTCGCGT CGACTCGTGG TC - #GGGGCCGT 300- CNCGCNCNTA GTGTCGGGTC TGGTCGGCGC CGTCGGTGGC ACGGCGACCG CG - #GGGGCATT 360- TTCCCGGCCG GGCTTGCCGG TGGAGTACCT GCAGGTGCCG TCGCCGTCGA TG - #GGCCGTGA 420- CATCAAGGTC CAATTCCAAA GTGGTGGTGC CAACTCGCCC GCCCTGTACC TG - #CTCGACGG 480- CCTGCGCGCG CAGGACGACT TCAGCGGCTG GGACATCAAC ACCCCGGCGT TC - #GAGTGGTA 540- CGACCAGTCG GGCCTGTCGG TGGTCATGCC GGTGGGTGGC CAGTCAAGCT TC - #TACTCCGA 600- CTGGTACCAG CCCGCCTGCN GCAAGGCCGG TTGCCAGACT TACAAGTGGG AG - #ACCTTCCT 660- GACCAGCGAG CTGCCGGGGT GGCTGCAGGC CAACAGGCAC GTCAAGCCCA CC - #GGAAGCGC 720- CGTCGTCGGT CTTTCGATGG CTGCTTCTTC GGCGCTGACG CTGGCGATCT AT - #CACCCCCA 780- GCAGTTCGTC TACGCGGGAG CGATGTCGGG CCTGTTGGAC CCCTCCCAGG CG - #ATGGGTCC 840- CACCCTGATC GGCCTGGCGA TGGGTGACGC TGGCGGCTAC AAGGCCTCCG AC - #ATGTGGGG 900- CCCGAAGGAG GACCCGGCGT GGCAGCGCAA CGACCCGCTG TTGAACGTCG GG - #AAGCTGAT 960- CGCCAACAAC ACCCGCGTCT GGGTGTACTG CGGCAACGGC AAGCCGTCGG AT - #CTGGGTGG1020- CAACAACCTG CCGGCCAAGT TCCTCGAGGG CTTCGTGCGG ACCAGCAACA TC - #AAGTTCCA1080- AGACGCCTAC AACGCCGGTG GNNGCCACAA CGGCGTGTTC GACTTCCCGG AC - #AGCGGTAC1140- GCACAGCTGG GAGTACTGGG GCGCGCAGCT CAACGCTATG AAGCCCGACC TG - #CAACGNCA1200- CTGGGTGCCA CGCCCAACAC CGGGCCCGNC NCAGGGCGCC TAGCTCCGAA CA - #GACACAAC1260- ATCTAGCNNC GGTGACCCTT GTGGNNCANA TGTTTCCTAA ATCCCGTCCC TA - #GCTCCCGC1320# 1357 GCTA CCTGACNNCA TGGGTTT- (2) INFORMATION FOR SEQ ID NO: 35:- (i) SEQUENCE CHARACTERISTICS:#acids (A) LENGTH: 353 amino (B) TYPE: amino acid (D) TOPOLOGY: linear- (ii) MOLECULE TYPE: protein- (iii) HYPOTHETICAL: NO- (ix) FEATURE: (A) NAME/KEY: misc-feature#-18o (B) LOCATION:#Xaa is Ala Arg or Gly Ala AlaN:- (ix) FEATURE: (A) NAME/KEY: misc-feature (B) LOCATION: 88#Xaa is Arg or GlyR INFORMATION:- (ix) FEATURE: (A) NAME/KEY: misc-feature (B) LOCATION: 249#Xaa is Arg or GlyR INFORMATION:- (ix) FEATURE: (A) NAME/KEY: misc-feature#286 (B) LOCATION: 281 to#Xaa is His Trp Val Pro Arg Pro or Ala Leu Gly Al - #a- (ix) FEATURE: (A) NAME/KEY: misc-feature (B) LOCATION: 288#Xaa is Pro or Pro Asn ThrATION:- (ix) FEATURE: (A) NAME/KEY: misc-feature (B) LOCATION: 291#Xaa is Pro or Ala ProFORMATION:#35: (xi) SEQUENCE DESCRIPTION: SEQ ID NO:- Met Arg Pro Asn Met His Gly Cys - # Val Glu Met Arg Met Arg GluAla#-45- Arg Met Gln Leu Val Asp Arg Val - # Arg Gly Ala Val Thr Gly MetSer30- Arg Arg Leu Val Val Gly Ala Val - # Xaa Xaa Leu Val Ser Gly LeuVal15- Gly Ala Val Gly Gly Thr Ala Thr - # Ala Gly Ala Phe Ser Arg ProGly# 5 1- Leu Pro Val Glu Tyr Leu Gln Val - # Pro Ser Pro Ser Met Gly ArgAsp# 20- Ile Lys Val Gln Phe Gln Ser Gly - # Gly Ala Asn Ser Pro Ala LeuTyr# 35- Leu Leu Asp Gly Leu Arg Ala Gln - # Asp Asp Phe Ser Gly Trp AspIle# 50- Asn Thr Pro Ala Phe Glu Trp Tyr - # Asp Gln Ser Gly Leu Ser ValVal# 65- Met Pro Val Gly Gly Gln Ser Ser - # Phe Tyr Ser Asp Trp Tyr GlnPro# 85- Ala Cys Xaa Lys Ala Gly Cys Gln - # Thr Tyr Lys Trp Glu Thr PheLeu# 100- Thr Ser Glu Leu Pro Gly Trp Leu - # Gln Ala Asn Arg His Val LysPro# 115- Thr Gly Ser Ala Val Val Gly Leu - # Ser Met Ala Ala Ser Ser AlaLeu# 130- Thr Leu Ala Ile Tyr His Pro Gln - # Gln Phe Val Tyr Ala Gly AlaMet# 145- Ser Gly Leu Leu Asp Pro Ser Gln - # Ala Met Gly Pro Thr Leu IleGly# 165- Leu Ala Met Gly Asp Ala Gly Gly - # Tyr Lys Ala Ser Asp Met TrpGly# 180- Pro Lys Glu Asp Pro Ala Trp Gln - # Arg Asn Asp Pro Leu Leu AsnVal# 195- Gly Lys Leu Ile Ala Asn Asn Thr - # Arg Val Trp Val Tyr Cys GlyAsn# 210- Gly Lys Pro Ser Asp Leu Gly Gly - # Asn Asn Leu Pro Ala Lys PheLeu# 225- Glu Gly Phe Val Arg Thr Ser Asn - # Ile Lys Phe Gln Asp Ala TyrAsn# 245- Ala Gly Gly Xaa His Asn Gly Val - # Phe Asp Phe Pro Asp Ser GlyThr# 260- His Ser Trp Glu Tyr Trp Gly Ala - # Gln Leu Asn Ala Met Lys ProAsp# 275- Leu Gln Arg Xaa Xaa Xaa Xaa Xaa - # Xaa Thr Xaa Gly Pro Xaa GlnGly# 290- Ala- (2) INFORMATION FOR SEQ ID NO: 36:- (i) SEQUENCE CHARACTERISTICS:#pairs (A) LENGTH: 1357 base (B) TYPE: nucleic acid (C) STRANDEDNESS: single (D) TOPOLOGY: linear- (ii) MOLECULE TYPE: DNA (genomic)- (iii) HYPOTHETICAL: NO- (iii) ANTI-SENSE: NO#36: (xi) SEQUENCE DESCRIPTION: SEQ ID NO:- CGACACATGC CCAGACACTG CGGAAATGCC ACCTTCAGGC CGTCGCGTCG GT - #CCCGAATT 60- GGCCGTGAAC GACCGCCGGA TAAGGGTTTC GGCGGTGCGC TTGATGCGGG TG - #GACGCCCA 120- AGTTGTGGTT GACTACACGA GCACTGCCGG GCCCAGCGCC TGCAGTCTGA CC - #TAATTCAG 180- GATGCGCCCA AACATGCATG GATGCGTTGA GATGAGGATG AGGGAAGCAA GA - #ATGCAGCT 240- TGTTGACAGG GTTCGTGGCG CCGTCACGGG TATGTCGCGT CGACTCGTGG TC - #GGGGCCGT 300- CGCGCGCCTA GTGTCGGGTC TGGTCGGCGC CGTCGGTGGC ACGGCGACCG CG - #GGGGCATT 360- TTCCCGGCCG GGCTTGCCGG TGGAGTACCT GCAGGTGCCG TCGCCGTCGA TG - #GGCCGTGA 420- CATCAAGGTC CAATTCCAAA GTGGTGGTGC CAACTCGCCC GCCCTGTACC TG - #CTCGACGG 480- CCTGCGCGCG CAGGACGACT TCAGCGGCTG GGACATCAAC ACCCCGGCGT TC - #GAGTGGTA 540- CGACCAGTCG GGCCTGTCGG TGGTCATGCC GGTGGGTGGC CAGTCAAGCT TC - #TACTCCGA 600- CTGGTACCAG CCCGCCTGCC GCAAGGCCGG TTGCCAGACT TACAAGTGGG AG - #ACCTTCCT 660- GACCAGCGAG CTGCCGGGGT GGCTGCAGGC CAACAGGCAC GTCAAGCCCA CC - #GGAAGCGC 720- CGTCGTCGGT CTTTCGATGG CTGCTTCTTC GGCGCTGACG CTGGCGATCT AT - #CACCCCCA 780- GCAGTTCGTC TACGCGGGAG CGATGTCGGG CCTGTTGGAC CCCTCCCAGG CG - #ATGGGTCC 840- CACCCTGATC GGCCTGGCGA TGGGTGACGC TGGCGGCTAC AAGGCCTCCG AC - #ATGTGGGG 900- CCCGAAGGAG GACCCGGCGT GGCAGCGCAA CGACCCGCTG TTGAACGTCG GG - #AAGCTGAT 960- CGCCAACAAC ACCCGCGTCT GGGTGTACTG CGGCAACGGC AAGCCGTCGG AT - #CTGGGTGG1020- CAACAACCTG CCGGCCAAGT TCCTCGAGGG CTTCGTGCGG ACCAGCAACA TC - #AAGTTCCA1080- AGACGCCTAC AACGCCGGTG GGCGCCACAA CGGCGTGTTC GACTTCCCGG AC - #AGCGGTAC1140- GCACAGCTGG GAGTACTGGG GCGCGCAGCT CAACGCTATG AAGCCCGACC TG - #CAACGGCA1200- CTGGGTGCCA CGCCCAACAC CGGGCCCGCC GCAGGGCGCC TAGCTCCGAA CA - #GACACAAC1260- ATCTAGCNNC GGTGACCCTT GTGGNNCANA TGTTTCCTAA ATCCCGTCCC TA - #GCTCCCGC1320# 1357 GCTA CCTGACNNCA TGGGTTT- (2) INFORMATION FOR SEQ ID NO: 37:- (i) SEQUENCE CHARACTERISTICS:#acids (A) LENGTH: 353 amino (B) TYPE: amino acid (D) TOPOLOGY: linear- (ii) MOLECULE TYPE: protein- (iii) HYPOTHETICAL: NO#37: (xi) SEQUENCE DESCRIPTION: SEQ ID NO:- Met Arg Pro Asn Met His Gly Cys - # Val Glu Met Arg Met Arg GluAla#-45- Arg Met Gln Leu Val Asp Arg Val - # Arg Gly Ala Val Thr Gly MetSer30- Arg Arg Leu Val Val Gly Ala Val - # Ala Arg Leu Val Ser Gly LeuVal15- Gly Ala Val Gly Gly Thr Ala Thr - # Ala Gly Ala Phe Ser Arg ProGly# 5 1- Leu Pro Val Glu Tyr Leu Gln Val - # Pro Ser Pro Ser Met Gly ArgAsp# 20- Ile Lys Val Gln Phe Gln Ser Gly - # Gly Ala Asn Ser Pro Ala LeuTyr# 35- Leu Leu Asp Gly Leu Arg Ala Gln - # Asp Asp Phe Ser Gly Trp AspIle# 50- Asn Thr Pro Ala Phe Glu Trp Tyr - # Asp Gln Ser Gly Leu Ser ValVal# 65- Met Pro Val Gly Gly Gln Ser Ser - # Phe Tyr Ser Asp Trp Tyr GlnPro# 85- Ala Cys Arg Lys Ala Gly Cys Gln - # Thr Tyr Lys Trp Glu Thr PheLeu# 100- Thr Ser Glu Leu Pro Gly Trp Leu - # Gln Ala Asn Arg His Val LysPro# 115- Thr Gly Ser Ala Val Val Gly Leu - # Ser Met Ala Ala Ser Ser AlaLeu# 130- Thr Leu Ala Ile Tyr His Pro Gln - # Gln Phe Val Tyr Ala Gly AlaMet# 145- Ser Gly Leu Leu Asp Pro Ser Gln - # Ala Met Gly Pro Thr Leu IleGly# 165- Leu Ala Met Gly Asp Ala Gly Gly - # Tyr Lys Ala Ser Asp Met TrpGly# 180- Pro Lys Glu Asp Pro Ala Trp Gln - # Arg Asn Asp Pro Leu Leu AsnVal# 195- Gly Lys Leu Ile Ala Asn Asn Thr - # Arg Val Trp Val Tyr Cys GlyAsn# 210- Gly Lys Pro Ser Asp Leu Gly Gly - # Asn Asn Leu Pro Ala Lys PheLeu# 225- Glu Gly Phe Val Arg Thr Ser Asn - # Ile Lys Phe Gln Asp Ala TyrAsn# 245- Ala Gly Gly Arg His Asn Gly Val - # Phe Asp Phe Pro Asp Ser GlyThr# 260- His Ser Trp Glu Tyr Trp Gly Ala - # Gln Leu Asn Ala Met Lys ProAsp# 275- Leu Gln Arg His Trp Val Pro Arg - # Pro Thr Pro Gly Pro Pro GlnGly# 290- Ala- (2) INFORMATION FOR SEQ ID NO: 38:- (i) SEQUENCE CHARACTERISTICS:#pairs (A) LENGTH: 1299 base (B) TYPE: nucleic acid (C) STRANDEDNESS: single (D) TOPOLOGY: linear- (ii) MOLECULE TYPE: DNA (genomic)- (iii) HYPOTHETICAL: NO- (iii) ANTI-SENSE: NO#38: (xi) SEQUENCE DESCRIPTION: SEQ ID NO:- ACTGCCGGGC CCAGCGCCTG CAGTCTGACC TAATTCAGGA TGCGCCCAAA CA - #TGCATGGA 60- TGCGTTGAGA TGAGGATGAG GGAAGCAAGA ATGCAGCTTG TTGACAGGGT TC - #GTGGCGCC 120- GTCACGGGTA TGTCGCGTCG ACTCGTGGTC GGGGCCGTCG GCGCGGCCCT AG - #TGTCGGGT 180- CTGGTCGGCG CCGTCGGTGG CACGGCGACC GCGGGGGCAT TTTCCCGGCC GG - #GCTTGCCG 240- GTGGAGTACC TGCAGGTGCC GTCGCCGTCG ATGGGCCGTG ACATCAAGGT CC - #AATTCCAA 300- AGTGGTGGTG CCAACTCGCC CGCCCTGTAC CTGCTCGACG GCCTGCGCGC GC - #AGGACGAC 360- TTCAGCGGCT GGGACATCAA CACCCCGGCG TTCGAGTGGT ACGACCAGTC GG - #GCCTGTCG 420- GTGGTCATGC CGGTGGGTGG CCAGTCAAGC TTCTACTCCG ACTGGTACCA GC - #CCGCCTGC 480- GGCAAGGCCG GTTGCCAGAC TTACAAGTGG GAGACCTTCC TGACCAGCGA GC - #TGCCGGGG 540- TGGCTGCAGG CCAACAGGCA CGTCAAGCCC ACCGGAAGCG CCGTCGTCGG TC - #TTTCGATG 600- GCTGCTTCTT CGGCGCTGAC GCTGGCGATC TATCACCCCC AGCAGTTCGT CT - #ACGCGGGA 660- GCGATGTCGG GCCTGTTGGA CCCCTCCCAG GCGATGGGTC CCACCCTGAT CG - #GCCTGGCG 720- ATGGGTGACG CTGGCGGCTA CAAGGCCTCC GACATGTGGG GCCCGAAGGA GG - #ACCCGGCG 780- TGGCAGCGCA ACGACCCGCT GTTGAACGTC GGGAAGCTGA TCGCCAACAA CA - #CCCGCGTC 840- TGGGTGTACT GCGGCAACGG CAAGCCGTCG GATCTGGGTG GCAACAACCT GC - #CGGCCAAG 900- TTCCTCGAGG GCTTCGTGCG GACCAGCAAC ATCAAGTTCC AAGACGCCTA CA - #ACGCCGGT 960- GGCGGCCACA ACGGCGTGTT CGACTTCCCG GACAGCGGTA CGCACAGCTG GG - #AGTACTGG1020- GGCGCGCAGC TCAACGCTAT GAAGCCCGAC CTGCAACGGG CACTGGGTGC CA - #CGCCCAAC1080- ACCGGGCCCG CGCCCCAGGG CGCCTAGCTC CGAACAGACA CAACATCTAG CG - #GCGGTGAC1140- CCTTGTGGTC GCCGCCGTAG ATGTTTCCTA AATCCCGTCC CTAGCTCCCG CC - #GCGGGCCG1200- TGTGGTTAGC TACCTGACGG GCTAGGGGTT GGCCGGGGCG GTTGACGCCG GG - #TGCACACA1260# 1299 GGTG GACACATGAA GGGTCGGTC- (2) INFORMATION FOR SEQ ID NO: 39:- (i) SEQUENCE CHARACTERISTICS:#acids (A) LENGTH: 338 amino (B) TYPE: amino acid (D) TOPOLOGY: linear- (ii) MOLECULE TYPE: protein- (iii) HYPOTHETICAL: NO#39: (xi) SEQUENCE DESCRIPTION: SEQ ID NO:- Met Gln Leu Val Asp Arg Val Arg - # Gly Ala Val Thr Gly Met SerArg30- Arg Leu Val Val Gly Ala Val Gly - # Ala Ala Leu Val Ser Gly LeuVal15- Gly Ala Val Gly Gly Thr Ala Thr - # Ala Gly Ala Phe Ser Arg ProGly# 5 1- Leu Pro Val Glu Tyr Leu Gln Val - # Pro Ser Pro Ser Met Gly ArgAsp# 20- Ile Lys Val Gln Phe Gln Ser Gly - # Gly Ala Asn Ser Pro Ala LeuTyr# 35- Leu Leu Asp Gly Leu Arg Ala Gln - # Asp Asp Phe Ser Gly Trp AspIle# 50- Asn Thr Pro Ala Phe Glu Trp Tyr - # Asp Gln Ser Gly Leu Ser ValVal# 65- Met Pro Val Gly Gly Gln Ser Ser - # Phe Tyr Ser Asp Trp Tyr GlnPro# 85- Ala Cys Gly Lys Ala Gly Cys Gln - # Thr Tyr Lys Trp Glu Thr PheLeu# 100- Thr Ser Glu Leu Pro Gly Trp Leu - # Gln Ala Asn Arg His Val LysPro# 115- Thr Gly Ser Ala Val Val Gly Leu - # Ser Met Ala Ala Ser Ser AlaLeu# 130- Thr Leu Ala Ile Tyr His Pro Gln - # Gln Phe Val Tyr Ala Gly AlaMet# 145- Ser Gly Leu Leu Asp Pro Ser Gln - # Ala Met Gly Pro Thr Leu IleGly# 165- Leu Ala Met Gly Asp Ala Gly Gly - # Tyr Lys Ala Ser Asp Met TrpGly# 180- Pro Lys Glu Asp Pro Ala Trp Gln - # Arg Asn Asp Pro Leu Leu AsnVal# 195- Gly Lys Leu Ile Ala Asn Asn Thr - # Arg Val Trp Val Tyr Cys GlyAsn# 210- Gly Lys Pro Ser Asp Leu Gly Gly - # Asn Asn Leu Pro Ala Lys PheLeu# 225- Glu Gly Phe Val Arg Thr Ser Asn - # Ile Lys Phe Gln Asp Ala TyrAsn# 245- Ala Gly Gly Gly His Asn Gly Val - # Phe Asp Phe Pro Asp Ser GlyThr# 260- His Ser Trp Glu Tyr Trp Gly Ala - # Gln Leu Asn Ala Met Lys ProAsp# 275- Leu Gln Arg Ala Leu Gly Ala Thr - # Pro Asn Thr Gly Pro Ala ProGln# 290- Gly Ala- (2) INFORMATION FOR SEQ ID NO: 40:- (i) SEQUENCE CHARACTERISTICS:#pairs (A) LENGTH: 3423 base (B) TYPE: nucleic acid (C) STRANDEDNESS: single (D) TOPOLOGY: circular- (ii) MOLECULE TYPE: plasmid vector- (iii) HYPOTHETICAL: NO#40: (xi) SEQUENCE DESCRIPTION: SEQ ID NO:- TTCCGGGGAT CTCTCACCTA CCAAACAATG CCCCCCTGCA AAAAATAAAT TC - #ATATAAAA 60- AACATACAGA TAACCATCTG CGGTGATAAA TTATCTCTGG CGGTGTTGAC AT - #AAATACCA 120- CTGGCGGTGA TACTGAGCAC ATCAGCAGGA CGCACTGACC ACCATGAAGG TG - #ACGCTCTT 180- AAAAATTAAG CCCTGAAGAA GGGCAGGGGT ACCAGGAGGT TTAAATCATG GT - #AAGATCAA 240- GTAGTCAAAA TTCGAGTGAC AAGCCTGTAG CCCACGTCGT AGCAAACCAC CA - #AGTGGAGG 300- AGCAGTAACC ATGGTTACTG GAGAAGGGGG ACCAACTCAG CGCTGAGGTC AA - #TCTGCCCA 360- AGTCTAGAGT CGACCTGCAG CCCAAGCTTG GCTGTTTTGG CGGATGAGAG AA - #GATTTTCA 420- GCCTGATACA GATTAAATCA GAACGCAGAA GCGGTCTGAT AAAACAGAAT TT - #GCCTGGCG 480- GCAGTAGCGC GGTGGTCCCA CCTGACCCCA TGCCGAACTC AGAAGTGAAA CG - #CCGTAGCG 540- CCGATGGTAG TGTGGGGTCT CCCCATGCGA GAGTAGGGAA CTGCCAGGCA TC - #AAATAAAA 600- CGAAAGGCTC AGTCGAAAGA CTGGGCCTTT CGTTTTATCT GTTGTTTGTC GG - #TGAACGCT 660- CTCCTGAGTA GGACAAATCC GCCGGGAGCG GATTTGAACG TTGCGAAGCA AC - #GGCCCGGA 720- GGGTGGCGGG CAGGACGCCC GCCATAAACT GCCAGGCATC AAATTAAGCA GA - #AGGCCATC 780- CTGACGGATG GCCTTTTTGC GTTTCTACAA ACTCTTTTGT TTATTTTTCT AA - #ATACATTC 840- AAATATGTAT CCGCTCATGA GACAATAACC CTGATAAATG CTTCAATAAT AA - #AAGGATCT 900- AGGTGAAGAT CCTTTTTGAT AATCTCATGA CCAAAATCCC TTAACGTGAG TT - #TTCGTTCC 960- ACTGAGCGTC AGACCCCGTA GAAAAGATCA AAGGATCTTC TTGAGATCCT TT - #TTTTCTGC1020- GCGTAATCTG CTGCTTGCAA ACAAAAAAAC CACCGCTACC AGCGGTGGTT TG - #TTTGCCGG1080- ATCAAGAGCT ACCAACTCTT TTTCCGAAGG TAACTGGCTT CAGCAGAGCG CA - #GATACCAA1140- ATACTGTCCT TCTAGTGTAG CCGTAGTTAG GCCACCACTT CAAGAACTCT GT - #AGCACCGC1200- CTACATACCT CGCTCTGCTA ATCCTGTTAC CAGTGGCTGC TGCCAGTGGC GA - #TAAGTCGT1260- GTCTTACCGG GTTGGACTCA AGACGATAGT TACCGGATAA GGCGCAGCGG TC - #GGGCTGAA1320- CGGGGGGTTC GTGCACACAG CCCAGCTTGG AGCGAACGAC CTACACCGAA CT - #GAGATACC1380- TACAGCGTGA GCATTGAGAA AGCGCCACGC TTCCCGAAGG GAGAAAGGCG GA - #CAGGTATC1440- CGGTAAGCGG CAGGGTCGGA ACAGGAGAGC GCACGAGGGA GCTTCCAGGG GG - #AAACGCCT1500- GGTATCTTTA TAGTCCTGTC GGGTTTCGCC ACCTCTGACT TGAGCGTCGA TT - #TTTGTGAT1560- GCTCGTCAGG GGGGCGGAGC CTATGGAAAA ACGCCAGCAA CGCGGCCTTT TT - #ACGGTTCC1620- TGGCCTTTTG CTGGCCTTTT GCTCACATGT TCTTTCCTGC GTTATCCCCT GA - #TTCTGTGG1680- ATAACCGTAT TACCGCCTTT GAGTGAGCTG ATACCGCTCG CCGCAGCCGA AC - #GACCGAGC1740- GCAGCGAGTC AGTGAGCGAG GAAGCGGAAG AGCGCTGACT TCCGCGTTTC CA - #GACTTTAC1800- GAAACACGGA AACCGAAGAC CATTCATGTT GTTGCTCAGG TCGCAGACGT TT - #TGCAGCAG1860- CAGTCGCTTC ACGTTCGCTC GCGTATCGGT GATTCATTCT GCTAACCAGT AA - #GGCAACCC1920- CGCCAGCCTA GCCGGGTCCT CAACGACAGG AGCACGATCA TGCGCACCCG TG - #GCCAGGAC1980- CCAACGCTGC CCGAGATGCG CCGCGTGCGG CTGCTGGAGA TGGCGGACGC GA - #TGGATATG2040- TTCTGCCAAG GGTTGGTTTG CGCATTCACA GTTCTCCGCA AGAATTGATT GG - #CTCCAATT2100- CTTGGAGTGG TGAATCCGTT AGCGAGGTGC CGCCGGCTTC CATTCAGGTC GA - #GGTGGCCC2160- GGCTCCATGC ACCGCGACGC AACGCGGGGA GGCAGACAAG GTATAGGGCG GC - #GCCTACAA2220- TCCATGCCAA CCCGTTCCAT GTGCTCGCCG AGGCGGCATA AATCGCCGTG AC - #GATCAGCG2280- GTCCAGTGAT CGAAGTTAGG CTGGTAAGAG CCGCGAGCGA TCCTTGAAGC TG - #TCCCTGAT2340- GGTCGTCATC TACCTGCCTG GACAGCATGG CCTGCAACGC GGGCATCCCG AT - #GCCGCCGG2400- AAGCGAGAAG AATCATAATG GGGAAGGCCA TCCAGCCTCG CGTCGCGAAC GC - #CAGCAAGA2460- CGTAGCCCAG CGCGTCGGCC GCCATGCCGG CGATAATGGC CTGCTTCTCG CC - #GAAACGTT2520- TGGTGGCGGG ACCAGTGACG AAGGCTTGAG CGAGGGCGTG CAAGATTCCG AA - #TACCGCAA2580- GCGACAGGCC GATCATCGTC GCGCTCCAGC GAAAGCGGTC CTCGCCGAAA AT - #GACCCAGA2640- GCGCTGCCGG CACCTGTCCT ACGAGTTGCA TGATAAAGAA GACAGTCATA AG - #TGCGGCGA2700- CGATAGTCAT GCCCCGCGCC CACCGGAAGG AGCTGACTGG GTTGAAGGCT CT - #CAAGGGCA2760- TCGGTCGACG CTCTCCCTTA TGCGACTCCT GCATTAGGAA GCAGCCCAGT AG - #TAGGTTGA2820- GGCCGTTGAG CACCGCCGCC GCAAGGAATG GTGCATGCAA GGAGATGGCG CC - #CAACAGTC2880- CCCCGGCCAC GGGGCCTGCC ACCATACCCA CGCCGAAACA AGCGCTCATG AG - #CCCGAAGT2940- GGCGAGCCCG ATCTTCCCCA TCGGTGATGT CGGCGATATA GGCGCCAGCA AC - #CGCACCTG3000- TGGCGCCGGT GATGCCGGCC ACGATGCGTC CGGCGTAGAG GATCCACAGG AC - #GGGTGTGG3060- TCGCCATGAT CGCGTAGTCG ATAGTGGCTC CAAGTAGCGA AGCGAGCAGG AC - #TGGGCGGC3120- GGCCAAAGCG GTCGGACAGT GCTCCGAGAA CGGGTGCGCA TAGAAATTGC AT - #CAACGCAT3180- ATAGCGCTAG CAGCACGCCA TAGTGACTGG CGATGCTGTC GGAATGGACG AT - #ATCCCGCA3240- AGAGGCCCGG CAGTACCGGC ATAACCAAGC CTATGCCTAC AGCATCCAGG GT - #GACGGTGC3300- CGAGGATGAC GATGAGCGCA TTGTTAGATT TCATACACGG TGCCTGACTG CG - #TTAGCAAT3360- TTAACTGTGA TAAACTACCG CATTAAAGCT TATCGATGAT AAGCTGTCAA AC - #ATGAGAAT3420# 3423- (2) INFORMATION FOR SEQ ID NO: 41:- (i) SEQUENCE CHARACTERISTICS:#pairs (A) LENGTH: 3474 base (B) TYPE: nucleic acid (C) STRANDEDNESS: single (D) TOPOLOGY: circular- (ii) MOLECULE TYPE: plasmid vector- (iii) HYPOTHETICAL: NO#41: (xi) SEQUENCE DESCRIPTION: SEQ ID NO:- AATTCCGGGG ATCTCTCACC TACCAAACAA TGCCCCCCTG CAAAAAATAA AT - #TCATATAA 60- AAAACATACA GATAACCATC TGCGGTGATA AATTATCTCT GGCGGTGTTG AC - #ATAAATAC 120- CACTGGCGGT GATACTGAGC ACATCAGCAG GACGCACTGA CCACCATGAA GG - #TGACGCTC 180- TTAAAAATTA AGCCCTGAAG AAGGGCAGGG GTACCAGGAG GTTTAAATCA TG - #GTAAGATC 240- AAGTAGTCAA AATTCGAGTG ACAAGCCTGT AGCCCACGTC GTAGCAAACC AC - #CAAGTGGA 300- GGAGCAGGGA ATTCACCATC ACCATCACCA CGTGGATCCC GGGCCCATGG CT - #TTCCGGAG 360- GCCTCTAGAG TCGACCGGCA TGCAAGCTTA AGTAAGTAAG CCGCCAGTTC CG - #CTGGCGGC 420- ATTTTTTTTG ATGCCCAAGC TTGGCTGTTT TGGCGGATGA GAGAAGATTT TC - #AGCCTGAT 480- ACAGATTAAA TCAGAACGCA GAAGCGGTCT GATAAAACAG AATTTGCCTG GC - #GGCAGTAG 540- CGCGGTGGTC CCACCTGACC CCATGCCGAA CTCAGAAGTG AAACGCCGTA GC - #GCCGATGG 600- TAGTGTGGGG TCTCCCCATG CGAGAGTAGG GAACTGCCAG GCATCAAATA AA - #ACGAAAGG 660- CTCAGTCGAA AGACTGGGCC TTTCGTTTTA TCTGTTGTTT GTCGGTGAAC GC - #TCTCCTGA 720- GTAGGACAAA TCCGCCGGGA GCGGATTTGA ACGTTGCGAA GCAACGGCCC GG - #AGGGTGGC 780- GGGCAGGACG CCCGCCATAA ACTGCCAGGC ATCAAATTAA GCAGAAGGCC AT - #CCTGACGG 840- ATGGCCTTTT TGCGTTTCTA CAAACTCTTT TGTTTATTTT TCTAAATACA TT - #CAAATATG 900- TATCCGCTCA TGAGACAATA ACCCTGATAA ATGCTTCAAT AATAAAAGGA TC - #TAGGTGAA 960- GATCCTTTTT GATAATCTCA TGACCAAAAT CCCTTAACGT GAGTTTTCGT TC - #CACTGAGC1020- GTCAGACCCC GTAGAAAAGA TCAAAGGATC TTCTTGAGAT CCTTTTTTTC TG - #CGCGTAAT1080- CTGCTGCTTG CAAACAAAAA AACCACCGCT ACCAGCGGTG GTTTGTTTGC CG - #GATCAAGA1140- GCTACCAACT CTTTTTCCGA AGGTAACTGG CTTCAGCAGA GCGCAGATAC CA - #AATACTGT1200- CCTTCTAGTG TAGCCGTAGT TAGGCCACCA CTTCAAGAAC TCTGTAGCAC CG - #CCTACATA1260- CCTCGCTCTG CTAATCCTGT TACCAGTGGC TGCTGCCAGT GGCGATAAGT CG - #TGTCTTAC1320- CGGGTTGGAC TCAAGACGAT AGTTACCGGA TAAGGCGCAG CGGTCGGGCT GA - #ACGGGGGG1380- TTCGTGCACA CAGCCCAGCT TGGAGCGAAC GACCTACACC GAACTGAGAT AC - #CTACAGCG1440- TGAGCATTGA GAAAGCGCCA CGCTTCCCGA AGGGAGAAAG GCGGACAGGT AT - #CCGGTAAG1500- CGGCAGGGTC GGAACAGGAG AGCGCACGAG GGAGCTTCCA GGGGGAAACG CC - #TGGTATCT1560- TTATAGTCCT GTCGGGTTTC GCCACCTCTG ACTTGAGCGT CGATTTTTGT GA - #TGCTCGTC1620- AGGGGGGCGG AGCCTATGGA AAAACGCCAG CAACGCGGCC TTTTTACGGT TC - #CTGGCCTT1680- TTGCTGGCCT TTTGCTCACA TGTTCTTTCC TGCGTTATCC CCTGATTCTG TG - #GATAACCG1740- TATTACCGCC TTTGAGTGAG CTGATACCGC TCGCCGCAGC CGAACGACCG AG - #CGCAGCGA1800- GTCAGTGAGC GAGGAAGCGG AAGAGCGCTG ACTTCCGCGT TTCCAGACTT TA - #CGAAACAC1860- GGAAACCGAA GACCATTCAT GTTGTTGCTC AGGTCGCAGA CGTTTTGCAG CA - #GCAGTCGC1920- TTCACGTTCG CTCGCGTATC GGTGATTCAT TCTGCTAACC AGTAAGGCAA CC - #CCGCCAGC1980- CTAGCCGGGT CCTCAACGAC AGGAGCACGA TCATGCGCAC CCGTGGCCAG GA - #CCCAACGC2040- TGCCCGAGAT GCGCCGCGTG CGGCTGCTGG AGATGGCGGA CGCGATGGAT AT - #GTTCTGCC2100- AAGGGTTGGT TTGCGCATTC ACAGTTCTCC GCAAGAATTG ATTGGCTCCA AT - #TCTTGGAG2160- TGGTGAATCC GTTAGCGAGG TGCCGCCGGC TTCCATTCAG GTCGAGGTGG CC - #CGGCTCCA2220- TGCACCGCGA CGCAACGCGG GGAGGCAGAC AAGGTATAGG GCGGCGCCTA CA - #ATCCATGC2280- CAACCCGTTC CATGTGCTCG CCGAGGCGGC ATAAATCGCC GTGACGATCA GC - #GGTCCAGT2340- GATCGAAGTT AGGCTGGTAA GAGCCGCGAG CGATCCTTGA AGCTGTCCCT GA - #TGGTCGTC2400- ATCTACCTGC CTGGACAGCA TGGCCTGCAA CGCGGGCATC CCGATGCCGC CG - #GAAGCGAG2460- AAGAATCATA ATGGGGAAGG CCATCCAGCC TCGCGTCGCG AACGCCAGCA AG - #ACGTAGCC2520- CAGCGCGTCG GCCGCCATGC CGGCGATAAT GGCCTGCTTC TCGCCGAAAC GT - #TTGGTGGC2580- GGGACCAGTG ACGAAGGCTT GAGCGAGGGC GTGCAAGATT CCGAATACCG CA - #AGCGACAG2640- GCCGATCATC GTCGCGCTCC AGCGAAAGCG GTCCTCGCCG AAAATGACCC AG - #AGCGCTGC2700- CGGCACCTGT CCTACGAGTT GCATGATAAA GAAGACAGTC ATAAGTGCGG CG - #ACGATAGT2760- CATGCCCCGC GCCCACCGGA AGGAGCTGAC TGGGTTGAAG GCTCTCAAGG GC - #ATCGGTCG2820- ACGCTCTCCC TTATGCGACT CCTGCATTAG GAAGCAGCCC AGTAGTAGGT TG - #AGGCCGTT2880- GAGCACCGCC GCCGCAAGGA ATGGTGCATG CAAGGAGATG GCGCCCAACA GT - #CCCCCGGC2940- CACGGGGCCT GCCACCATAC CCACGCCGAA ACAAGCGCTC ATGAGCCCGA AG - #TGGCGAGC3000- CCGATCTTCC CCATCGGTGA TGTCGGCGAT ATAGGCGCCA GCAACCGCAC CT - #GTGGCGCC3060- GGTGATGCCG GCCACGATGC GTCCGGCGTA GAGGATCCAC AGGACGGGTG TG - #GTCGCCAT3120- GATCGCGTAG TCGATAGTGG CTCCAAGTAG CGAAGCGAGC AGGACTGGGC GG - #CGGCCAAA3180- GCGGTCGGAC AGTGCTCCGA GAACGGGTGC GCATAGAAAT TGCATCAACG CA - #TATAGCGC3240- TAGCAGCACG CCATAGTGAC TGGCGATGCT GTCGGAATGG ACGATATCCC GC - #AAGAGGCC3300- CGGCAGTACC GGCATAACCA AGCCTATGCC TACAGCATCC AGGGTGACGG TG - #CCGAGGAT3360- GACGATGAGC GCATTGTTAG ATTTCATACA CGGTGCCTGA CTGCGTTAGC AA - #TTTAACTG3420- TGATAAACTA CCGCATTAAA GCTTATCGAT GATAAGCTGT CAAACATGAG AA - #TT3474- (2) INFORMATION FOR SEQ ID NO: 42:- (i) SEQUENCE CHARACTERISTICS:#pairs (A) LENGTH: 3301 base (B) TYPE: nucleic acid (C) STRANDEDNESS: single (D) TOPOLOGY: circular- (ii) MOLECULE TYPE: plasmid vector- (iii) HYPOTHETICAL: NO#42: (xi) SEQUENCE DESCRIPTION: SEQ ID NO:- TTCCGGGGAT CTCTCACCTA CCAAACAATG CCCCCCTGCA AAAAATAAAT TC - #ATATAAAA 60- AACATACAGA TAACCATCTG CGGTGATAAA TTATCTCTGG CGGTGTTGAC AT - #AAATACCA 120- CTGGCGGTGA TACTGAGCAC ATCAGCAGGA CGCACTGACC ACCATGAAGG TG - #ACGCTCTT 180- AAAAATTAAG CCCTGAAGAA GGGCAGGGGT ACCAGGAGGT TTAAATATTC CA - #TGGGGGGG 240- ATCCTCTAGA GTCGACCTGC AGCCCAAGCT TGGCTGTTTT GGCGGATGAG AG - #AAGATTTT 300- CAGCCTGATA CAGATTAAAT CAGAACGCAG AAGCGGTCTG ATAAAACAGA AT - #TTGCCTGG 360- CGGCAGTAGC GCGGTGGTCC CACCTGACCC CATGCCGAAC TCAGAAGTGA AA - #CGCCGTAG 420- CGCCGATGGT AGTGTGGGGT CTCCCCATGC GAGAGTAGGG AACTGCCAGG CA - #TCAAATAA 480- AACGAAAGGC TCAGTCGAAA GACTGGGCCT TTCGTTTTAT CTGTTGTTTG TC - #GGTGAACG 540- CTCTCCTGAG TAGGACAAAT CCGCCGGGAG CGGATTTGAA CGTTGCGAAG CA - #ACGGCCCG 600- GAGGGTGGCG GGCAGGACGC CCGCCATAAA CTGCCAGGCA TCAAATTAAG CA - #GAAGGCCA 660- TCCTGACGGA TGGCCTTTTT GCGTTTCTAC AAACTCTTTT GTTTATTTTT CT - #AAATACAT 720- TCAAATATGT ATCCGCTCAT GAGACAATAA CCCTGATAAA TGCTTCAATA AT - #AAAAGGAT 780- CTAGGTGAAG ATCCTTTTTG ATAATCTCAT GACCAAAATC CCTTAACGTG AG - #TTTTCGTT 840- CCACTGAGCG TCAGACCCCG TAGAAAAGAT CAAAGGATCT TCTTGAGATC CT - #TTTTTTCT 900- GCGCGTAATC TGCTGCTTGC AAACAAAAAA ACCACCGCTA CCAGCGGTGG TT - #TGTTTGCC 960- GGATCAAGAG CTACCAACTC TTTTTCCGAA GGTAACTGGC TTCAGCAGAG CG - #CAGATACC1020- AAATACTGTC CTTCTAGTGT AGCCGTAGTT AGGCCACCAC TTCAAGAACT CT - #GTAGCACC1080- GCCTACATAC CTCGCTCTGC TAATCCTGTT ACCAGTGGCT GCTGCCAGTG GC - #GATAAGTC1140- GTGTCTTACC GGGTTGGACT CAAGACGATA GTTACCGGAT AAGGCGCAGC GG - #TCGGGCTG1200- AACGGGGGGT TCGTGCACAC AGCCCAGCTT GGAGCGAACG ACCTACACCG AA - #CTGAGATA1260- CCTACAGCGT GAGCATTGAG AAAGCGCCAC GCTTCCCGAA GGGAGAAAGG CG - #GACAGGTA1320- TCCGGTAAGC GGCAGGGTCG GAACAGGAGA GCGCACGAGG GAGCTTCCAG GG - #GGAAACGC1380- CTGGTATCTT TATAGTCCTG TCGGGTTTCG CCACCTCTGA CTTGAGCGTC GA - #TTTTTGTG1440- ATGCTCGTCA GGGGGGCGGA GCCTATGGAA AAACGCCAGC AACGCGGCCT TT - #TTACGGTT1500- CCTGGCCTTT TGCTGGCCTT TTGCTCACAT GTTCTTTCCT GCGTTATCCC CT - #GATTCTGT1560- GGATAACCGT ATTACCGCCT TTGAGTGAGC TGATACCGCT CGCCGCAGCC GA - #ACGACCGA1620- GCGCAGCGAG TCAGTGAGCG AGGAAGCGGA AGAGCGCTGA CTTCCGCGTT TC - #CAGACTTT1680- ACGAAACACG GAAACCGAAG ACCATTCATG TTGTTGCTCA GGTCGCAGAC GT - #TTTGCAGC1740- AGCAGTCGCT TCACGTTCGC TCGCGTATCG GTGATTCATT CTGCTAACCA GT - #AAGGCAAC1800- CCCGCCAGCC TAGCCGGGTC CTCAACGACA GGAGCACGAT CATGCGCACC CG - #TGGCCAGG1860- ACCCAACGCT GCCCGAGATG CGCCGCGTGC GGCTGCTGGA GATGGCGGAC GC - #GATGGATA1920- TGTTCTGCCA AGGGTTGGTT TGCGCATTCA CAGTTCTCCG CAAGAATTGA TT - #GGCTCCAA1980- TTCTTGGAGT GGTGAATCCG TTAGCGAGGT GCCGCCGGCT TCCATTCAGG TC - #GAGGTGGC2040- CCGGCTCCAT GCACCGCGAC GCAACGCGGG GAGGCAGACA AGGTATAGGG CG - #GCGCCTAC2100- AATCCATGCC AACCCGTTCC ATGTGCTCGC CGAGGCGGCA TAAATCGCCG TG - #ACGATCAG2160- CGGTCCAGTG ATCGAAGTTA GGCTGGTAAG AGCCGCGAGC GATCCTTGAA GC - #TGTCCCTG2220- ATGGTCGTCA TCTACCTGCC TGGACAGCAT GGCCTGCAAC GCGGGCATCC CG - #ATGCCGCC2280- GGAAGCGAGA AGAATCATAA TGGGGAAGGC CATCCAGCCT CGCGTCGCGA AC - #GCCAGCAA2340- GACGTAGCCC AGCGCGTCGG CCGCCATGCC GGCGATAATG GCCTGCTTCT CG - #CCGAAACG2400- TTTGGTGGCG GGACCAGTGA CGAAGGCTTG AGCGAGGGCG TGCAAGATTC CG - #AATACCGC2460- AAGCGACAGG CCGATCATCG TCGCGCTCCA GCGAAAGCGG TCCTCGCCGA AA - #ATGACCCA2520- GAGCGCTGCC GGCACCTGTC CTACGAGTTG CATGATAAAG AAGACAGTCA TA - #AGTGCGGC2580- GACGATAGTC ATGCCCCGCG CCCACCGGAA GGAGCTGACT GGGTTGAAGG CT - #CTCAAGGG2640- CATCGGTCGA CGCTCTCCCT TATGCGACTC CTGCATTAGG AAGCAGCCCA GT - #AGTAGGTT2700- GAGGCCGTTG AGCACCGCCG CCGCAAGGAA TGGTGCATGC AAGGAGATGG CG - #CCCAACAG2760- TCCCCCGGCC ACGGGGCCTG CCACCATACC CACGCCGAAA CAAGCGCTCA TG - #AGCCCGAA2820- GTGGCGAGCC CGATCTTCCC CATCGGTGAT GTCGGCGATA TAGGCGCCAG CA - #ACCGCACC2880- TGTGGCGCCG GTGATGCCGG CCACGATGCG TCCGGCGTAG AGGATCCACA GG - #ACGGGTGT2940- GGTCGCCATG ATCGCGTAGT CGATAGTGGC TCCAAGTAGC GAAGCGAGCA GG - #ACTGGGCG3000- GCGGCCAAAG CGGTCGGACA GTGCTCCGAG AACGGGTGCG CATAGAAATT GC - #ATCAACGC3060- ATATAGCGCT AGCAGCACGC CATAGTGACT GGCGATGCTG TCGGAATGGA CG - #ATATCCCG3120- CAAGAGGCCC GGCAGTACCG GCATAACCAA GCCTATGCCT ACAGCATCCA GG - #GTGACGGT3180- GCCGAGGATG ACGATGAGCG CATTGTTAGA TTTCATACAC GGTGCCTGAC TG - #CGTTAGCA3240- ATTTAACTGT GATAAACTAC CGCATTAAAG CTTATCGATG ATAAGCTGTC AA - #ACATGAGA3300# 3301- (2) INFORMATION FOR SEQ ID NO: 43:- (i) SEQUENCE CHARACTERISTICS:#acids (A) LENGTH: 338 amino (B) TYPE: amino acid (D) TOPOLOGY: linear- (ii) MOLECULE TYPE: protein- (iii) HYPOTHETICAL: NO#43: (xi) SEQUENCE DESCRIPTION: SEQ ID NO:- Met Val Arg Ser Ser Ser Gln Asn - # Ser Ser Asp Lys Pro Val AlaHis# 15- Val Val Ala Asn His Gln Val Glu - # Glu Gln Gly Ile His His HisHis# 30- His His Val Asp Pro Gly Pro Met - # Ala Phe Arg Arg His Gly ProGly# 45- Leu Pro Val Glu Tyr Leu Gln Val - # Pro Ser Pro Ser Met Gly ArgAsp# 60- Ile Lys Val Gln Phe Gln Ser Gly - # Gly Ala Asn Ser Pro Ala LeuTyr# 80- Leu Leu Asp Gly Leu Arg Ala Gln - # Asp Asp Phe Ser Gly Trp AspIle# 95- Asn Thr Pro Ala Phe Glu Trp Tyr - # Asp Gln Ser Gly Leu Ser ValVal# 110- Met Pro Val Gly Gly Gln Ser Ser - # Phe Tyr Ser Asp Trp Tyr GlnPro# 125- Ala Cys Gly Lys Ala Gly Cys Gln - # Thr Tyr Lys Trp Glu Thr PheLeu# 140- Thr Ser Glu Leu Pro Gly Trp Leu - # Gln Ala Asn Arg His Val LysPro# 160- Thr Gly Ser Ala Val Val Gly Leu - # Ser Met Ala Ala Ser Ser AlaLeu# 175- Thr Leu Ala Ile Tyr His Pro Gln - # Gln Phe Val Tyr Ala Gly AlaMet# 190- Ser Gly Leu Leu Asp Pro Ser Gln - # Ala Met Gly Pro Thr Leu IleGly# 205- Leu Ala Met Gly Asp Ala Gly Gly - # Tyr Lys Ala Ser Asp Met TrpGly# 220- Pro Lys Glu Asp Pro Ala Trp Gln - # Arg Asn Asp Pro Leu Leu AsnVal# 240- Gly Lys Leu Ile Ala Asn Asn Thr - # Arg Val Trp Val Tyr Cys GlyAsn# 255- Gly Lys Pro Ser Asp Leu Gly Gly - # Asn Asn Leu Pro Ala Lys PheLeu# 270- Glu Gly Phe Val Arg Thr Ser Asn - # Ile Lys Phe Gln Asp Ala TyrAsn# 285- Ala Gly Gly Gly His Asn Gly Val - # Phe Asp Phe Pro Asp Ser GlyThr# 300- His Ser Trp Glu Tyr Trp Gly Ala - # Gln Leu Asn Ala Met Lys ProAsp# 320- Leu Gln Arg Ala Leu Gly Ala Thr - # Pro Asn Thr Gly Pro Ala ProGln# 335- Gly Ala__________________________________________________________________________ | The invention relates to recombinant polypeptides and peptides which can also be used for the diagnosis of tuberculosis. The invention also relates to a process for preparing the above polypeptides and peptides, which are in a state of biological purity such that they can be used as part of the active principle in the preparation of vaccines against tuberculosis. The invention additionally relates to nucleic acids coding for said polypeptides and peptides. | 2 |
CROSS-REFERENCES
This application is a U.S. National stage application of PCT/EP2011/056863, filed on Apr. 29, 2011 which claims priority to French Patent Application No. 1053413 filed on May 3, 2010. Each of which is incorporated by reference in there entireties for all purposes.
The invention relates to the treatment of harvested vegetables and, in particular, to the treatment of harvested vegetables with a view to extracting there from a vegetable substance, in particular a juice.
More particularly, the invention relates to a treatment of vegetable tissues with a pulsed electric field.
One particularly advantageous application of the invention relates to the treatment of sugar beet for the sugar industry.
BACKGROUND OF THE INVENTION
It has already been proposed in the prior art to treat beet cossettes or other vegetable matter, such as chicory, potatoes, carrots, fruits with pulsed electric fields in order to extract substances there from.
Specifically, by subjecting a vegetable tissue to pulses of an electric field, the cellular membranes of the tissue are rendered permeable or destroyed so that the cellular juice can be recovered. Such a technique is generally known by the term “electroporation”.
In this regard, reference may be made to the document WO 2009/129991, which describes such a method for the electroporation of beet cossettes with a pulsed electric field.
In the method described in said document, the beets are first ground into cossettes, and a liquid phase is added to the cossettes. The mixture obtained is subsequently conveyed without pressure into a reaction chamber in which a pulsed electric field is sustained.
This method requires the use of a conductive liquid mixed with the cossettes in order, on the one hand, to facilitate their delivery to the treatment chamber and, on the other hand, to overcome the drawbacks associated with the relative inhomogeneity of the mixture of cossettes in the treatment chamber, creating nonconductive voids between the cossettes.
The presence of this liquid phase requires the use of a pulsed electric field generator having a high capacity, of the order of 60 kV, and consequently a treatment chamber having relatively large dimensions.
It is therefore an object of the invention to overcome this drawback and to provide a method for treating vegetable tissues which makes it possible to extract a juice from the tissues without requiring the use of a liquid phase.
SUMMARY OF THE INVENTION
The invention therefore relates, according to a first aspect, to a method for treating vegetable tissues with a pulsed electric field in order to extract therefrom a vegetable substance, in particular a juice, wherein the vegetable tissues are compacted in order to reduce the residual space between the tissues, and the compacted vegetables are subjected to a pulsed electric field in at least one treatment chamber.
Thus, by virtue of this prior compacting phase, it is possible to bring the vegetable tissues into the form of a compact volume making it possible to reduce the residual space between pieces of tissue and, consequently, to distribute the pulsed electric field homogeneously through the vegetable tissues.
Furthermore, this compacting phase makes it possible to convey the vegetable tissues to the treatment chamber or chambers without needing to mix the tissues with a liquid phase. While maintaining a constant generator capacity, it is then possible to treat more vegetable tissues. While maintaining a constant vegetable treatment capacity, it is possible to reduce the capacity of the generator and/or the quantity of the generator or generators and the size of the treatment chamber or chambers.
In one embodiment, after the treatment of the vegetable tissues with a pulsed electric field, a first juice is extracted from the treatment chamber.
This is because it has been observed that the prior phase of stressing the vegetable tissue makes it possible to obtain a first pressing juice easily. It has furthermore been observed that this first juice is of increased purity.
According to yet another characteristic of this treatment method, after the extraction of the first juice, the vegetable tissues are subjected to an additional juice extraction treatment. For example, it is possible to use a treatment of extraction by diffusion or pressing.
Preferably, before the step of compacting the vegetable tissues, cutting of the vegetables is carried out. Such a prior cutting step makes it possible to improve the homogeneity of the mixture in the treatment chamber or chambers by further reducing the space between the vegetables.
For example, a root-cutting tool is used for this purpose.
The method may furthermore comprise a prior step of washing the vegetables. It is furthermore possible to inject compressed air into the treatment chamber before the treatment of the compacted tissues with a pulsed electric field.
According to yet another characteristic of the extraction method, the step of treating the compacted vegetables is carried out by means of one or more treatment chambers arranged in series or in parallel.
Thus, even when using pulsed electric field generators of relatively low capacity and treatment chambers of relatively small dimensions, it is possible to treat relatively large masses of vegetable tissues.
It is furthermore possible to regulate the parameters of the pulsed electric field as a function of the nature of the vegetables to be treated.
The invention also relates, according to a second aspect, to an apparatus for treating vegetable tissues with a pulsed electric field in order to extract there from a vegetable substance, in particular a juice.
This apparatus comprises a stage of compacting the vegetable tissues and at least one treatment chamber comprising means for generating a pulsed electric field in said chamber in order to treat the compacted tissues.
This apparatus furthermore comprises, in one embodiment, means for extracting a first juice coming from the treatment chamber.
This apparatus may also comprise an additional stage of treatment of the vegetable tissues, in particular by diffusion or by pressing, which is arranged downstream of the treatment chamber.
According to yet another characteristic of the apparatus, it comprises a stage of cutting the vegetables, which is arranged upstream of the compacting stage.
This cutting stage may comprise a root cutter.
In one embodiment, the means for generating a pulsed electric field comprise a pulsed electric field generator delivering an electric field of between about 0.1 and 1 kV/cm.
BRIEF DESCRIPTION OF THE DRAWINGS
Other objects, characteristics and advantages of the invention will become apparent on reading the following description, which is provided merely by way of non-limiting example and given with reference to the appended drawings, in which:
FIG. 1 schematically illustrates a first exemplary embodiment of an apparatus for treating vegetable tissues according to the invention;
FIG. 2 illustrates a second embodiment of an apparatus for treating tissues according to the invention; and
FIG. 3 illustrates a third embodiment of an apparatus for treating tissues according to the invention.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 represents a first exemplary embodiment of an apparatus for treating vegetable tissues according to the invention.
This apparatus is intended to treat, with a pulsed electric field, vegetable tissues taken from harvests, in particular but not exclusively sugar beet with a view to recovering there from a cellular juice and, in general, a vegetable substance, for example pulp.
It will be noted that, when the apparatus is intended for the treatment of all types of vegetables, fruits, plants or legumes with a view to extracting there from a juice or a substance, this does not depart from the scope of the invention.
The treatment used is based on the application of a pulsed electric field to the vegetables to be treated.
Specifically, when vegetable tissue is placed in an electric field, the difference between the intra- and extracellular compositions generates an accumulation of electric charges on the membrane surfaces and an increase in the transmembrane potential.
The attraction between the charges of opposite signs accumulated on either side of the membrane causes compression of the latter.
The elastic force generated by the membrane tends to oppose this compression. When the applied electric field exceeds a critical value, the compression force applied on either side of the membrane under the effect of the attraction of the charges of opposite signs becomes greater than the resisting elastic force of the membrane, and pores appear, or they are enlarged if they exist in the membrane. At this stage, the electroporation is assumed to remain reversible. When the amplitude of the electric field and/or the duration of its application are increased, irreversible permeabilization and destruction of the cellular membrane are observed, then making it possible to recover the cellular juice.
Thus, the apparatus illustrated in FIG. 1 essentially comprises, considering the treatment direction of the vegetable tissues: a first stage 1 of cutting the vegetables; a stage 2 of conveying the cut vegetables, for example a volumetric conveyor system; a third stage 3 of compacting the cut tissues, arranged downstream of the second conveying stage 2 ; and a chamber 4 for treatment of the cut and compacted vegetables, which is associated with a pulsed electric field generator 5 .
The cutting stage 1 corresponds to the first stage of the apparatus. It is supplied with vegetables to be treated, as harvested. This stage 1 is adapted to cut the vegetables with a specific geometry making it possible to reduce the void ratio between the cut elements once they are amassed. To this end, for example, a root cutter traditionally used in the beet, sugar or chicory industry is used. For other roots, such as manioc, a grater may be used.
The compacting stage 3 , for its part, pressurizes the cut vegetables in order to further reduce the residual space between the vegetables and, in particular, the space between the cut vegetables.
In other words, the purpose is to deliver a homogeneous mass of cut vegetables to the treatment chamber 4 , minimizing the spaces without vegetable matter so that it is not necessary to use a liquid phase or an electrically conductive gel in the treatment chamber, and consecutive treatments involving loss of such a phase or such a gel.
This compacting phase may be carried out by any suitable tool or press capable of exerting a sufficient pressure on the cut vegetables so as to compact them and thus reduce the residual spaces, without exerting an excessive pressure tending to result in juice extraction.
As indicated above, downstream of the compacting stage, the apparatus comprises a treatment chamber associated with a pulsed electric field generator 5 .
During operation, the generator 5 is intended to create and sustain a pulsed electric field in the internal volume of the chamber 4 , which is filled with cut and compacted vegetables, the parameters of which field may be adapted as a function of the nature of the vegetables treated.
It is thus possible, for example, to vary the frequency, the width of the pulses, the output voltage and, in general, the shape of the voltage signal delivered by the generator as a function of the nature of the vegetable tissues to be treated. These parameters may also be modified in order to adapt to the quality or characteristics of the products as a function of the growing areas or climatic conditions, or in the event of diseases.
It will, however, be noted that, by virtue of the prior compacting step, it is possible to convey the vegetables to the treatment chamber without mixing the vegetables with a liquid phase.
It is also possible, by virtue of this compacting phase, to use a treatment chamber of small dimensions as well as a pulsed electric field generator 5 of low capacity, in so far as this compacting step obviates the use of a liquid phase or an electrically conductive gel in order to fill the empty spaces which would otherwise exist between the vegetables and, consequently, all treatments involving loss of this liquid phase or this gel.
It is thus possible to use a pulsed electric field generator with a power of between 15 and 20 kV, capable of providing an electric field of between about 0.1 and 1 kV/cm in the treatment chamber 4 .
Likewise, the treatment chamber 4 may, by way of nonlimiting example, have a cross section of between 50 mm and 500 mm, and a length of between 200 mm and 2 m approximately, depending on the cross section.
Such characteristics make it possible to treat masses of vegetable tissues of between about 1 and 150 ton(s)/hour.
It will be noted that the prior compacting phase combined with the treatment with pulsed electric fields makes it possible to provide a stage 6 of extraction of a first juice J 1 at the exit of the treatment chamber 4 .
Specifically, the pulsed electric fields make it possible to treat vegetables during very short voltage peaks, of the order of a few microseconds, generating very little dissipation of electrical energy by the Joule effect in the vegetable tissue. It is thus possible to obtain a cold juice of high purity, and in any event, of increased quality compared with the traditional techniques of extraction by pressing or diffusion.
It will be noted that, for beet juice, it is generally necessary to employ a subsequent phase of lime and carbon dioxide purification. In so far as the prior compacting phase and the treatment with a pulsed electric field make it possible to obtain a juice of increased purity, this subsequent purification phase is greatly facilitated. The purification may then be of the less intensive lime and carbon dioxide type, but also either partially or else entirely purification using microfiltration and ultrafiltration membranes, depending on the nature of the vegetables and the quality of the extracted juices.
Downstream of the treatment chamber 4 , the apparatus also comprises additional vegetable tissue treatment stages, of conventional type, allowing complementary extraction of a juice J 2 .
For example, as illustrated, it is possible either to use a stage 7 of treatment by pressing or, as a variant, a stage 8 of treatment by diffusion followed by a stage 9 of treatment by pressing.
Lastly, it will be noted that the apparatus may furthermore be provided with a stage 10 of washing the vegetables, for example arranged upstream of the cutting stage 1 .
Thus, by virtue of the presence of this washing stage, which makes it possible to impart a degree of moisture to the vegetables in the form of a film on the surface of the vegetables, the apparatus may be provided with an optional stage 11 of compressed air injection into the treatment chamber before the first electric field application, in order to create a humid atmosphere in this chamber in the form of a mist, further increasing the treatment efficiency by creating an electrically conductive atmosphere in the treatment chamber 4 while also making it possible to lubricate the walls of the chamber.
It will be noted that, by virtue of the use of the compacting phase combined with the use of a pulsed electric field generator of relatively low capacity and with a treatment chamber of reduced dimensions, the invention which has just been described makes it possible to obtain treatment apparatuses of reduced dimensions or to obtain an increase in the quality of the recovered juices and in the efficiency of the treatment carried out in the additional treatment stages 7 , 8 and 9 following an increase in the pressing ratios, a reduction in the diffusion extraction, a reduction in temperature, etc.
It will, however, be noted that the invention is not limited to the embodiment described.
Specifically, in the embodiment described above, the apparatus comprises a single treatment chamber 4 associated with a pulsed electric field generator 5 .
With a view to increasing the treatment capacity, it is possible to use a plurality of treatment chambers arranged in parallel ( FIG. 2 ) or, as a variant, in series ( FIG. 3 ).
It will be noted that it is possible to provide as many treatment chambers as necessary in parallel or in series, supplied by one or more generators in parallel, in order to ensure sufficient electroporation compatible with industrial treatment methods. | The apparatus for treating plant tissues using a pulsed electric field is intended for the extraction of plant substances from tissues, in particular a juice. It comprises a step of compacting ( 3 ) the plant tissues and at least one treatment chamber ( 4 ) comprising means for the generating a pulsed electric field in said chamber for treating the compacted tissues. | 0 |
BACKGROUND OF THE INVENTION
[0001] Blending of fluids is important in many different industries. Blending can be done either in an approximated manner or in an extremely precise manner depending upon the use of the final product. For example, blending in a precise manner is often performed when different colors of base fluids, having otherwise similar physical properties, are mixed. If the goal is to produce a final mixture having a desired color, then precise measuring of the base fluids is critical.
[0002] When precise blending is performed, the blending process is often gravimetric. A receiving container is placed upon a precise measuring scale. Base fluids from multiple sources are added individually to the container through a metering pump and valve system. Each source may have its own dedicated metering system or a single metering system being fed from multiple fluid sources may by used.
[0003] Valves used in the metering systems often operate in a pressure release manner. Such a valve includes a piston and piston rod holding a seal, wherein the seal stops flow when the valve is in a closed position. The piston and the rod are biased to the closed position by spring force. By applying pressure into the valve via compressed air or another fluid, in a space on the opposite side of the piston from the spring(s), the rod seal is lifted out of a bore, and thus, opens the valve to a certain degree, dependent on the amount of air pressure applied.
[0004] When a selected amount of fluid of a particular type is to be added in the receiving container, pressure is first applied at a high level in order to open the valve wide, and move most of the required fluid into the receiving container quickly. As the desired amount of fluid is approached, pressure is reduced so that the flow rate of added fluid is also reduced. However, even at this lower rate, it is difficult to add very small amounts of fluid. A drawback of the art, at present, is that the precision of the gravimetric scale is greater than the precision of available valve systems. An improved distribution valve is desired.
[0005] One technique that has been tried with existing valves is to repeatedly pulse the valve with air pressure, so as to open and close the valve quickly. Unfortunately, this does not produce drops reliably in common valves. What is further desired is a new method of using an improved valve which can deliver fluid repeatedly and reliably in a precise dropwise manner.
BRIEF SUMMARY OF THE INVENTION
[0006] The present invention overcomes deficiencies in the art. A valve device is provided that includes a valve body defining a chamber for receiving fluid to be dispensed from the valve device, a seal contact surface located on the valve body, near a location where fluid discharges from the chamber, one or more grooves formed in the seal contact surface, and a reciprocatable piston rod supporting a seal that slidingly contacts the seal contact surface, the piston rod being received at least partially within the chamber.
[0007] The groove(s) and seal have structural configurations that prevent the seal from fully blocking the groove when the piston rod is in a first position where the seal contacts a portion of the seal contact surface including the groove, and as a result fluid within the chamber may enter the groove when the piston rod is in this first position. The piston rod and seal can also be moved to a second position on the seal contact surface that is downstream of the groove. Fluid flow out of the chamber is fully prevented when the piston rod and seal are in the second position.
[0008] A method of dispensing fluid in variable amounts is also provided that includes the steps of providing a valve device as described above, repeatedly moving the piston from the first position to the second position, thus allowing fluid within the chamber to repeatedly enter and pass through the groove and valve device in a dropwise manner.
[0009] The method further includes the step of moving the piston rod to a third position, upstream of the groove, where the seal is spaced apart from the seal contact surface, thus allowing fluid to exit the valve in a stream.
[0010] These and other features, aspects and advantages of the present invention will be fully described by the following description, appended claims, and accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] In the following figures, some of the same or similar types of elements or corresponding parts are provided with the same reference numbers in order to prevent the item from needing to be reintroduced.
[0012] FIG. 1 is a schematic representation of a system and method for distributing fluids;
[0013] FIG. 2 is an exploded view of a first embodiment of the valve device of the present invention;
[0014] FIG. 3A is a cross sectional view of the first embodiment of the valve device with the piston rod in a first position;
[0015] FIG. 3B is a detailed view of a portion of FIG. 3A ;
[0016] FIG. 4A is a cross sectional view of the first embodiment of the valve device with the piston rod in a second position;
[0017] FIG. 4B is a detailed view of a portion of FIG. 4A ;
[0018] FIG. 5A is a cross sectional view of the first embodiment of the valve device with the piston rod in a third position;
[0019] FIG. 5B is a detailed view of a portion of FIG. 5A ;
[0020] FIG. 6 is a cross sectional view of a variation of the first embodiment of the valve device;
[0021] FIG. 7 is a cross sectional view of another variation of the first embodiment of the valve device;
[0022] FIG. 8 is an exploded view of a second embodiment of the valve device of the present invention;
[0023] FIG. 9 is a cross sectional view of the second embodiment of the valve device with a piston rod in a first position;
[0024] FIG. 10 is a cross sectional view of the second embodiment of the valve device with the piston rod in a third position; and
[0025] FIG. 11A is a cross sectional view of an insert component in the second embodiment of the invention; and
[0026] FIG. 12 is a top view and detailed portion of the insert component.
DETAILED DESCRIPTION OF THE INVENTION
[0027] An improved system and method for distributing fluids is provided. Referring to FIG. 1 , the system 10 shown schematically, in general, includes a receiving container 12 for mixed fluids, one or more improved dispensing valve devices 14 , described in more detail below, pumps 16 , containers holding base supply fluids 18 , compressed air supplies 20 and associated solenoids 22 for the valves and pumps, a scale 24 , and computer-based controls 26 that receive input from an operator and control the system 10 accordingly.
[0028] Improved distribution is facilitated by a first embodiment of the improved dispensing valve device 14 shown in FIG. 2 , and described in more detail below. The valve device 14 includes, amongst other components, a distal end cap 30 , a main body 32 , a seal contact surface 34 , a piston rod 36 supporting an O-ring seal 114 , a spring and piston system 38 , and a proximal end cap 40 . The term “downstream” is used herein and refers to moving away from the portion of the main body that holds the liquid being dispensed.
[0029] The system 10 for distributing fluids is shown in FIG. 1 . A scale 24 is situated on a stationary surface, for example, the floor in a factory. A receiving container 12 is placed on top of the scale 24 such that the weight of base fluids added to the receiving container 12 may be measured. One or more improved dispensing valve devices 14 of the present invention are situated above the receiving container 12 . In order to avoid the repeated cleaning of a commonly used valve, one valve device 14 for each base fluid is used herein. The dispensing valve devices 14 preferably are configured in a circular pattern (not shown), although any configuration of dispensing valve devices 14 is possible. Each dispensing valve device 14 includes a supply port for base fluid and preferably a return port for base fluid, as described below. Each dispensing valve device 14 also includes a supply port for pressurized air. Base fluid is supplied to each dispensing valve device 14 from a corresponding supply container 18 . For example, when colored inks are blended, a supply of base liquid ink of a particular color, for instance red, is taken from a supply container 18 by a dedicated pump 16 and pumped to a dedicated dispensing valve device 14 above the receiving container 12 . The ink can be returned to the supply container 18 from the valve device continuously in order to prevent ink from drying in and clogging transfer lines and the dispensing valve device 14 .
[0030] The source of compressed air 20 supplies the pumps 16 and also the dispensing valve devices 14 . Through a solenoid 22 , the compressed air is provided periodically, as required. The air is supplied at different pressures, as required, via a series of regulators 42 or a single, adjustable regulator.
[0031] Computer-based controls 26 manage/change the timing and pressure of air supplied to the dispensing valve devices 14 and the pumps 16 . The computer controls 26 receive input from an operator and also status information, most particularly the weight measured by the scale 24 . The computer controls 26 also receive information regarding the amount of fluids in the supply containers 18 for inventory purposes. The computer controls 26 are programmed with various color mixing recipes within their memory, and with preset routines for distributing compressed air pressure to the pumps 16 and valve devices 14 in order to complete the preparation of such a recipe. The computer controls 26 use input from an operator to specify exact formulas, fluid amounts to be dispensed, and certain operating details. This input may be done at an operator's station 44 or at a remote computer connected to the computer controls 26 .
[0032] The valve device 14 shown in FIGS. 2 , 3 A and 3 B includes a main body 32 that has an end cap 30 threadingly attached to it at a distal end. The distal end cap 30 is cylindrical with a central axial bore 50 therein. A gasket 52 is placed between the distal end cap 30 and the main body 32 to prevent leakage of fluids out of the bottom of the main body 32 . The distal end cap 30 includes an annular seat 51 to receive the gasket 52 .
[0033] The main body 32 is generally cylindrical and hollow. The main body 32 preferably includes at least three fluid ports therein with associated fittings attached to the exterior of the main body 32 at each port. A fluid supply port 54 is located approximately one quarter of the way along the length of the main body 32 , closer to the distal end. Two pipe sections 56 and 58 are provided, connected together in an L-shape with the shorter of the two pipe sections (not shown in FIG. 3A ) connected to the supply port 54 . A supply of base fluid is provided through these pipe sections and into the main body 32 through the supply port 54 . Two additional pipe sections 60 and 62 are provided, connected together in an L-shape with the shorter of the two pipe sections 60 connected to a return port 64 , located about one third of the way along the length of the main body 32 , closer to the distal end. Base fluid may be returned through these pipes back to a supply container 18 . An air fitting 66 is attached to the third port 68 , located approximately halfway along the length of the main body 32 , and compressed air is introduced into the main body 32 through this fitting 66 and port 68 to move the piston rod 36 in the main body 32 . Axially, the third port 68 is located between the supply and return ports 54 and 64 . Two threaded lateral apertures 70 are located approximately halfway along the length of the main body 32 and extend into its open center. Screws 72 are secured in these apertures 70 and hold a divider 138 , described below. Four lateral apertures 74 in combination with pins 75 are used to facilitate holding the proximal washer 166 in place.
[0034] Referring to FIGS. 5A and 5B , returning to the distal end cap 30 and the longitudinal bore 50 provided therein, beginning at the distal end and extending toward the proximal end, the bore 50 includes at least two distinct sections 92 and 94 with different diameters. The inner surface 95 of the end cap 30 , defining the first bore section 92 is a contact surface for the seal 114 supported on the piston rod 36 . The first section 92 also has the smallest diameter in the bore 50 . Two countersunk transition sections 98 and 100 are located between the first and second bore sections 92 and 94 . The first transition section 98 has a sidewall 102 with an angle with respect to a longitudinal axis of about 160 degrees. The second transition section 100 is adjacent to the second bore section 94 . The sidewall 104 of the second transition 100 is at an angle of approximately 140 degrees with respect to the longitudinal axis of the valve device 14 .
[0035] Two longitudinal grooves 106 extend from the first bore section 92 to the second bore section 94 . These grooves 106 are generally rectangular and have a sloped distal end 108 that extends from the base of the groove 106 to the wall surface of the first bore section 92 . The sloped distal end 108 is at an angle of between 140-160 degrees to the longitudinal axis of the valve device 14 . This helps prevent damage to the O-ring seal 114 on the piston rod 36 when it moves across the grooves 106 . The distal end of each groove 106 ends about midway along the length of the first bore section 92 . The depth of each groove 106 is approximately 0.03 inches and has a width of approximately 0.04 inches. The grooves 106 are narrow enough to prevent the O-ring seal 114 on the piston rod 36 from fully expanding into and blocking the groove 106 . Thus, if the size of groove 106 is modified, the flexible O-ring seal 114 size is changed accordingly or vise-versa, such that this feature persists. Preferably, the grooves 106 are linear and oriented in a direction parallel to the movement of the piston rod 36 .
[0036] Below the grooves 106 (downstream when considering the direction of fluid movement on discharge from the valve) is simply a smooth portion of a contact surface against which the O-ring seal 114 is compressed when moved by the piston rod past the grooves. When in this position, the O-ring forms a complete seal, so no fluid can pass by.
[0037] The width, depth and number of grooves 106 in the seal contact surface 95 of the end cap 30 determine how much fluid can pass through the valve device 14 when the seal 114 on the piston rod 36 is aligned with the grooves 106 . Edges of the grooves 106 that are on the seal contact surface 95 and that periodically contact the O-ring seal 114 are rounded so that the O-ring seal 114 is not damaged when it moves across the grooves 106 . The second section 94 of the longitudinal bore 50 has a greater diameter than the first section 92 , and the diameter is generally constant.
[0038] Referring to FIGS. 2 and 3A , the piston rod 36 is elongate and is more narrow at its distal end. The piston rod's distal end fits into the end cap 30 , as described in more detail below. A first piston portion 110 begins at the distal end and has a constant diameter, except for an annular groove 112 that is within the outer surface of the first piston portion 110 adjacent the distal end. The O-ring seal 114 is seated in this annular groove 112 . A second portion 118 is adjacent to and has a greater diameter than the first portion 110 and has an annular seat the supports an O-ring 143 . An axial bore 126 is placed in the proximal end of the piston rod 36 and this bore 126 is threaded.
[0039] Referring to FIGS. 2 and 3A , a spring and piston system 38 , including a divider 138 , is used to create three separate chambers 132 , 134 and 136 within the main body 32 and used to provide desired motion of the components held therein. The cylindrical divider 138 is placed midway along the length of the main body's interior. This divider 138 is held in place with screws 72 placed through apertures 70 within the side wall of the main body 32 . The divider 138 is cylindrical with an axial bore 140 extending along its entire length. The divider 138 includes a O-ring seal or cup seal 142 contacting the piston rod 36 that passes through the divider's bore 140 and two O-ring seals 144 on the exterior of the divider 138 contacting the inner wall of the main body 32 . This divider 138 segregates the main body 32 into a first lower chamber 132 for receiving the base fluid and an upper space, part of which receives compressed air.
[0040] A piston/seal 150 is located in the upper space of the main body 34 and is slidable axially therein. The piston/seal 150 includes an annular groove 152 into which a U-cup ring 154 of rubber or another slidable material fits. The ring 154 allows easy sliding movement of the piston/seal 150 in the main body 32 . The piston/seal 150 divides the upper space into the second and third chambers 134 and 136 .
[0041] A cylindrical motion stop 162 is unsecured. The piston/seal 150 uses a screw 160 that secures the piston/seal 150 to the piston rod 36 . The cylindrical motion stop 162 is located within the third chamber 136 between the piston/seal 150 and the proximal end cap 40 and positions a spring 164 therein. A washer 166 is placed between the spring 164 and the proximal end cap 40 . This spring 164 biases the piston/seal 150 downwards. The motion stop 162 stops upward motion of the piston/seal 150 when the stop 162 contacts the washer 166 .
[0042] The improved valve device of the present invention can be used in a similar manner to valves in the prior art in a system previously described in the Background section, with different amounts of air pressure applied thereto to open the valve device 14 different amounts.
[0043] Referring to FIGS. 2 , 3 A and 3 B, base fluids are circulated through the valve device 14 , entering at the supply port 54 and exiting at the return port 64 . Compressed air, or another fluid, is supplied at the air fitting 66 at the other supply port 68 of the main body 34 . Compressed air enters into the second chamber 134 and pushes the movable piston/seal 150 upwards, also lifting the piston rod 36 to allow fluid to exit the valve device 14 .
[0044] Air fitting 66 is supplied with air from a three port, two position valve, thus movement into a second position releases air pressure within the valve device 14 while in a first position compressed air can be added to the valve device 14 .
[0045] The valve device 14 is shown in FIG. 3A with the piston rod 36 in a closed position. At this time, preferably no fluid is being circulated in the lower chamber 132 of the main body 34 , and the air pressure in the second chamber 134 of the main body is low, thus the piston rod 36 is kept in a lowest position by spring force. Referring to FIGS. 5A and 5B , when it is desirable to add base fluid to the receiving container placed below the valve device 14 , air pressure is applied to the second chamber 134 of the main body 32 . The piston/seal 150 moves, against spring force, upwards along with the piston rod 36 into a higher position, thus opening a space 170 between the piston rod 36 and seal contact surface 34 . The pump for base fluid being actuated, base fluid flows through this space 170 and into the receiving container (not shown) in a stream. Typically, a pressure of approximately 90 psi is applied to open the piston rod 36 to this position. Approximately, 90%-98% of the required fluid is distributed from the valve device 14 with the piston rod 36 in this position. When approximately 98% of the desired amount of added base fluid is met, the air pressure provided is reduced, thus closing the valve device 14 via spring force of the spring 164 . The air pressure to the valve is then repeatedly pulsed causing the piston rod to move from the position shown in FIG. 3A to the intermediate position shown in FIG. 4A . Depending on the viscosity of the fluid being distributed from the valve device the pumps are either constantly actuated, or not actuated when the piston rod is in the intermediate position, as more viscous fluid requires more pressure to enter the grooves and exit the valve device. Here, fluid can only enter/flow through the grooves 106 within the end cap 30 . Preferably, each pulse of the piston rod 36 allows one drop of fluid to pass into the receiving container. Air pressure is provided at approximately 20-25 psi in order to have the piston rod 36 reach this intermediate position shown in FIGS. 4A and 4B . The height the piston rod 36 is lifted may be changed by reducing/increasing the pressure of air provided, thus requiring more/less than one pulse to allow a single drop of fluid to pass through the valve device and into the receiving container. If the pressure is increased sufficiently and the viscosity is low engough, a short stream is emitted instead of a single drop on each pulse. For even greater amounts, the pressure may be raised on each pulse such that the piston rod 36 fully exits the first bore section 92 .
[0046] During this pulsing process, on each stroke, fluid is pushed into the grooves by the pressure of the pumps (and gravity) and then out of the grooves and the valve device. In the intermediate position, the seal on the piston rod expands into the grooves only enough to block approximately 20% of the area of the grooves. Thus, the pumps and gravity can still force some fluid through the grooves. The relationship between the pump force and surface tension caused in the grooves determines how much fluid can pass therethough, as well as of course, the viscosity of the fluid being distributed. The frequency of the pulsing of the piston rod (moving between closed and intermediate postions) also determines how much fluid may exit. Typical pulse rates can be 2 pulses per second, but any pulse rate is possible. Increased pressure lifts the piston rod higher in each pulse stroke, and may be so as that the seal of the piston rod is spaced from the seal contact surface.
[0047] FIG. 6 shows an alternative version of a piston rod 80 and end cap 82 . Here, similarly sized linear grooves 84 are placed in the piston rod 80 while a seal 86 is supported on the inner surface 88 of the end cap 82 . In FIG. 7 , no seal is placed on the piston rod 90 . Close tolerance of the piston rod 90 and end cap 30 provides the required seal function.
[0048] Referring to FIGS. 8 , 9 A-B and 11 , in a second embodiment of the invention, an insert 234 fits within the main body 32 , with a distal end portion of the insert 276 pressed into an alternate distal end cap 230 . The insert 234 includes the narrow distal end portion 276 and a wider proximal end portion 278 . The distal end portion 276 is cylindrical and includes an annular groove 280 on its exterior surface. The groove 280 holds the O-ring 282 that seals against an inner surface of the distal end cap bore 250 when the insert 234 is pressed therein. Progressing along the exterior surface of the insert 234 from the distal end portion 276 to the proximal end portion 278 , the surface includes a step from the smaller diameter to the larger diameter proximal end portion 278 . On opposite sides of the proximal portion 276 , two axially extending apertures 284 with rounded ends 286 are provided. These apertures 284 extend laterally into an inner bore of the proximal end portion 278 . Three rectangular grooves 288 extend axially along almost the entire length of the exterior surface of the proximal end portion 278 and are spaced, radially, equal from each other. These grooves align the insert 234 within the main body 32 . A circular transverse aperture 290 passes through the sidewall of the proximal portion 278 near the proximal end as well and extends into a center bore. This aperture provides access for a wrench to tighten a set screw on the piston rod 236 .
[0049] Returning to the distal end portion 276 of the seat device 234 , a longitudinal bore 250 is provided therein, beginning at the distal end and extending toward the proximal end. The bore includes at least three distinct sections 292 , 294 and 296 with different diameters. The first section 292 has the smallest diameter and is adjacent the distal end of the seat device 234 . Two countersunk transition sections 298 and 300 are located between the first and second bore sections 292 and 294 . The first transition section 298 has a sidewall 302 with a smaller angle with respect to a longitudinal axis of the seat device 234 than the second transition section's sidewall 304 , the second transition section 300 being adjacent to the second bore section 294 . The sidewall of the second transition 304 is at an angle of approximately 140 degrees with respect to the longitudinal axis of the seat device 234 .
[0050] Two longitudinal grooves 306 extend from the first bore section 292 into the first transition section 298 . These grooves 306 are generally rectangular and have a sloped distal end 308 that extends from the base of the groove 306 to the wall surface of the first bore section 292 . The sloped distal end 308 is at an angle of 160 degrees to the longitudinal axis of the seat device 234 . This helps prevent damage to the O-ring on the piston when it moves across the grooves. The proximal end of each groove 308 ends at about the transition between the first and second countersunk sections 298 and 300 . The distal end of each groove 306 ends about midway along the length of the first bore section 292 . The depth of each groove 306 is approximately 0.03 inches and has a width of approximately 0.04 inches. The grooves 306 are narrow enough to prevent the O-ring 314 from fully expanding into and blocking the groove 306 . Thus, if the size of the O-ring 312 is modified, the size of the groove 306 can be changed accordingly, or vise-versa.
[0051] The depth and number of grooves 306 in the inner surface of the insert 234 determine how much fluid can enter and pass through the valve device 214 when the seal 314 on the piston rod 236 passes over the grooves 306 . Edges of the grooves 306 that are on the surface of the insert 234 that contact the O-ring seal 314 are rounded so that the O-ring seal 314 is not damaged when it moves along the grooves 306 .
[0052] The second section 294 of the longitudinal bore has a greater diameter than the first section 292 . The second section 294 is located between the first section 292 and the third section 296 . The third section 296 has a greater diameter than both the first and second sections of the longitudinal bore, and is constant. The third section 296 of the bore extends to the proximal end of the insert 234 . Three or more wings 299 are spaced equally around the outer surface of the section 278 of the insert 234 and help guide the insert within the main body 32 .
[0053] The surface of first section 292 of the longitudinal bore functions as the contact surface for the seal 314 on the piston rod 236 . Referring to FIGS. 8 and 9B , the piston rod 236 is elongate and is more narrow at its distal end. The piston rod's distal end fits into the insert 234 , as described in more detail below. A first piston portion 310 begins at the distal end and has a constant diameter. An annular groove 312 is within the outer surface of the first piston portion 310 adjacent the distal end. An O-ring 314 is seated in this annular groove 312 . A second portion 316 , which is adjacent to the first portion 312 is conical with a diameter which gets larger progressing away from the piston's distal end. A third portion 318 is adjacent to the second portion 316 and has a diameter greater than both the first and second portions 310 and 316 . The third portion 318 includes a transverse circular bore 320 passing through the full diameter of the piston. A second transverse circular bore 322 , offset 90 degrees from the first transverse bore 320 passes from the exterior surface of the piston into the first bore 320 . The second bore 322 is threaded. A cross pin 323 is inserted through the first bore 320 and extends from each end of the bore 320 . A set screw 325 holds the cross pin 323 in position. A fourth piston portion 324 is adjacent to the third piston portion 318 and extends from the third piston portion 318 to the proximal end of the piston. The fourth portion 324 has a diameter greater than the first and second portions 310 and 316 , but smaller than the third portion 318 . An axial bore 326 is placed in the proximal end of the piston and this bore is threaded.
[0054] Referring to FIGS. 8 and 9B , a spring and piston system 330 is used to create three separate chambers 332 , 334 and 336 within the main body 232 and used to provide desired motion of the components held therein. A first cylindrical divider 138 is placed midway along the length of the main body's interior. This divider 138 is the same as the divider within the first embodiment of the invention. This divider 138 segregates the main body into a first lower chamber 332 for receiving the base fluid and an upper space, part of which receives compressed air.
[0055] A piston/seal 350 is located in the upper space of the main body 234 and is slidable axially therein. The piston/seal 350 includes an annular groove 352 into which a U-cup ring 358 of rubber or another slidable material fits. The ring 358 allows easy sliding movement of the piston/seal 350 in the main body 232 . The piston/seal 350 divides the upper space into the second and third chambers 334 and 336 .
[0056] A spring 356 is located between and abuts the divider 138 and piston/seal 350 . Thus, this spring 356 biases the divider 138 and piston/seal 350 apart. The piston/seal 350 includes an axial bore. A screw 360 passes through this axial bore and secures an O-ring 354 and the piston/seal 350 to the proximal end of the piston rod 236 . Thus, when the piston/seal 350 is biased away from the divider 138 , the piston rod 236 is lifted, and moves out of a sealing position within the insert 234 .
[0057] A cylindrical motion stop 362 is also unsecured. The cylindrical motion stop 362 is located within the third chamber 336 between the piston/seal 350 and the proximal end cap 340 and positions a third spring 364 therein. This spring 364 biases the piston/seal 350 toward the divider 138 and against the spring force of the second spring 356 .
[0058] Again, air pressure is added through the air fitting 66 into chamber 334 . This moves the piston/seal 350 and piston rod 316 upwards. FIG. 9B shows the valve device 214 in a closed position. FIG. 10 shows the valve 214 device in a full open position. The piston rod 236 raises the insert 234 up as well in this highest position, the pin 323 sliding within the aperture 284 until abuts the edge then raising the insert 234 (refer to FIG. 8 ). Thus, fluid can pass out of the valve device 214 in two ways. Fluid flows past the piston rod 236 , around the seal and also around the exterior of the insert 234 and the seal 282 thereon, thus, a large amount of liquid can be discharged. The grooves 288 within the insert 234 aid in this fast flow.
[0059] The valve device has been described as using compressed air to move the piston rod, thus opening the valve. Any compressed fluid could be used alternatively. Also alternatively, a mechanical system, such as an electric motor linear actuator and associated gears/cams may be used to raise the piston rod instead of an air driven system. The return fluid port is optional, as all fluid within the valve may be dispensed instead of returning fluid to the supply container. Alternatively, any seal that does not fully fill the groove in the seal contact surface can be used instead of O-ring seals.
[0060] In one example of operation of the valve device, which is not limiting other operating speeds, a cycle of movement is from a first position where the seal is against a smooth portion of the seal contact surface to a second position where the seal is against grooves in the seal contact surface and back to first position, and at least 2 cycles are performed per second.
[0061] The valve device and method have been described for use in mixing fluid ink. Other fluids that may be mixed included different paints, or pharmaceutical ingredients.
[0062] This new valve device and method of operation allows fluid to be distributed in a very precise dropwise manner.
[0063] Although the invention has been shown and described with reference to certain preferred and alternate embodiments, the invention is not limited to these specific embodiments. Minor variations and insubstantial differences in the various combinations of materials and methods of application may occur to those of ordinary skill in the art while remaining within the scope of the invention as claimed and equivalents. | The present invention overcomes deficiencies in the art. A valve device is provided that includes a valve body defining a chamber for receiving fluid to be dispensed from the valve device, a seal contact surface located on the valve body, near a location where fluid discharges from the chamber, one or more grooves within the seal contact surface, and a reciprocatable piston rod supporting a seal that selectively contacts the seal contact surface, the piston rod being received at least partially within the chamber. The groove and seal have structural configurations that prevent the seal from fully blocking the groove when the piston rod is in a first position where the seal contacts a portion of the seal contact surface including the groove, and as a result fluid within the chamber may enter the groove when the piston rod is in this first position. A method of dispensing fluid in variable amounts is also provide that includes the steps of providing a valve device as described above, repeatedly moving the piston from the first position to the second position, thus allowing fluid within the chamber to enter the groove and then be swept out of the valve device in a dropwise manner. | 5 |
SUMMARY
Present invention relates to a light control circuit for camcorders, in particular a circuit that, when recording, automatically enables a light connected to the camcorder circuit then places the camcorder in a record mode with delay time to automatically adjust brightness of the light according to the environmental illuminance but, when in pause, puts off the light.
BRIEF DESCRIPTION OF DRAWINGS
FIG. 1 shows a conventional light control circuit for camcorders.
FIG. 2 shows a camcorder light control circuit according to the present invention.
FIG. 3 shows an application to a camcorder of the light control circuit of this invention.
FIG. 4 shows waveforms of illuminance detection circuit in FIG. 2(C) according to the present invention.
FIG. 5 shows waveforms of respective sections of the light control circuit in FIG. 2(D) by illuminances according to the invention.
Codes in the drawings indicate the following: L indicates a light, T indicating a trigger circuit, Vcc a supply voltage terminal, C1-C6 capacitors, R1-R25 resistors, Vac an alternating power source, RY1 a relay, SW1-SW4 switches, Q1-Q6 transistors, OP1-OP4 amplifiers, BD1 a bridge diode, ZD1 a zenor diode, D1 a diode, PD1-PD3 photo diodes, PC photo coupler, PTR1-PTR3 photo transistors, UJT1 unijunction transistor, CDS1 an illuminance detection element, TH1 a thyristor, and TA1 a triac.
DETAILED DESCRIPTION OF THE INVENTION
In a conventional construction, as in FIG. 1, the light insulated by a photocoupler (PC) is connected serially to AC source (Vac) on one side while on the other side connected serially to resistor (R1) and capacitor (C1) and also to thrysitor (TH1), which is parallel to resistor (R1) and capacitor (C1) and whose gate (G) connecting to resistor (R2). The thyristor circuit is connected to trigger circuit (T).
On the other hand, the side including photo diode (PD1) applies voltage (Vcc) through switch (SW1) to select automatic or manual operation. A selection of automatic makes connection of (Vcc) to the emitter of transistor (Q2) and simultaneously, through resistor (R3) to the collector of transistor (Q1). The voltage from the collector of transistor (Q2) divided by resistors (R4 and R5) applies to the base of transistor (Q1), whose emitter is connected to the anode side of photo diode (PD1).
A selection of manual operation by switch (SW1) applies voltage through switch (SW2) and resistor (R12) to the anode side of photo diode (PD1). The record signal (REC) connects via resistor (R9) to the collector of transistor (Q4) and to the base of transistor (Q3) and pause signal (PAUSE) applies voltage divided by resistors (R11 and R10) to the base of transistor (Q4) whose emitter is grounded, and in turn applies voltage divided by resistors (R6 and R7) to the base and emitter of transistor (Q2).
The operation of the above circuit shall be described as follows. Referring to FIG. 1, with switch (SW1) on manual operation and switch (SW2) being open or "off", the photo diode (PD1) does not conduct current so as not to actuate trigger circuit (T) such that thyristor (TH1) remains "off" and maintains the light (L) also "off". With switch (SW2) closed or "on", photo diode (PD1) conducts to activate the photo transistor (PTR1) for trigger circuit (T) to drive the gate (G) of thyristor (TH1), which turns "on" to apply current to the light (L) for its illumination. With switch (SW1) on automatic, light (L) operates on/off according to record signal (REC) and pause signal (PAUSE).
That is, when record signal (REC) is "high", the pause signal (PAUSE) is "low" for the transistor (Q4) to be non-conducting and for the transistor (Q3) to conduct causing transistor (Q2) to conduct and then transistor (Q1). Therefore, source (Vcc) applies current via resistor (R3) and transistor (Q1) to the diode (PD1) causing illumination of the light (L). (The operation of the light section shall be the same as in manual operation and thus omitted from description.)
Upon pressing the pause button in the recording state, the pause signal (PAUSE) is "high" which turns "on" transistor (Q4) and applies a "low" to the base of transistor (Q3) to turn it "off" which also turns off transistors (Q2 and Q1) cutting off photo diode (PD1) and thus thyristor (TH1) terminating the light (L).
As shown above, in the conventional art, the application of record signal (REC) turns on the light after the start of recording such that the recording proceeds initially from a dark state. Additionally, the light turns on irrespective of the brightness in the surroundings and thus waste power, and the fixed illumination irrespective of variation in the brightness of surroundings resulting in an overexposed condition for picture.
This invention is designed to overcome the above disadvantages. Referring to the drawings, the construction shall be described as follows.
FIG. 2 shows a light control circuit for camcorders according to this invention. The construction of the circuit is such that it comprises a record signal delay circuit (A) that operates according to the manipulation of record/pause switches (SW1 and SW2), ON/OFF control circuit (B) for light (L), illuminance detection circuit (C) and light control circuit (D) for adjustment of brightness. The record signal delay circuit (A) receives application of supply voltage (Vcc) by the activation of transistor (Q1) on actuation of switch (SW1). The collector of transistor (Q3) is connected via resistors (R4 and R5) to the "+" terminal of OP amplifier (OP1) and for the emitter of (Q3) is connected to the anode of diode (D1) and capacitor (C1), resistor (R3) connects the cathode of diode (D1) and to resistors (R4 and R5) with the collector of transistor (Q1) connecting via resistor (R2) to the "-" terminal of OP amplifier (OP1).
The operation of transistor (Q2) by manipulation of switch (SW2) applies source (Vcc) to the base of transistor (Q4) in the light ON/OFF control circuit (B) and the microcomputer. The collector of (Q4) and the "-" terminal of OP amplifier (OP1) connected via resistor (R10) which also is connected to the base of transistor (Q5), whose collector connecting to the base of transistor (Q6). The collector of (Q6) in turn connects to relay (RY1) via resistor (R13) and also to the base of transistor (Q3) in time delay circuit (A). Switch (SW3) connects (Vcc) in the automatic mode to the emitter of (Q6) and in the manual mode to the collector of the (Q6), and relay (RY1) operates in association with switch (SW4) that turns on/off the direct current rectified at bridge diode (BD1) in the light control circuit (D).
Illuminance detection circuit (C) is constructed that supply voltage (Vcc) is divided between resistor (R14) and illuminance detecting element (CDS1) to be applied to the "+" terminals of OP amplifiers (OP2-OP4), whose "-" terminals are supplied with voltages from source (Vcc) divided by respective pair of resistors (R15 and R16, R17 and R18, R19 and R20) and whose outputs are arranged to drive respective photo diodes (PD1-PD3) in light control diode (D).
The luminance-following light control circuit (D) is so constructed that light (L) and triac (TA1) connect to AC supply voltage (Vac), which is rectified by bridge diode (BD1) and regulated by zener diode (ZD1) to apply to the base (B2) of unijunction photo transistors (PTR1-PTR3) in parallel connection respectively connecting to resistors (R21-R23) and between whose emitter (E) and base (B1) are connected a resistor and a capacitor (C2). The operation of the circuit shall be described in reference to the drawings.
Referring to the circuit in FIG. 2, with record switch (SW1) at "on" and switch (SW3) at automatic mode, record signal is applied via record signal delay circuit (A) to the microcomputer and also directly to the ON/OFF control switch (SW4) to control light (L), while illuminance detection circuit (C) detects illuminance to connect through photo couplers (PC1-PC3) to light control circuit (D) to control the light according to the surrounding illuminance.
That is, with "on" of (SW1), supply voltage (Vcc) applies via transistor (Q1) and resistors (R2 and R10) to the base of transistor (Q5) to turn "on" transistors (Q5 and Q6) and drive relay (RY1). Consequently, the relay (RY1) closes switch (SW4) for operating light control circuit (D) to turn on light (L) under control of the illuminance, and transistors (Q1, Q5, Q6, Q3) conduct such that supply voltage (Vcc) charges capacitor (C1) with time constant (τ=R4×C1) via resistor (R4) and transistor (Q3). However, when capacitor (C1) is charged above a predetermined voltage which is higher than the voltage divided by resistors (R2 and R9) and applied to the "-" terminal of OP-amp (OP1), the OP-amp (OP1) gives "high" signal output. This time-delayed record signal is applied to microcomputer to turn "on" the recorder. operation.
Meanwhile, the switching-on of pause switch (SW2) causes (Q2) to conduct and apply voltage (Vcc) to the microcomputer and to the base of (Q4) to interrupt the recording operation of the camcorder and cause (Q4) to conduct, so that transistors (Q5, Q6) are turned "off" turning (RY1) "off" and thus turning (SW4) "off" to put out the light (L).
When (SW3) is on automatic, (SW4) comes under control of switches (SW1, SW2), but when (SW3) is on manual operation, voltage (Vcc) is applied through the manual operator terminal and the collector of (Q6) and (R13) to (RY1) for its operation to maintain the "on" state of light (L1). However, when the switch (SW3) is on neutral terminal (NC), relay (RY1) stops its operation.
Once switch (SW4) is turned "on", the light control circuit (D) comes into operation to control the brightness of light. Thus, voltage (Vcc) divided by resistor (R14) and illuminance detection element (CDS1) varies according to the nature of the detector (CDS1) whose resistance decreases as illuminance becomes higher. Also, voltages (V1-V3) respectively divided by resistors (R15, R16), (R17, R18) and (R19, R20) apply to the respective "-" terminals of three OP-amps (OP2-OP4), the voltages being in the order of V1<V2<V3.
FIG. 3 illustrates the interrelationship of the present invention with the remaining portion of a camcorder.
FIG. 4 (A) shows a curve indicating the characteristics of illuminance detector (CDS1). When the detector (CDS1) moves from a dark place (B) toward a brighter place (W), the resistance of (CDS1) decreases as shown in FIG. 4(A) so that the voltage applied to (CDS1) reduces to make "high" the output of OP-amps (OP2-OP4) so as to turn "off" photo diodes (PD1-PD3) previously being "on" in reverse order from (PD3) as in FIG. 4(B) and to increase in order the parallel resistences between the base (B2) and the emitter (E) of unijunction transistor (UJT1).
Accordingly, as the parallel resistances grow, the trigger pulses in FIG. 5(d) become delayed to reduce "on-time" of triac (TA1) such that the amount of power applied to load gradually decreases.
FIG. 5 shows waveforms at respective parts of light control circuit (D) employing a triac (TA1). Alternating current source (Vac) is rectified by bridge diode (BD1) to form a waveform as in FIG. 5(b) and is regulated by zener diode (ZD1) to form a waveform as in (c) of FIG. 5.
The voltage in (c), that is the resultant value of parallel resistances by resistors (R21-R23) increases to make time constant (time constant (τ=R×C2) also increase so that the triggered point is also delayed to reduce the "on-time" of (TA1) and thus reduce the brightness of the light. On the contrary, if the surrounding illuminance gets darker, the light increases brightness.
Consequently, the light control circuit for camcorder of this invention automatically turns on and off according to the record and pause signals of the camcorder to thus eliminate the inconvenience of the conventional art for manually manipulating the light for its "on and off". Also, the system of the invention is that the record signal first turns on the light before proceeding to the record mode in the camcorder so as to prevent brightness applying to the recording scene and to automatically adjust the brightness of the light according to the surrounding illuminance. As described above, this invention presents an effect of photographing clean scenes irrespective of the surrounding illumination, always with no inconvenience at all. | A light control circuit for a video camcorder, where said video camcorder includes an illumination light. The light control circuit includes a pause switch for enabling the light control circuit. A light on/off control is responsive to the pause switch and controls a light control relay. A record signal delay is responsive to the on/off control and applied a record signal to a microcomputer a predetermined elapsed time after operation of the light on/off control. An illuminance detector is responsive to illuminance surrounding the video camcorder and generates a comparison output signal indicative of the surrounding illuminance. A light control is responsive to the light control relay and controls the illumination light associated with said camcorder. | 8 |
BACKGROUND OF THE INVENTION
(1) Field of the Invention
In modern aircraft, cruising elevations of 35,000 ft. or greater are not uncommon. While the atmospheric pressure outside the aircraft becomes very low at such altitude, it is required that the pressure inside the aircraft cabin remain as near sea level pressure as possible to provide adequate oxygen for the passengers. However, if cabin pressure is not permitted to decrease, the pressure difference between inside cabin pressure and outside ambient pressure can become sufficiently great at high altitude to cause a catastrophic rupturing of the aircraft. Accordingly, it has been standard practice to permit cabin pressure to decrease to a value corresponding to an altitude of about 8,000 ft. Thus, structural integrity of the aircraft can be maintained while providing adequate oxygen for passenger breathing.
This variation in cabin pressure must be accomplished without sacrificing passenger comfort. Since the human ear is more sensitive to increases in pressure (descent in elevation) than to decreases in pressure (ascent in elevation), the passenger comfort factor is complicated by the need for different permissible maximum change rates, for use in each phase of operation. Furthermore, for maximum passenger comfort the cabin pressure should not be subject to pressure spikes or changes when the aircraft momentarily climbs or drops in altitude.
(2) Prior art
The importance of cabin pressure control when viewed in light of passenger comfort and safety has imposed a great burden on the flight crew work load. This burden is ever increasing while the present tendency is to reduce the size of the flight crew. For these reasons, methods of automatic cabin pressure control have been developed which require minimum work by the flight crew. However, these prior art automatic cabin pressure control systems are known to have significant deficiencies. Although flight crew work load is greatly reduced, the attention of one member of the flight crew periodically must be focused on the cabin altimeter to clock the rate of cabin pressure change or to compare it with the aircraft altimeter to be assured that the single automatic cabin pressure controller is functioning properly. Also, automatic controllers in general will compute a rate of cabin pressure change which is a function of the differential between existing cabin pressure and its final value or the existing aircraft altitude and its final value. Previously chosen references upon which the rate of cabin pressure was based resulted in a rate of change which was subject to instantaeous rapid changes when the aircraft altitude would change rapidly due to air pockets or foul weather. Examples of this prior type of automatic cabin pressure controller are found in U.S. Pat. No. 3,473,460 to F. R. Emmons and U.S. Pat. No. 3,461,790 to R. C. Kinsell.
SUMMARY OF THE INVENTION
The present invention obviates these and other deficiencies of prior art control systems. The continual or intermittent observation of the cabin altimeter is eliminated by the use of dual automatic controllers. One controller is designated "primary" and performs the cabin pressure control functions while the other controller is designated "standby" and monitors the performance of the primary controller. The controllers are continually and automatically monitored to detect whether both controllers are either simultaneously on or simultaneously off and a system is incorporated to prevent such a situation. The standby controller monitors the actual rate of change of cabin pressure and compares it with a preselected rate of change limit. If the actual rate of change of cabin pressure substantially exceeds the preselected rate of change limit, a switch-over signal is initiated and the standby controller shuts off the primary controller and takes command of the cabin pressure control. This switch-over, however, is blocked if the excess rate of change is caused by insufficient air inflow rather than a controller defect. Automatic transfer of control from primary to standby is also blocked when the excess rate of cabin pressure change is due to the pilot causing the aircraft to climb at a rate greater than that upon which the preselected cabin pressure change rate was based. Simultaneously, the preselected rate of change is incremented by a predetermined amount to permit a more rapid climb in cabin altitude and thereby maintain a safe differential pressure between outside ambient pressure and inside cabin pressure.
The primary and standby controllers are completely identical and therefore interchangeable and they actually alternate roles on successive flights so that the cabin pressure control capability of each unit can be regularly verified. Each controller has a light which when on, indicates to the controller that it is the primary for that flight. If control should be switched from primary to standby due to a detected malfunction of the primary controller, or its associated selector or drive motor, the automatic successive flight switching function will be blocked so that the light on the primary controller for the last flight remains illuminated. This enables the maintenance crew to readily determine which of the identical controllers or associated components requires repair.
The present invention obviates the second enumerated prior art deficiency by controlling the cabin pressure as a function of sensed atmospheric pressure only. The cabin pressure approximately follows the curve ##EQU1## where P c is the cabin absolute pressure, P a is the ambient atmosphere absolute pressure and a and b are constants. This relation is independent of aircraft cruising altitude. By proper selection of the constants a and b, an essentially linear function is produced. This function permits P c to track P a , reaching their permitted minimum values together, but still prevents P c from being extremely sensitive to minor rapid changes in P a .
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a block diagram of a dual automatic cabin pressure control system of this invention;
FIG. 2 is a block diagram of one of the dual automatic controllers of FIG. 1;
FIG. 3 is a block diagram of ΔP limit logic for use in the controller of FIG. 2;
FIG. 4 is a graph of rate increment vs. differential pressure for a maximum ΔP amplifier of FIG. 3;
FIG. 5 is a schematic diagram of a cabin altitude function generator for the controller of FIG. 2;
FIG. 6 is a series of graphs labeled 6A-6C showing voltage/time relationships for the cabin altitude function generator of FIG. 5;
FIG. 7A is a graph of cabin pressure vs. ambient pressure for the controller of FIG. 2;
FIG. 7B is a graph of cabin pressure vs. ambient pressure for a prior art controller;
FIG. 8 is a block diagram of automatic transfer circuit of FIG. 1;
FIG. 9 is a logic diagram of a malfunction detection logic of FIG. 8;
FIG. 10 is a logic diagram of a successive flight transfer of FIG. 8;
FIG. 11 is a logic diagram of an on-off control interconnect showing the interconnect logic for the system of FIG. 8; and
FIG. 12 is a plan view of a cabin pressure selector panel suitable for the system of the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1 illustrates a dual automatic cabin pressure control system embodying the present invention. A selector panel 10 (see also FIG. 12) is manually controlled to produce output voltages corresponding to the landing altitude, set by a selector knob 4, landing field barometric pressure correction, set by a selector knob 5 and a selected limit of the rate of cabin pressure change, set by a selector knob 6. These voltages are transmitted through conductors 12 and 14 to identical automatic cabin pressure controllers 16 and 17, respectively.
The cabin pressure selector 10 may include dual sets of selector potentiometers driven by the selector knobs 4, 5, and 6, one for cabin pressure controller 16 and one for cabin pressure controller 17. These dual sets of potentiometers would preferably be ganged together so that the command voltages for both controllers are the same. Controllers 16 and 17 are connected through conductors 18 and 19, respectively, to an actuator 20 which controls opening and closing of an outflow valve (not shown).
Each of the controllers 16 and 17 preferably operates a separate outflow valve motor in the actuator 20 with only the mechanical valve linkage and reduction gears in common. Each controller has its own power supply, sensor units, electronic logic and control circuits (illustrated in FIG. 2) so that they operate completely independent of each other, minimizing the possibility that both controllers could be disabled at the same time.
Controller 16 receives an input voltage proportional to ambient atmospheric pressure from an atmosphere pressure sensor 21 through conductor 22 and an input voltage proportional to cabin pressure from a cabin pressure sensor 23 through conductor 24. Controller 17 receives corresponding input voltages from an atmosphere pressure sensor 26 through conductor 28 and from cabin pressure sensor 29 through conductor 30. Pressure sensors 21, 23, 26 and 29 may be any suitable pressure transducers which produce a detectable change in output responsive to changes in pressure. An automatic transfer circuit 32 receives inputs from automatic cabin pressure controller 17 through conductor 33, from automatic transfer circuit 34 through conductor 36 and from selector panel 10 through conductor 37. Automatic transfer circuit 32 is also connected to automatic cabin pressure controller 16 through operation of a relay (illustrated schematically as conductor 38), to actuator 20 through conductor 39 and to automatic transfer circuit 34 through conductor 40. Automatic transfer circuit 34 receives an input from actuator 20 through conductor 41, from automatic cabin pressure controller 16 through conductor 42, and from selector panel 10 through conductor 43 and sends an input to automatic cabin pressure controller 17 through operation of a relay (illustrated schematically as conductor 44).
Each automatic transfer circuit is associated with and controls one of the automatic cabin pressure controllers. Automatic transfer circuit 32 is associated with automatic cabin pressure controller 16 and automatic transfer circuit 34 is associated with automatic cabin pressure controller 17. Automatic cabin pressure controllers 16 and 17 and automatic transfer circuits 32 and 34 also receive inputs from a landing gear switch 46 through conductors 48, 50, 52 and 54, respectively, and from a throttle switch 56 through conductors 58, 60, 62 and 64, respectively, the purposes for which will be subsequently described in detail.
During each flight, on an alternating basis, one controller functions as the primary controller and the other serves as the standby controller. The primary controller is in actual control of the cabin pressure throughout the flight. In the course of the flight, the standby controller monitors the performance of the primary controller. If the primary controller should malfunction, the standby controller will take over control of cabin pressure. If no malfunction occurs, identity of the primary controller is transferred upon landing for the next flight. This automatic transfer of the primary mode between controllers on successive flights enables each controller of the dual automatic control system to automatically check the other on a regular basis to provide maximum reliability for the entire system. Each of the cabin pressure controllers utilizes the input voltages from its corresponding atmosphere pressure sensors to compute a desired corresponding cabin pressure. This is compared to the voltage corresponding to cabin pressure from the cabin pressure sensor to generate an error signal utilized by the primary controller to control the position of the actuator 20.
Referring now to FIG. 2, the automatic cabin pressure controller 16 and associated components are illustrated in detail, it being understood that controller 17 (FIG. 1) has an identical set of components similarly connected.
The conductor 12 connecting the selector panel 10 to the controller 16 comprises a conductor 12a which connects the potentionmeter of the "rate limit" selector 6 of the selector panel (FIG. 12) to a rate logic circuit 66 of the controller. A conductor 12b connects selectors 4 and 5 for landing field altitude and barometric pressure of the selector panel 10 to a high altitude discriminator circuit 68. A conductor 12c connects the selector panel 10 to a power supply 70 in the controller 16 which provides operating voltage for the selector panel 10. The power supply 70 is also connected by a conductor 42a to a power loss detector circuit which will be subsequently described in connection with FIG. 9.
The rate logic circuit 66 receives additional input from a cabin altitude function generator 72 through a conductor 74, from a descent detector circuit 76 through a conductor 78, and from the cabin pressure sensor 23 through a conductor 24a. The cabin pressure sensor 23 also provides its voltage signal through a conductor 24b to a ΔP limit logic circuit 80. This signal is also conveyed by a conductor 24c to a rate amplifier 90 and by a conductor 42b to a malfunction detection logic circuit which will be described in connection with FIG. 9, and to dynamic compensator 100 by conductor 24d.
Connection of the atmosphere pressure sensor 21 to the controller 16 is by a conductor 22a to the cabin altitude function generator 72, via a conductor 22b to the descent detector 76, and by a conductor 22c to the ΔP limit logic circuit 80. The cabin altitude function generator 72 is also connected by a conductor 84 to the descent detector 76 and by a conductor 86 to the high altitude discriminator 68 which is in turn connected by a conductor 88 to the rate amplifier circuit 90. The ΔP limit logic circuit 80 is also connected to the rate logic circuit 66 by a conductor 92 and connected by a conductor 42c to the malfunction detection logic circuit of FIG. 9.
A ground logic circuit 94 in the controller 16 receives a DC input signal from a source of direct current voltage 96 by parallel paths through the landing gear switch 46 via conductor 48 and through the throttle switch 56 via conductor 58. Output from the ground logic circuit 94 is provided to the descent detector circuit 76 through conductor 98 then to a dynamic compensator circuit 100 through a conductor 102, and to driver 110 through conductor 103.
The output produced by the rate logic circuit 66 is transmitted through conductor 104 to the rate amplifier 90 which produces a corresponding output which is transmitted to the dynamic compensator 100 via conductor 106. The resulting controller output is transmitted from the dynamic compensator 100 through the conductor 108 to a driver circuit 110 of the actuator 20. The driver circuit 110 is connected in a feedback loop comprising conductor 112, contact 114c of switch 114 (see FIG. 8), motor 116, conductor 118, tachometer 120, and conductor 122 for controlling operation of the motor 116. Operation of the motor 116 controls operation of the outflow valve (not shown) to which it is coupled through a gearbox 126 and magnetic clutch 128. The clutch 128 is selectively controlled between its engaged and disengaged positions by a direct current voltage which is supplied from the DC source 96 through a manual/automatic selector switch 130 and conductor 132 to the actuating winding 134 of the clutch.
The position of contact 114c determines whether the controller is in actual control of the cabin pressure rate of change. The entire controller is functioning whether it is operating in the primary or standby mode. The difference is that when the controller is primary and no malfunction has been detected, it will be in control of the cabin pressure change rate due to its contact 114c being closed. The standby controller will be functioning but not controlling the cabin pressure because its corresponding switch is open. When a malfunction is detected or the standby controller is selected manually, the controller will control the cabin pressure even though it is operating in the standby mode.
In operation, the automatic cabin pressure controller 16 utilizes manually selected inputs from the selector panel 10 and inputs corresponding to ambient atmospheric pressure and cabin pressure from the sensors 21 and 23, respectively, to produce an output voltage for controlling position of the outflow valve (not shown).
The cabin altitude function generator 72, which will be subsequently described in detail in connection with FIG. 5, receives an input voltage from the atmospheric pressure sensor 21 through conductor 22a which is proportional to ambient atmospheric pressure outside the airplane and utilizes this voltage to compute an output voltage corresponding to a calculated value of cabin pressure. The functional relationship established by the cabin altitude function generator 72 automatically provides a corresponding cabin altitude for every possible aircraft altitude so that no manual selection of cruise altitude by the crew is necessary to effect a proper rate of cabin pressure change, it being understood that the maximum permissible cabin altitude (generally 8,000 ft.) is established at the maximum design altitude for the airplane. This output voltage is altered during descent by a positive DC voltage from descent detector 76.
The descent detector 76 receives the ambient pressure responsive voltage from the atmosphere pressure sensor 21 through conductor 22b and utilizes this voltage to determine when the airplane has begun its final descent in preparation for landing. In the preferred embodiment, this is determined to be when the airplane has descended at a rate of at least 1,000 ft. per minute for a period of one minute. When such has been determined, the descent detector 76 transmits an output voltage to the rate logic 66 through conductor 78, which causes the output to be at full value. This output will be maintained at this level regardless of subsequent changes in the airplane's mode of flight until the airplane has landed, whereupon the ground logic circuit 94 will transmit a resetting signal through conductor 98 to the descent detector 76 in response to closing of the landing gear switch 46.
The positive output voltage of cabin altitude function generator 72 is transmitted through conductor 74 to the rate logic 66 wherein it is added to a negative input voltage proportional to actual cabin pressure, which voltage is received from cabin pressure sensor 23 through conductor 24a. The result of this addition indicates whether the aircraft is ascending or whether it is in the dwell function. If the difference between the actual cabin pressure and the commanded cabin pressure is great, the aircraft is ascending; if the difference is small the aircraft is in the dwell function. Accordingly, if the output of the cabin altitude function generator 72 is sufficiently greater than the output of the cabin pressure sensor 23 so as to indicate that the airplane is in a scheduled climb, the rate logic will produce an output through the conductor 104 which is at a first predetermined level, preferably 100% of the input voltage from conductor 12a. If less than this predetermined difference exists, the rate limit will be scaled to lesser value, preferably about 50% of the rate limit input. The rate logic 66 is able to determine whether or not the aircraft is descending through a signal from descent detector 76 through conductor 78 which is true when the aircraft is descending and false otherwise.
From the selector panel 10, the rate logic 66 receives an input voltage through conductor 12a which corresponds to a manually selected limit of rate of cabin pressure change or "rate limit". In the preferred embodiment rate logic 66 has two possible outputs, either 100% of the input it receives from selector panel 10 or 50% of the input it receives from selector panel 10. If on the basis of the information that it receives from the sum of the actual cabin pressure and the commanded cabin pressure or from descent detector it determines that the aircraft is either ascending or descending it will pass 100% of the input value of rate limit. If rate logic 66 determines that the aircraft is in the dwell function, it will only pass 50% of the rate limit input from selector panel 10.
The output of rate logic 66 is passed to rate amplifier 90 through conductor 104 to determine at what level rate amplifier 90 will saturate. At a summing node of rate amplifier 90 the output of high altitude discriminator 68 through conductor 88 and the output of cabin pressure sensor 23 through conductor 24c are combined to supply the amplification input.
The selector panel 10 provides an output voltage through conductor 12b to the high altitude discriminator 68 which corresponds to the preselected landing field altitude, corrected for barometric pressure. Also fed to the high altitude discriminator is the output of the cabin altitude function generator 72 which is proportional to the calculated cabin altitude, i.e. the altitude to which the controller 16 should cause the aircraft cabin to reach. The high altitude discriminator 68 blocks the voltage signal corresponding to the lower of these altitudes and transmits the signal corresponding to the higher altitude to the rate amplifier 90 through conductor 88. The rate amplifier 90 compares this to the signal corresponding to actual cabin pressure received from the cabin pressure sensor 23 through conductor 24c. If comparison of these signals indicates that actual cabin pressure corresponds to an altitude lower than that transmitted by the high altitude discriminator 68, the rate amplifier 90 will not be permitted to produce a command signal calling for descent in cabin altitude.
This feature of the rate amplifier 90 is designed to operate during descent of the aircraft to a landing field having an altitude significantly greater than sea level, such as the airport at Denver or Mexico City. During descent, actual cabin pressure will be lower than the pressure indicated by the cabin altitude function generator 72, indicating that the cabin is at a higher altitude than that required. As aircraft altitude decreases, cabin altitude will decrease correspondingly. Because the maximum cabin altitude is only about 8,000 ft, it will reach the level of the landing field much before the aircraft reaches that altitude. If descent of the cabin were permitted to continue, it would then be necessary to provide an extended period of depressurization of the aircraft after it had landed. Accordingly, after the desired cabin altitude as indicated by the output of the cabin altitude function generator 72 has reached an altitude equivalent to that selected for the landing field, the high altitude discriminator 68 will prevent further descent of the cabin supplying the landing field altitude as the command altitude. When actual cabin pressure has reached a barometrically corrected value for this altitude, descent of the aircraft cabin terminates.
An additional input to the rate logic 66 is provided by ΔP limit logic circuit 80. The circuit receives inputs from the pressure sensors 21 and 23 corresponding to atmospheric pressure and cabin pressure and determines therefrom the pressure differential between inside cabin and outside ambient pressures in a manner which will be described in detail in connection with FIG. 3. If this pressure differential is greater than a predetermined value so as to potentially endanger the structural integrity of the plane, an output is produced by the ΔP limit logic circuit 80 to the rate logic 66 through conductor 92 which increments the output signal of the rate limiter by an amount proportional to the excess pressure differential between atmosphere and cabin pressure. This causes the output of the rate logic to be modified so as to change the saturation level of rate amplifier 90, regardless of the relationship of the commanded altitude to the actual altitude.
The input to rate amplifier 90 from high altitude discriminator 68 through conductor 88 is always positive. High altitude discriminator 68 receives two inputs, one from the selector panel 10 which is the landing field altitude with barometric correction and one from the cabin altitude function generator 72 through conductor 86. Both of these inputs are positive and the discriminator 68 will compare the two to determine which is the higher altitude or lowest pressure. The lowest pressure is the signal that is passed to rate amplifier 90. Cabin pressure sensor 23 always has a negative output thus a negative voltage is passed to rate amplifier 90 through conductor 24c. The summation of the positive high altitude discriminator output and the cabin pressure sensor output determines whether the aircraft is ascending or descending. If the aircraft is ascending, the output voltage of high altitude discriminator 68 which will be the commanded cabin pressure will always be lower than the actual pressure from cabin pressure sensor 23. Therefore, for the ascending function, the input to rate amplifier 90 will be negative voltage. When the aircraft is descending, the commanded cabin pressure from high altitude discriminator will be greater than the actual cabin pressure from cabin pressure sensor 23. Thus, the input voltage to rate amplifier 90 will be positive.
Whether the input voltage is positive or negative determines the ultimate saturation point for rate amplifier 90. In the preferred embodiment the saturation point for negative inputs corresponds to the input from rate logic 66, whereas for positive inputs the saturation point corresponds to 3/7th of the input from rate logic 66. The output of rate amplifier 90 is the rate command which is input to dynamic compensator 100 through conductor 106 where it is combined with the first derivative of the output of cabin pressure sensor 23.
The output of rate amplifier 90 has the reverse sign of the input. Thus, when the aircraft is ascending and the input is negative, the output signal to open the valves (which is the output of the rate amplifier 90) will be positive. When the plane is descending so that an output signal which will tend to close the valves for pressurizing the aircraft cabin is required, the output of rate amplifier 90 will be negative.
The first derivative of the cabin pressure, which is calculated by the dynamic compensator 100, will be negative when the plane is ascending since this will be a decrease in cabin pressure and it will be positive when the plane is descending since this is an increase in cabin pressure. Also input into the summing node of dynamic compensator 100 is the output of ground logic 94 through conductor 102. The output of ground logic 94 which becomes the input to dynamic compensator 100 is one of three states, it is either a positive DC, a negative DC or zero. When the aircraft is required to be prepressurized for takeoff, the voltage input to dynamic compensator 100 is positive DC to override the summation of the first derivative of cabin pressure and the output of rate amplifier 90. When the aircraft has landed and it is required that the aircraft be depressurized, the output of the ground logic 94 to compensator 100 is a negative voltage which again will override the summation of the first derivative of cabin pressure and the output of rate amplifier 90. While the aircraft is in flight the output of ground logic 94 is zero so that the summation of derivative of cabin pressure and the output of rate amplifier 90 are the determining factors for opening or closing the actuator valve. If the aircraft is ascending the output of rate amplifier 90 will be positive and the first derivative of the cabin pressure will be negative. The rate command from rate amplifier 90 is modified by the value of the first derivative to lessen it so that the rate command does not tell the valve to open as fas as if it were unmodified. If the aircraft is descending the output of rate amplifier 90 will be negative and the first derivative of cabin pressure will be positive and again the summation is merely the modification of the rate command from rate amplifier 90.
Dynamic compensator 100 takes the summation of the first derivative of cabin pressure and the rate command of rate amplifier 90, whether modified by inputs from ground logic 94 or not, and passes this signal to driver 110 through conductor 108.
Thus a cabin rate change command is transmitted from the rate amplifier 90 through conductor 106 to the dynamic compensator 100 which conditions the signal to be suitable for transmission to the driver 110. In addition, a signal is transmitted to the dynamic compensator 100 from the ground logic circuit 94 when the landing gear switch is closed indicating that the aircraft has landed to command that the outflow valve (not shown) be fully opened.
The rate command passed to the driver 110 causes this circuit to apply a voltage to the motor 116, assuming contact 114c is closed, suitable to operate the motor in a desired direction and rate of speed. Contact 114c is closed when the automatic cabin pressure controller is in control of the cabin pressure or "on". When the switch is open, the controller is deemed to be "off". Operation of the motor causes the tachometer 120 to produce a feedback signal permitting proper control of the motor by the driver.
The electromagnetic clutch 128 is engaged whenever the manual/automatic selector switch 130 is in the automatic position. When the this switch is set at manual, actuating winding 134 is de-energized so that the clutch 128 disengages and the valve is no longer controlled by the motor 116. This permits the aircraft crew to manually control the outflow valve by conventional means (not shown).
FIG. 3 is a block diagram of ΔP limit logic 80 of FIG. 2. Summing node 136 receives a constant voltage input proportional to the maximum allowable differential between ambient atmosphere pressure and cabin pressure through conductor 138. A voltage proportional to the cabin pressure is received from cabin pressure sensor 23 through conductor 24b, and a voltage proportional to ambient atmospheric pressure is transmitted from atmosphere pressure sensor 21 to summing node 136 through conductor 22c. The output of summing node 136 is applied to a maximum ΔP amplifier 140 through conductor 142. The output of maximum ΔP amplifier 140 goes through a conductor 144 and bifurcates to conductor 92 which provides the input into rate logic 66 and to conductor 146 which provides input into an inhibit generator 148. Inhibit generator 148 then sends a signal to the automatic transfer circuit through conductor 42c which acts as a ΔP inhibit signal.
The inputs to summing node 136 from maximum ΔP reference through conductor 138 and the atmosphere pressure from the atmosphere pressure sensor 21 through conductor 22c are both negative. The input of the cabin pressure from cabin pressure sensor 23 through conductor 24b is positive.
ΔP limit logic 80 compares these two signals and if the cabin to atmosphere differential exceeds a preselected value for any reason, ΔP limit logic will increase the preselected rate limit to compensate for the increased climb rate of the aircraft.
In operation, the atmospheric pressure and cabin pressure are constantly monitored by the application to summing node 136 of voltage signals which are proportional to pressure. By subtracting the cabin pressure voltage from the atmospheric pressure voltage, it obtains a voltage proportional to the differential pressure. To this differential pressure is added a voltage proportional to the allowable ΔP so that only when the differential pressure exceeds this value will the limit logic supply an increment. The excess differential pressure is than amplified to produce an incremental increase in cabin pressure change rate. This is applied to the rate logic 66 to increment the rate as previously described.
While ΔP limit logic 80 is overriding the selected rate limit, it also prevents automatic transfer to the standby controller by issuing a "true" logic signal to the automatic transfer logic of the other controller by conductor 42c, the effect of which will be later explained.
It will be noted that in the preferred embodiment maximum ΔP amplifier 140 is reverse biased when a negative voltage is applied to the input through conductor 142. Since the ambient atmosphere pressure P a will always be less than or equal to cabin pressure P c , a positive voltage will appear at conductor 142 and forward bias the amplifier. However, an output at conductor 144 from maximum ΔP amplifier 140 is not desired until the differential between the cabin pressure and the atmosphere pressure exceeds a predetermined level. By the introduction of a negative maximum ΔP voltage through conductor 138 into summing node 136, a positive voltage will not appear at conductor 142 until P c exceeds the summation of the negative maximum ΔP reference voltage and the atmosphere pressure voltage.
The result can be seen on FIG. 4. The output remains at zero until the input reaches the value designated as A, at which point, P c is greater than maximum ΔP reference plus P a and a positive voltage appears at conductor 142 and forward biases maximum ΔP amplifier 140. Maximum ΔP amplifier 140 is preferably a linear amplifier and produces an output through conductor 144 that increases linearly until it reaches a value designated as C. The output of the amplifier 140 is applied to inhibit generator 148 which informs the automatic transfer circuit that the detected difference from scheduled cabin pressure is not due to controller malfunction. This inhibits tranfer. The signal is also applied to the rate logic 66 of controller 16 which increments the rate signal by an amount proportional to the output of the maximum ΔP amplifier 140.
If the input, for example, is a voltage equal to that shown as D on the graph, the output will correspond to the value noted as E. The output of rate logic 66 will be incremented by the voltae represented by E. C on the output axis is the value where maximum ΔP amplifier 140 saturates and the output corresponds to an input of B from summing node 136. As the sum of the cabin pressure voltage, the atmospheric pressure voltage and the maximum ΔP reference voltage exceeds value B, amplification will no longer take place.
In the preferred embodiment, C on the graph would correspond to a voltage proportional to a rate increment of 800 ft. per minute. Therefore the rate, although incremented above the selected rate limit, will never exceed the selected rate limit plus 800 feet per minute.
It should be noted that the preferred embodiment ΔP limit logic 80 is used in conjunction with a dual automatic cabin pressure controller. However, the ΔP limit logic 80 can be used with a single automatic controller system wherein the maximum ΔP amplifier 140 will only increment the rate of the automatic controller and not pass a signal to inhibit generator or in the alternative will pass a signal to an inhibit generator which will prevent an error occurring on annunciator panel which may be used in conjunction with the single automatic controller system.
Referring now to FIG. 5, cabin altitude function generator 72 consists primarily of three amplifiers U1, U2 and U3 and two sets of common emitter connected transistors, transistor Q1 connected with transistor Q2 and transistor Q3 connected with transistor Q4.
The input for a positive output at amplifier U1 is voltage V 6 which is the sum of V 2 through resistor R1 and the voltage feedback from the output of amplifier U1 through resistor R2. The input for a negative output of amplifier U1 is voltage V 7 which is the voltage produced by the feedback loop consisting of a common emitter connected transistors Q1 and Q2.
The output of amplifier U1 is voltage V 4 . This voltage is applied through resistor R5 to the bases of transistors Q3 and Q4 and through resistor R3 to the bases of transistors Q1 and Q2. The emitters of transistors Q1 and Q2 are connected and through resistor R4 to feed amplifier U1 and capacitor C1. Capacitor C1 is connected to ground. The collector connection of transistor Q1 is at voltage V 3 and the collector connection of transistor Q2 is ground. Voltage V 3 is composed of the output voltage of amplifier U3 and the voltage which comes from resistor network R9, R10, R11, and R13. This resistive network receives only positive voltages from conductor 22c since negative voltages are blocked by diode D1. Resistive network R9, R10, R11 and R13 receives a negative input voltage at conductor 42a 2 which is the inverse of positive voltage V 2 at conductor 42a 1 . The voltage which determines a negative output at amplifier U3 is composed of voltage minus V 1 through conductor 22a 2 which passes through resistor R12 and the output voltage of resistive network R9, R10, R11 and R13. The voltage which determines a positive output from amplifier U3 is determined by a ground connection.
Voltage V 4 also feeds common emitter connected transistors Q3 and Q4 through resistor R5 which bifurcates and feeds the bases of Q3 and Q4. The collector of Q4 is connected to ground and the collector of Q3 is connected to conductor 22a 1 which supplies voltage V 1 which is a voltage proportional to the atmospheric pressure from the atmosphere pressure sensor 21. The emitters of transistors Q3 and Q4 are connected together and supply voltage V 8 which passes through resistor R6 and over capacitor C2 to supply the input that determines the positive voltage output from amplifier U2. The voltage that determines a negative output from the amplifier U2 is determined by the feedback loop from the output of U2 through resistor R7 to the negative determining terminal of U2 and from resistor R8 which is connected to ground. The output of amplifier U2 is V 0 .
V 0 is the output at conductor 74 to rate logic 66 and to high altitude discriminator 68 through conductor 86. V 1 is the input that comes in through conductor 22a 1 from atmosphere pressure sensor 21. V 1 is a voltage proportional to the ambient atmospheric pressure. V 2 is a constant positive DC voltage used as a biasing voltage which comes from the power supply 70. V 1 is input at conductor 22a 1 and -V 1 is input at conductor 22a 2 . V 2 is input at conductor 42a 1 and -V 2 is input at conductor 42a 2 .
Voltage V 2 is applied through resistor R1 which causes a voltage drop so that a somewhat diminished voltage V 6 is applied to the positive terminal of amplifier U1. When V 6 is more positive than V 7 which is at the negative terminal of amplifier U1, the output voltage V 4 of amplifier U1 will be a positive voltage which will travel through resistor R3 to the bases of the common emitter connected transistors Q1 and Q2.
When V 4 is positive, NPN transistor Q1 will be on and PNP transistor Q2 will be off. When transistor Q1 is on, voltage V 3 will pass through the transistor and appear as voltage V 5 at the emitter connection to resistor R4. R4 is part of the RC charging network with capacitor C1 and voltage V 7 at the negative input terminal of amplifier U1 will increase expotentially to the maximum value of V 5 which is equal to V 3 .
When V 7 charges to a value slightly greater in value than voltage V 6 , the output of amplifier U1 will go negative, and V 4 will become negative. When V 7 is negative it will feed back through resistor R2 to voltage V 6 and cause voltage V 6 also to swing negative. V 4 will pass through resistor R3 to the bases of the Q1, Q2 common emitter connection and will turn transistor Q1 off and will turn transistor Q2 on. When transistor Q2 is on, voltage V 7 will discharge toward zero through capacitor C1 and resistor R4 since transistor Q2 has its collector connected to ground. When V 7 discharges to a value slightly less than V 6 , the output of amplifier U1 will again swing positive and V 4 will also become positive. When V 4 goes positive it will make V 6 slightly more positive through resistor R2 and V 4 will pass through resistor R3 again to the common emitter connection Q1, Q2 and turn transistor Q1 on and transistor Q2 off and repeat the cycle as previously described.
Thus voltage V 4 will appear as a square wave. Voltage V 4 also passes through resistor R5 and feeds the base connections of the common emitter connection between NPN transistor Q3 and PNP transistor Q4. When V 4 is negative, transistor Q4 will be conducting and the output of transistor Q4 will be zero since its collector is grounded. When voltage V 4 is positive, transistor Q3 will be conducting and will pass voltage V 1 through transistor Q3 to resistor R6. Thus, voltage V 8 at resistor R6 will have the same relationship to voltage V 1 as voltage V 5 has to voltage V 3 . Resistor R6 and capacitor C2 filter voltage V 8 which is the positive input to amplifier U2. Amplifier U2 scales voltage V 8 so that the proper voltage V 0 is output at conductors 74 which is applied to the rate logic 66 and conductor 86 which is applied to high altitude discriminator 68.
Voltage V 5 is the output of amplifier U3 and will remain as a positive output as long as the input to amplifier U3 at its negative determining terminal is less than zero. The input to amplifier U3 is -V 1 which is the negative of the atmosphere pressure sensor 21 output. To voltage -V 1 is added a negative voltage, -V 2 , through resistor R11. This is modified by the positive feedback through resistor R13. The input to amplifier U3 is also modified by the input from conductor 22c which must pass through a diode before adding to voltage -V 2 and -V 1 . A negative voltage will reverse bias the diode and nothing will pass. A positive voltage will forward bias the diode and will add directly to the negative voltages V 2 and V 1 through the resistive network R9 and R10. The voltage at conductor 22c is negative when the plane is ascending and positive when the plane is descending so that the resistive network of R9 and R10 only affect the input to amplifier U3 when the plane is descending.
FIG. 6 is a series of graphs labeled 6A-6C which show the various voltage relationships associated with cabin altitude function generator 72. Graph 6A shows the relationship of voltages V 3 , V 6 , V 2 and V 7 . As can be seen, voltage V 6 has symmetrical swings around voltage V 2 which is caused by feedback resistor R2. Voltage V 7 will expotentially charge towards voltage V 3 to a value slightly greater than V 6 whenever transistor Q1 is on. When Q1 is turned off and Q2 is turn on, voltage V 7 will exponentially discharge towards zero to a value slightly less than voltage V 6 which has shifted to the negative side of V 2 due to the negative feedback through resistor R2. When V 7 becomes less positive than V 6 , the output of amplifier U1 goes positive, turns Q2 off and Q1 on thus repeating the cycle. Graph 6B shows voltage V 4 and its respective values when Q1 is on and Q2 is off and also when Q1 is off and Q2 is on. Graph 6C shows the relationship of V 3 and V 5 . V 5 is equal to V 3 when Q1 is on and Q2 is off. When Q2 is on V 5 equals the collector voltage of Q2 which is at ground.
It will be noted that due to feedback resistor R2, voltage V 6 will be symmetrical with respect to V 2 since voltage V 4 is symmetrical with respect to zero and the average value of V 6 will be equal to V 2 . It should also be noted that if the circuit is scaled so that V 7 is nearly linear, then the average value of V 2 is equal to V 7 , because it is symmetrical around V 2 . The average value of V 7 is equal to the average value of V 5 or
V.sub.7 (ave)=V.sub.5 (ave)
Thus the following relationships are established:
V.sub.2 =V.sub.6 (ave)=V.sub.7 (ave)
The average value of V 5 is equal to V 3 multiplied by the time period that Q1 is on (t 1 ) divided by the time period Q1 is on plus the time period when Q2 is on (t 2 ) or ##EQU2##
The time period that Q1 is on divided by the time period Q1 is on plus the period Q2 is on is the duty cycle of V 4 or the duty cycle of ##EQU3##
Since transistor Q3 and Q4 are driven by V 4 in the same manner as Q1 and Q2, V 8 bears the same relationship to V 1 as V 5 bears to V 3 ##EQU4## since the duty cycle is determined by V 4 , ##EQU5## which gives an output voltage proportionate to the sensed atmospheric pressure.
FIG. 7A is a graph of the function generated by the preferred embodiment of cabin altitude function generator 72. Curve AB is the function used during climb and cruise while no input from atmosphere pressure sensor 21 is passing into the circuit through conductor 22c due to the reverse biasing of diode D1. The orientation of diode D2 prevents resistors R9 and R10 from affecting the characteristics of amplifier U3. Curve AC is the function used during descent when diode D1 is forward biased and a positive voltage is added into the input terminal of amplifier U3 through resistive network R9 and R10, R11 and R13. In the preferred embodiment curve AB is generated on the basis of keeping the cabin pressure rates at a minimum when the aircraft is ascending at its maximum rate without exceeding the maximum ΔP for which the aircraft is designed. For curve AB, P c as generated by the function is always greater than P a as long as P a is less than or equal to X. For P a greater than X, P c becomes less than P a . Under these conditions it can be seen that when attempting to land at an altitude which has a corresponding pressure greater than X, the cabin pressure would try to be less than the ambient pressure. This would be the equivalent of commanding the outflow valve to open so that the inside cabin pressure could go below the outside ambient pressure which is an impossible condition. This would result in the outflow valve being fully opened with no cabin pressure rate control. In order to avoid this, resistors R9 and R10 are introduced on descent influencing the denominator of the cabin pressure function generated in the preferred embodiment by making the negative voltage input to amplifier U3 less negative thus lowering the value of voltage V 3 . The function of the preferred embodiment cabin altitude function generator is ##EQU6##
Since the value of K 2 P a +K 3 is proportional to V 3 , lowering of V 3 will lower the denominator and thus give a curve as depicted by curve AC. The situation where P a is greater than point X or the altitude of the aircraft is lower than the altitude corresponding to point X, does not present a problem on takeoffs due to the fact that the aircraft ambient pressure P a will be decreasing faster than the cabin pressure and operation on the curve AB will never occur and P a will always be less than P c .
FIG. 7B shows the relationship between the cabin pressure (P c ) and the ambient aircraft pressure (P a ) of previous automatic cabin pressure controllers. The ideal relationship as shown in FIG. 7A by curve A-B was attempted through straight line approximations DE, EF and FG. Although previous attempts consist of many straight line segments to approximate the ideal curve, three straight line segments are depicted for demonstration. As can be seen, two deficiencies occur in this method of constructing a cabin pressure versus ambient pressure curve. The first is that the straight line approximations do not quite achieve the curve as desired; the second is that through the use of straight line approximations, points of inflection occur at every joining of the straight line segments. The points of inflection do not appear to be far reaching in effect on the curve P c versus P a . However, when the rate of change of cabin pressure (the first derivative of P c ) is calculated, points of inflection appear as spikes on what should appear as a straight line for a constant rate of change of cabin pressure.
Referring now to FIG. 8, the automatic transfer circuit 34 and associated components are illustrated in detail, it being understood that automatic transfer circuit 32 has an identical set of components similarly connected
Malfunction detection logic 150 is connected to power supply 70 of the automatic controller 16 through conductors 42a and 42b and is connected to cabin pressure selector 10 through conductors 43a and 43b. Malfunction detection logic 150 is also connected to a valve switch 124 through conductor 41, ΔP limit logic 80 through conductor 42c, throttle switch 56 through conductor 64a, landing gear switch 46 through conductor 54a, automatic/manual transfer reset 154 through conductor 156, automatic transfer inhibit 158 through both conductors 160 and 162, to primary/standby status memory 164 through conductor 166, to standby off logic 168 through conductor 170, to OR gate 172 through conductor 174, and to automatic transfer circuit 32 through conductor 36a.
The connections in automatic transfer circuit 32 from conductors originating in automatic transfer circuit 34 are shown as dotted lines adjacent to the conductor originating in automatic transfer circuit 34 and included within a single circle. With this in mind it can be seen that malfunction detection logic 150 of automatic transfer circuit 34 is connected to automatic transfer inhibit 158 and OR gate 176, both of automatic transfer circuit 32 through conductor 36a.
OR gate 176 of automatic transfer circuit 34 is connected with successive flight transfer 206 through conductor 177, to standby off logic 168 through conductor 178, and to interconnect logic 180 through conductor 182 on its input side.
OR gate 176 is connected to on-off control 184 through conductor 186 on its output side. On-off control 184 is connected to automatic cabin pressure controller 17 through conductors 44a and 44b, to interconnect logic 180 through conductors 188 and 190, to standby off logic 168 through inverter 192 via conductor 194, to primary/standby status memory 164 through conductor 196, to primary on latch 198 through conductor 200, to successive flight transfer 206 through conductor 208, to AND gate 210 through conductor 212, and to interconnect logic 180 of automatic transfer circuit 32 through conductor 36d. The output side of OR gate 172 is connected to on-off control 184 through conductor 214. In addition to being connected to malfunction detection logic 150 through conductor 174, the input side of OR gate 172 is also connected to successive flight transfer 206 through conductor 216, primary on latch 198 through conductor 218, and interconnect logic 180 through conductor 220.
Interconnect logic 180 is connected to on-off control 184 of automatic transfer circuit 32 through conductor 40d. Primary on latch 198 is connected to standby off logic 168 of automatic transfer circuit 32 through conductor 40b, so standby off logic 168 of automatic transfer circuit 34 is connected to primary on-latch 198 of automatic transfer circuit 32. Standby off logic 168 also is connected to primary/standby status memory 164 through conductor 222 and to selector panel 10 through inverter 223 via conductor 43c. Primary/standby status memory 164 has dual connections to successive flight transfer 206 through conductors 224 and 226. Primary/standby status memory 164 is connected to AND gate 210 through conductor 228, to primary lamp 230 through conductor 232, to exclusive OR gate 234 of automatic transfer circuit 34 through conductor 236, and to exclusive OR gate 234 of automatic transfer circuit 32 through conductor 36c.
Since the circuits of automatic transfer 32 and 34 are identical, exclusive OR gate 234 of automatic transfer circuit 34 receives an input from primary/standby status memory 164 of automatic transfer circuit 32 through conductor 40c. On its output side, exclusive OR gate 234 is connected to auto/manual transfer reset 154 through conductor 238. Auto/manual transfer reset 154 is connected to cabin pressure selector 10 through conductor 240 and to auto transfer inhibit 158 through conductor 242. Auto transfer inhibit 158 is connected to successive flight transfer 206 through conductor 244 and to cabin pressure selector 10 through conductor 246. Successive flight transfer 206 is connected to throttle switch 56 through conductor 64b and to landing gear switch 46 through conductor 54b.
During each flight one controller is operated in the primary mode and one controller is operated in the standby mode. When the aircraft lands, successive flight transfer 206 will switch modes of the controllers for the next flight. The specific details of connections and operation of successive flight transfer 206 will be discussed in connection with FIG. 11. However, its output is of immediate interest. If automatic cabin pressure controller 17 is "on", successive flight transfer 206 of automatic transfer circuit 34 will issue a true signal to primary/standby status memory 164 through conductor 226 and to OR gate 176 through conductor 177 upon closing of the landing gear switch 46 at aircraft touchdown. Any true input at OR gate 176 is passed through conductor 186 to on-off control 184. On-off control 184 then energizes coil 114b of control switch 114 which opens contact 114c between driver 110 and motor 116 (see FIG. 2). If automatic cabin pressure controller 17 is off, successive flight transfer 206 will issue a true signal to primary/standby status memory 164 through conductor 224 and to OR gate 172 through conductor 216 upon closure of the landing gear switch 46. Any true input at OR gate 172 is passed through conductor 214 to on-off control 184. On-off control 184 then energizes coil 114a of control switch 114 which closes contact 114c between driver 110 and motor 116 (see FIG. 2).
Successive flight transfer 206 receives an input through conductor 208 from on-off control 184 to indicate whether or not the controller is on. Successive flight transfer 206 also programs the primary/standby status memory 164 and instructs it as to which mode automatic cabin pressure controller 17 will operate for the next flight. If a true signal is issued to primary/standby status memory 164, through conductor 226, it will indicate that automatic cabin pressure controller 17 is going to be operating in the standby mode. If a true signal is issued through conductor 224 that will indicate that automatic cabin pressure controller 17 will be operating in the primary mode for the upcoming flight.
When automatic cabin pressure controller 17 is operating in the standby mode, automatic transfer circuit 34 is monitoring the performance of cabin pressure of automatic cabin pressure controller 16. If cabin pressure controller 16 malfunctions, automatic transfer circuit 34 will switch control to automatic cabin pressure controller 17. When automatic cabin pressure controller 17 is operating in the primary mode, automatic transfer circuit 34 is disabled and automatic transfer circuit 32 monitors the performance of cabin pressure controller 17. Automatic transfer circuit 32 will switch control to automatic cabin pressure controller 16 if automatic cabin pressure controller 17 malfunctions.
Malfunction detection logic 150 receives inputs from controller 16, cabin pressure selector panel 10, throttle switch 56, landing gear switch 46 and the valve switch 124; the specific details of which will be discussed in connection with FIG. 9. On the basis of the inputs which malfunction detection logic 150 receives, it is able to determine such information as whether the aircraft is in flight, whether it is ascending or descending, whether the cabin pressure change rate exceeds the selected rate, whether the ΔP limit logic 80 is controlling the cabin pressure rate of change, whether a flow problem exists in the aircraft, and whether the primary automatic cabin pressure controller is adequately powered.
The normal output of malfunction detection logic 150 at conductor 174 is a false or zero output. Malfunction detection logic 150 of the preferred embodiment is set or its output at conductor 174 goes true if, while the aircraft is in flight, either the primary automatic cabin pressure controller loses power, or the cabin pressure is ascending at a rate in excess of the selected rate and neither the ΔP limit logic 80 is controlling nor does a flow problem exist, or the aircraft cabin altitude is descending at a rate greater than the selected rate. A true output from the malfunction detection logic 150 at conductor 174 simultaneously turns automatic cabin pressure controller 17 on and automatic cabin pressure controller 16 off.
Automatic cabin pressure controller 17 is turned on by the true signal passing to OR gate 172 through conductor 174 which in turn activates on-off control 184 as previously described. Automatic cabin pressure controller 16 is turned off by passing the true signal to automatic transfer circuit 32 through conductor 36a. The connections in automatic transfer circuit 32 can be seen by dotted line 40a which shows the identical connections between the malfunction detection logic of automatic transfer circuit 32 and automatic transfer circuit 34. The true signal is received by OR gate 176 of automatic transfer circuit 32 through conductor 40a. It is then passed to its on-off control 184 through conductor 186 which turns its controller off as previously described.
Not only does malfunction detection logic 150 turn one controller off and one controller on, it also sets automatic transfer inhibit 158 of automatic transfer circuit 34 and an identical automatic transfer inhibit in automatic transfer 32. Again, the connection in automatic transfer circuit 32 can be seen in dotted conductor 40a which comes from automatic transfer circuit 32. By setting automatic transfer inhibit, automatic transfer back to the malfunctioning controller is blocked, the malfunction detection logic 150 is disabled and the successive flight transfer circuit 206 is inhibited so that the status of the controllers will remain the same as when the malfunction occurred.
When automatic transfer inhibit 158 is set, it will relay a signal to the cabin pressure selector panel through conductor 246 which will illuminate a light 3 (see FIG. 12) indicating to the flight crew that automatic transfer function is locked out. Additionally, the fact that the standby is in control of the cabin pressure rate of change is annunciated to the crew through AND gate 210, which receives a true signal from the primary/standby memory 164 through conductor 228 when the controller is in the standby mode. In addition to the signal that it receives through conductor 228, AND gate 210 also receives a signal through conductor 212 which comes from on-off control 184 which is true when the controller 17 is on. Whenever the controller 17 is standby and on, the output of the AND gate 210 will go to cabin pressure selector panel 10 and illuminate a light 2 (FIG. 12) which indicates that the standby is in control of the cabin pressure.
Provision is made on cabin pressure selector panel 10 for the manual selection of either the primary or the standby controller. When toggle switch 1 (see FIG. 12) is moved to the standby position, it will issue a true signal through conductor 43b which will set malfunction detection logic 150 and malfunction detection logic will issue a true signal through conductor 174. This true will also issue through conductor 43c to inverter 223 which is connected to standby off logic 168. The inverter will change the true signal to a false and will have no effect on standby off logic.
When the toggle switch is moved to the primary position a false signal is issued through conductors 43b and 43c. This false signal will arrive at malfunction detection logic 150 and will not change its output. However, a false signal through conductor 43c will go to inverter 223, causing a true signal to be issued to standby off logic 168, setting it so that its output will be a true. When standby off logic 168 is set and is issuing a true signal as its output, the true signal will reset malfunction detection logic 150 and its output at conductor 174 will be a false. The true signal will then pass to OR gate 176 through conductor 178 which turns the automatic cabin pressure controller 17 off as previously described.
This true signal is also applied to automatic transfer circuit 32 through conductor 36b. This connection can be seen by dotted conductor 40b which shows the connection between standby off logic of automatic transfer circuit 32 to primary on latch 198 of automatic transfer circuit 34.
When automatic cabin pressure controller 16 is turned off by on-off control 184, the absence of a true signal is communicated through conductor 194 to inverter 192. Inverter 192 then issues a true output to standby off logic 168 which resets standby off logic. Resetting standby off logic 168 changes its output to zero or a false signal thus completing the loop and returning standby off logic to its normal state. Primary on latch 198 is set by a true signal from standby off logic of automatic transfer circuit 32 and will issue a true signal to OR gate 172 which will turn automatic cabin pressure controller 17 on as has been previously described. When automatic cabin pressure controller system 17 is turned on by on-off control 184, a true signal is issued which will return to primary on latch 198 through conductor 200 and reset the primary on latch again to its normal state which is no output.
If automatic transfer has taken place and the flight crew wishes to return control of the cabin pressure rate to a primary controller, this can also be done by pushing the reset switch in cabin pressure selector panel 10. Depressing the reset button will issue a signal to automatic/manual transfer reset 154 which will then pass to malfunction detection logic 150 through conductor 156 and automatic transfer inhibit 158 through conductor 242. Resetting the malfunction detection logic 150 will cause the output at conductor 174 to go to zero or false. Resetting the automatic transfer inhibit 158 will remove the previously established inhibit and will extinguish the illumination of transfer lock out in the cabin pressure selector panel 10. Resetting automatic transfer inhibit 158 will also remove the inhibit from successive flight transfer 206 through conductor 244 and from malfunction detection logic 150 through conductor 160. Thus while use of toggle switch 1 (FIG. 12) alone will restore control to the primary controller, a transfer lockout switch which may be incorporated into the transfer lockout light 3, may be activated to reset the automatic monitoring and transfer features associated with the standby controller.
When primary/standby status memory 164 is instructed by successive flight transfer 206 as to whether automatic cabin pressure controller will be primary or standby, it will issue a signal to exclusive OR gate 234 through conductor 236. A true input into exclusive OR gate 234 indicates that automatic cabin pressure controller is in a standby mode. A false input indicates primary mode. This true signal is also passed to automatic transfer circuit 32 through conductor 36c. The connections within automatic transfer circuit 32 can be seen by the identical connections within automatic transfer circuit 34 as shown by dotted conductor 40c which is input into exclusive OR gate 234. Exclusive OR gate 234 receives the output coming from primary/standby status memory of automatic transfer circuit 32 through conductor 40c.
If both inputs to exclusive OR gate 234 are either true or false indicating that both controllers are either in the primary or standby mode, exclusive OR gate 234 will issue a true signal to the automatic/manual transfer reset 154 through conductor 238. Automatic/manual transfer reset 154 will then reset the malfunction detection logic 150 and automatic transfer inhibit 158. By resetting malfunction detection logic 150 it will indicate that, whatever its output is, it should be reset to zero. By this, the controllers are prevented from simultaneously operating in either the primary or in the standby mode.
Primary/standby status memory 164 will also issue a true signal to primary lamp 230 through conductor 232 if automatic cabin pressure controller 17 is primary for this flight. This lamp indicates to the flight crew which cabin pressure controller is operating in the standby mode so that if a malfunction is noted by the flight crew, the maintenance crew will know which automatic cabin pressure controller malfunctioned. Operation of automatic transfer inhibit 158 upon malfunction prevents the change of primary controller by successive flight transfer 206 upon landing and maintains illumination of primary lamp 230 for repair identification.
In order to prevent a situation where both automatic cabin pressure controllers are either on or off, an interconnect logic 180 is provided, the detailed operation of which will be discussed in connection with FIG. 11. Interconnect logic 180 receives inputs from on/off control 184 of automatic transfer circuit 34 and on-off control of automatic transfer circuit 32. If automatic cabin pressure controller 17 is on, interconnect logic 180 will receive a true input through conductor 190, if it is off it will receive a true input through conductor 188. Whether automatic cabin pressure controller 17 is on is also issued as a true signal to the interconnect logic of automatic transfer circuit 32. The connections in automatic transfer circuit 32 can best be seen through dotted conductor 40d which connects interconnect logic 180 with on-off control of automatic transfer circuit 32.
Interconnect logic 180 will evaluate these inputs and determine whether both controllers are on or both controllers are off. If both controllers are on, interconnect logic 180 will issue a true signal to OR gate 176 through conductor 182 which, in turn, will turn the automatic cabin pressure controller off as has been previously described. If both controllers are off, interconnect logic 180 will issue a true signal to OR gate 172 through conductor 220 which, in turn, will turn automatic cabin pressure controller 17 on as has been previously described.
Referring now to FIG. 9, the basic malfunction monitoring and switch over circuitry of the malfunction detection logic 150 of automatic transfer circuit 34 is shown in detail, it being understood that malfunction detection logic of automatic transfer circuit 32 has an identical set of components similarly connected. Additional inputs described in connection with FIG. 8 for switching between primary and standby controllers are not duplicated herein.
Power loss detector 248 is connected to the power supply of automatic cabin pressure controller 16 through conductor 42a and the input side of OR gate 250 through conductor 252. The input side of OR gate 250 is also connected to rate monitor circuit 254 through conductor 256 and to AND gate 258 through conductor 260. Rate monitor circuit 254 is connected to automatic cabin pressure controller 16 through conductor 42b and to cabin pressure selector panel 10 through conductor 43a.
AND gate 258 is connected to valve switch 124 through conductors 262 and 41 (FIG. 8) and to the inhibit generator of ΔP limit logic of automatic cabin pressure controller 16 (FIG. 1) through inverter 264 through conductor 42c and to rate monitor circuit 254 through conductor 265. The output side of OR gate 250 is connected to the input side of AND gate 266 through conductor 268. The input side of the AND gate 266 is also connected to the output side of OR gate 270 through conductor 272. The input side of OR gate 270 is connected to throttle switch 56 through conductor 64a and to inverter 274 through conductor 276. Inverter 274 is connected to landing gear switch 46 through conductor 54a.
The output side of AND gate 266 is connected to malfunction switch over control 278 through conductor 280. Malfunction switch over control 278 is connected to OR gate 172 (FIG. 8) through conductor 174.
The input side of AND gate 282 is connected to rate monitor circuit 254 through conductor 284 and to inverter 286 through conductor 288. Inverter 286 is connected to valve switch 124 through conductors 290 and 262. The output side of AND gate 282 is connected to flow light 7 (FIG. 12) through conductor 294.
Malfunction switch over control 278 will issue a true signal to OR gate 172 (see FIG. 8) through conductor 174 which will turn off automatic cabin pressure controller 16 and turn on automatic cabin pressure controller 17 when it receives a true signal from AND gate 266 through conductor 280. AND gate 266 will issue a true output only when the input from OR gate 250 through conductor 268 and the input from OR gate 270 through conductor 272 are both true.
The output from OR gate 270 indicates whether or not the aircraft is in flight. If the aircraft is in flight the output will be true, if the aircraft is on the ground the output will be false. Flight is indicated when either one of two inputs to OR gate 270 is true. The first input from throttle switch 56 will be true when the throttle is in the advanced position. The second input through conductor 276 from inverter 274 will be true when the signal from landing gear switch 46 through conductor 54a to inverter 274 is false. The landing gear switch 46 issues a false signal when the landing gear switch is open. When the aircraft is on the ground, landing gear switch will be closed and will be issuing a true signal. This true signal will arrive at inverter 274 and a false signal will be issued to OR gate 270 through conductor 276. When the aircraft is in the air the landing gear switch will be closed and a false signal will be issued to inverter 274. When a false signal is received by inverter 274 a true signal is passed to OR gate 270 through conductor 276 thus, when the aircraft is in the air a true signal will be issued by OR gate 270 to AND gate 266 through conductor 272. Input from the throttle switch provides a flight signal when the aircraft is in the process of taking off. Whether the aircraft is in flight acts as an inhibit since a true input will be present when the aircraft is in flight and a true input is necessary before AND gate 266 will issue a true output to malfunction switch over control 278.
OR gate 250 will issue a true output to AND gate 266 through conductor 268 when either of its three inputs is true. One input to OR gate 250 is from power loss detector 248. Power loss detector 248 receives a power signal from automatic cabin pressure controller 16. As long as power from the power supply is within a specified range in automatic cabin pressure controller 16 the output of power loss detector 248 is false. When power deviates from the specified range in automatic cabin pressure controller 16, power loss detector 248 issues a true signal to OR gate 250 through conductor 252. This true signal will be passed to AND gate 266 through conductor 268 which, in turn, will issue a true signal to malfunction switch over control 278 if a true signal has been received from OR gate 270 indicating that the aircraft is in flight.
A second input to OR gate 250 comes from rate monitor circuit 254. Rate monitor circuit 254 receives an input of the sensed cabin pressure climb rate from automatic cabin pressure controller 16 through conductor 42b and the selected rate limit from cabin pressure selector panel 10 through conductor 43a. Rate monitor 254 compares these two inputs and determines whether the cabin pressure change rate exceeds the selected rate limit. If the aircraft is descending and the sensed rate exceeds the selected rate limit it will issue a true signal to OR gate 250 through conductor 256. This true signal will be passed by OR gate 250 to AND gate 266 through conductor 268 as has been previously described.
The third input to OR gate 250 of the preferred embodiment comes from AND gate 258. AND gate 258 receives three inputs, all of which must be true before it will issue a true signal to OR gate 250. The first input is from rate monitor circuit 254. When rate monitor circuit 254 determines that the sensed cabin pressure change rate exceeds the selected rate limit and the aircraft is ascending, it will issue a true signal to AND gate 258 through conductor 265.
The second input to AND gate 258 is from valve switch 124. When the valve switch is closed it will issue a false signal. A true signal will be issued by the valve switch 124 when it is open.
The third input to AND gate 258 is from ΔP limit logic of automatic cabin pressure controller 16. Under normal conditions the inhibit generator of ΔP limit logic will be issuing a false signal which will be input to inverter 264 through conductor 42c. The output of inverter 264 under normal conditions will be a true signal and will not block the output of the AND gate 258. When the ΔP limit logic is incrementing the cabin pressure rate of change it will also issue a true signal to inverter 264 through conductor 42c. The true signal arriving at inverter 264 will be passed to AND gate 258 as a false signal thus inhibiting the output of AND gate 258. The output of AND gate 258, when true, indicates that the cabin is ascending at a rate greater than the preselected rate limit and the output flow valves are not completely closed and that the ΔP limit logic is not controlling the cabin pressure rate of change.
Malfunction switchover control 278 will issue a true signal indicating that automatic cabin pressure controller 17 should be turned on only when the plane is in flight and either the automatic cabin pressure controller 16 has lost power, or the cabin is descending at a rate greater than the selected rate, or the cabin is ascending at a rate greater than the selected rate limit while the ΔP limit logic is not in control and the outflow valve is not completely closed.
Malfunction detection logic 150 performs an annunciation function in addition to detecting a malfunction in the primary controller. The output of rate monitor circuit 254 bifurcates and one output goes to AND gate 258 and the other to AND gate 282 through conductor 284. AND gate 282 also receives an output from inverter 286 through conductor 288. The input to inverter 286 comes from valve switch 124. As was said earlier, valve switch 124 issues a true signal when the outflow valve is open and a false signal when the valve is closed. When the outflow valve is closed, the false signal is input to inverter 286 which will pass a true signal to AND gate 282 through conductor 288. AND gate 282 will issue an output through conductor 294 to cabin pressure selector panel 10 illuminating flow light 7 when it receives a signal from rate monitor circuit 254 that the altitude of the cabin is ascending at a rate greater than the selected rate limit and the outflow valve closed. Thus, illumination of flow light 7 indicates to the flight crew that the cabin pressure is decreasing while the outflow valves are fully closed. This means that there is a leak on the aircraft of a magnitude greater than the cabin inflow and that the failure to properly pressurize is not due to a faulty automatic cabin pressure controller. The crew is then aware that it must either plug the leak or increase inflow to permit proper control of cabin pressure.
Referring now to FIG. 10, the detailed connections of successive flight transfer circuit 206 are illustrated. The throttle switch 56 is connected via conductor 64b 2 to an AND gate 296, to AND gate 298 through inverter 300 via conductor 64b 1 , and to a latch 302 through conductor 304. The landing gear switch 46 is connected via conductor 54b 2 to AND gate 296, to AND gate 298 through conductor 54b 1 , to AND gate 306 through conductor 308, and to inverter 310 through conductor 312. Inverter 310 is connected to a latch 314 through conductor 316.
The input side of AND gate 306 is also connected to latch 314 through conductor 318 and the inverter 320 of AND gate 306 is connected to automatic transfer inhibit 158 through conductor 244. The output side of AND gate 306 is connected to landing gear switch control 322 through conductor 324. Landing gear switch control 322 is connected to primary/standby status memory 164 through conductors 224 and 226, to OR gate 172 through conductor 216, and to OR gate 176 through conductor 177 (see FIG. 8). Landing gear switch control 322 is also connected to on-off control 184 through conductor 208. Latch 314 is connected to OR gate 326 through conductor 328. OR gate 326 is connected to latch 302 through conductor 330 and to sixty second delay 332 through conductor 334. Latch 302 is connected to twenty second delay 336 through conductor 338. Twenty second delay 336 is connected to the output side of the AND gate 298 through conductor 340. Sixty second delay 332 is connected to the output side of AND gate 296 through conductor 342.
AND gate 298 and AND gate 296 both receive two inputs. One input is from the landing gear switch 46 and the other input is from the throttle switch 56. Landing gear switch 46 will issue a true signal when it is closed, indicating that the aircraft is on the ground. Throttle switch 56 will issue a true signal when it is advanced, indicating that the aircraft is taking off or is in flight. The input to AND gate 298 from throttle switch 56 must pass through inverter 300 before it becomes an input to AND gate 298 thus when the aircraft is on the ground, the input to AND gate 298 is true and when the aircraft is in flight, the input to AND gate 298 is true. When the aircraft is in flight, the input to AND gate 296 is true. Since neither the input to AND gate 298 through conductor 54b 1 nor the input to AND gate 296 through conductor 54b 2 from landing gear switch 46 passes through an inverter, both AND gates 296 and 298 receive true inputs only when the aircraft is on the ground. If landing gear switch 46 closes, it issues a true signal to AND gate 298 through conductor 54b 1 and to AND gate 296 through conductor 54b 2 . If the throttle switch 56 is not in the advanced position, indicating that the aircraft has landed, it issues a false signal to AND gate 296 through conductor 64b 2 and to inverter 300 through conductor 64b 1 . AND gate 296 will have a false output while AND gate 298 will have a true output since the false input to inverter 300 results in a true input to AND gate 298. This condition indicates that the aircraft has landed and the controller should switch modes. When AND gate 298 has a true output, it is passed to twenty second delay 336 through conductor 340. The twenty second delay is to eliminate transfers due to bounce on landing. After the twenty second delay a true signal is passed to latch 302 through conductor 338. Latch 302 is set and will issue a true output to OR gate 326 through conductor 330. OR gate 326 will then issue a true signal to set latch 314 through conductor 328. Latch 314 then issues a true signal to AND gate 306 through conductor 318 which passes to landing gear switch control 322 through conductor 324. Landing gear switch control 322 then switches modes between the controllers as described in connection with FIG. 8.
During take off, throttle switch 56 is advanced issuing a true signal to AND gate 296 and, through inverter 300, a false signal to AND gate 298. Thus the output of AND gate 298 becomes a false and the output of AND gate 296 becomes a true. The output of AND gate 296 passes to sixty second delay 332 through conductor 342. The true signal from throttle switch 56, when advanced, will reset latch 302 through conductor 304 and the output of latch 302 will become a false to OR gate 326 through conductor 330. Latch 302 is reset so that the transfer can again take place the next time the aircraft lands. If landing gear switch 46 does not open within 60 seconds after advanced throttle, sixty second delay 332 will issue a true to OR gate 326 through conductor 334 which will be passed to set latch 314 through conductor 328.
Assuming the normal take off, landing gear switch 46 will open thus issuing a false input to AND gate 296 through conductor 54b 2 and the AND gate 298 through conductor 54b 1 . However, the false signal issued by landing gear switch 46 passes to inverter 310 through conductor 312 which in turn issues a true signal to reset latch 314 through conductor 316 and causes the output of latch 314 to AND gate 306 through conductor 318 to return a false. The output of landing gear switch is received by AND gate 306. If the aircraft is in flight a false signal is received and successive flight transfer is blocked. Automatic transfer inhibit 158 will issue a true signal to inverter 320 through conductor 244 when the automatic transfer inhibit has been activated. A true signal to inverter 320 will be passed to AND gate 306 as a false signal, preventing a true output by AND gate 306. Thus while automatic transfer inhibit is issuing a true signal no landing gear switch transfer will take place.
Referring now to FIG. 11, the interconnect logic 180 of automatic transfer circuit 34 and automatic transfer circuit 32 are shown in detail along with their interconnections. Since the internal connections of interconnect logic 180 of automatic transfer circuit 34 and the interconnect logic of automatic transfer circuit 32 are identical, the connections of interconnect logic 180 of automatic transfer circuit 34 only will be described.
The input side of AND gate 344 is connected to on-off control 184 through conductor 190 which is in turn connected to terminal 346 through conductor 36d; it is also connected to terminal 348 and terminal 350 through conductor 352, and to terminal 354 through conductor 356. The output side of AND gate 344 is connected to OR gate 176 through conductor 182.
The input side of AND gate 358 is connected to on-off control 184 through conductor 188, to terminal 348 and terminal 350 through conductor 360 and through inverter 362 to terminal 354. Terminal 354 of automatic transfer circuit 34 is connected to terminal 346 of automatic transfer circuit 32. The remaining external terminals of the interconnect logic 180 of automatic transfer circuit 34 are unconnected. Terminal 348 and terminal 364 of the interconnect logic 180 of automatic transfer circuit 32 are connected to each other.
If automatic cabin pressure controller 16 and automatic cabin pressure controller 17 are either both on or both off, the interconnect logic 180 will operate on automatic cabin pressure controller 17 through interconnect logic 180 of automatic transfer circuit 34 to turn controller 17 on if both controllers were off or to turn controller 17 off if both controllers were on. Change in status of controller 16 is prevented by the disabling connection between terminal 348 and terminal 364 of automatic transfer circuit 32. By connecting terminal 348 to terminal 364, a false signal is input to AND gate 344 and AND gate 358 of interconnect logic of automatic transfer circuit 32. Since each of the AND gates of interconnect logic of automatic transfer circuit 32 will constantly have a false input, they will never have a true or operative output and further discussion of their operation is unnecessary.
When automatic cabin pressure controller 17 is on, on-off control 184 issues a true signal which passes to AND gate 344 through conductor 190. If automatic cabin pressure controller 6 is simultaneously on, on-off control of automatic transfer circuit 32 will issue a true signal which will pass through terminal 346 of the interconnect logic of automatic transfer circuit 32 to terminal 354 of interconnect logic 180 of automatic transfer circuit 34. This true signal will pass to inverter 362 and be input into AND gate 358 as a false and to AND gate 344 through conductor 356 as a true signal. The third input to AND gate 344 will be from terminal 350 or the power supply which will be a constant true input. Three true inputs at AND gate 344 will result in a true output to OR gate 176 through conductor 182 and will turn automatic cabin pressure controller 17 off as described in connection with FIG. 9.
If automatic cabin pressure controller 17 is off, on-off control 184 will issue a true signal to AND gate 358 through conductor 188. If automatic cabin pressure controller 16 is off, on-off control of automatic transfer circuit 32 will be issuing a false signal to terminal 346. This false signal will then pass to terminal 354 of interconnect logic 180 of automatic transfer circuit 34 and pass to inverter 362 which in turn will issue a true signal to AND gate 358. The false signal at terminal 354 is also passed to AND gate 344 through conductor 356 which will keep the output at AND gate 344 false. The third input to AND gate 358 is from terminal 350 which is a constant true signal through conductor 360. The three true inputs to AND gate 358 will result in a true output to OR gate 172 through conductor 220. A true signal at the input to OR gate 172 will turn automatic cabin pressure controller 17 on as described in connection with FIG. 8.
The purpose of having identical interconnect logics in automatic transfer circuits 32 and 34 is to retain the complete interchangeability of the two units. Providing external terminals allows the disabling of one interconnect logic while the other remains completely functional.
Specific embodiments of an aircraft cabin pressure control system have been shown, illustrating and describing the use of dual automatic controllers, a method for alternating their use in an aircraft, a method for achieving a linear rate of change of cabin pressure, a way of identifying the defective controller when it malfunctions, a method for determining whether an unexpected result was due to a controller malfunction, methods for preventing both controllers from being in the same state, a method for detecting undesirable rate changes in cabin pressure, and a method for preventing disasters due to the differential between cabin pressure and outside ambient pressure. It is to be understood that the foregoing embodiments are presented by way of example only and that the invention is not to be construed as being limited thereto, but only by the proper scope of the following claims. | A cabin pressure control system uses two identical controllers which serve, on alternate flights, as primary controller while the other serves as standby. Identical circuitry on the units cooperate if both controllers attempt to control cabin pressure together, or if neither assumes control, to place one of the units in control of cabin pressure. | 1 |
RELATED APPLICATIONS
This application is a CIP of U.S. Ser. No. 194,108 filed May 16, 1988, now abandoned.
BACKGROUND OF THE INVENTION
This invention relates to the catalytic dehydrogenation of a lower-alkyl-substituted ethylbenzene, and, more particularly, to the oxidative dehydrogenation of a C 1 to C 4 alkyl-monosubstituted ethylbenzene over an inorganic, pyrophosphate-containing catalyst to form a C 1 to C 4 alkyl-monosubstituted styrene.
The dehydrogenation of an organic compound such as an alkane or alkyl-substituted aromatic is an important industrial process and, although the reaction occurs thermally, it is more often run catalytically, most often in the absence of oxygen in a vapor-phase reaction. An example of such a nonoxidative reaction is the conventional synthesis of styrene which involves the dehydrogenation of ethylbenzene in the absence of oxygen over potassium-and/or chromia-promoted iron oxide catalysts at about 570°-640° C. Other examples of such nonoxidative, catalytic dehydrogenations are the reaction of p-ethyltoluene to p-methylstyrene at 625° C. over a copper aluminum borate as taught in U.S. Pat. No. 4,590,324, and the reaction of an alkylaromatic containing at least two carbon atoms in at least one alkyl group to form an alkenyl aromatic over an aluminum borate doped with an alkali or alkaline earth compound as taught in U.S. Pat. No. 4,645,753. In the temperature range employed, there is, in the non-oxidative dehydrogenation, a significant amount of catalyst coking, hydrocarbon cracking and a less than desirable catalyst lifetime and selectivity. This is true particularly when the ethylbenzene is alkyl-substituted, for example, in the dehydrogenation of an ethyl toluene to a methylstyrene and becomes more severe with increase in the size of the alkyl substituent.
If an oxidant such as air or diluted oxygen is added to the catalytic dehydrogenation of ethylbenzene to make the reaction oxidative, the process temperature range can be reduced to the 450°-550° C. range resulting in less melting and catalyst coking. In U.S. Pat. No. 3,957,897, the use of certain alkali metal pyrophosphates is taught for the oxidative dehydrogenation of ethylbenzene to styrene in the temperature range 450°-650° C. The magnesium salt is taught as being most effective of the magnesium, calcium, and strontium for the process, and the barium salt, which is described only for comparative purposes, is taught as having a very low conversion (28.5%) and an average selectivity (92.6%).
The compound K 3 Fe 3 H 14 (PO 4 ) 8 .4H 2 O is described in the open literature in J. Agr. Food Chem. 14, (1) 27-33 (1966) and it is there reported that it may be synthesized from a soluble source of Fe (III) such as FeCl 3 .6H 2 O. The calcination of this material has not been reported nor has the calcination product, KFe 3 H 6 (P 2 O 7 ) 4 .
Now it has been found that barium pyrophosphate is, contrary to the '897 patent teaching, more effective than other alkaline earth pyrophosphates when used in catalysts for the oxidative dehydrogenation of p-(t-butyl)ethylbenzene to p-(t-butyl)styrene, and can lead to conversions in excess of 42 weight percent, the catalyst exhibiting substantial resistance to deactivation and coking. Excellent conversion and selectivity in the dehydrogenation of a lower alkyl-monosubstituted ethylbenzene have also been found for the pyrophosphate-containing calcination product of K 3 Fe 3 H 14 (PO 4 ) 8 .nH 2 O for which an improved method of preparation has been found.
BRIEF DESCRIPTION OF THE INVENTION
In one aspect, the invention describes a vapor-phase process comprising contacting under dehydrogenation conditions a lower-alkyl-monosubstituted ethylbenzene and an oxygen-containing gas containing less than about twenty mol percent oxygen with a catalyst composition containing the pyrophosphate calcination product of the compound KFe 3 H 14 (PO 4 ) 8 .nH 2 O, wherein n is about four or less, to selectively form a lower-alkyl-monosubstituted styrene.
In another aspect, the invention embraces making the compound KFe 3 H 14 (PO 4 ) 8 .nH 2 O wherein n runs between about 1 and about 4 by contacting Fe 2 O 3 with a solution made from phosphoric acid and a potassium carbonate to form a slurry, heating and agitating said slurry for an extended period, and isolating said KFe 3 H 14 (PO 4 ) 8 .nH 2 O.
In still another aspect, the invention describes a new material essentially of formula KFe 3 H 6 (P 2 O 7 ) 4 which can be made by calcination of K 3 Fe 3 H 14 (PO 4 ) 8 .nH 2 O where n runs between about 1 and about 4, at a temperature above about 400° C. By "essentially of formula KFe 3 H 6 (P 2 O 7 ) 4 " it is meant that small amounts of impurities may be present in combination with the pyrophosphate.
In yet another aspect, the invention encompasses a vapor-phase process comprising contacting under dehydrogenation conditions p-(t-butyl)ethylbenzene and an oxygen-containing gas containing less than about twenty mol percent oxygen with a catalyst composition containing barium pyrophosphate to selectively form a lower-alkyl-monosubstituted styrene.
DETAILED DESCRIPTION OF THE INVENTION
Organic compounds which may be dehydrogenated by this invention include lower-alkyl-monosubstituted ethylbenzenes. By lower-alkyl is meant a C 1 to C 5 alkyl group. More preferred is the use of C 1 to C 4 alkyl-monosubstituted ethylbenzene, and most preferred is the use of a t-butylethylbenzene, particularly para-t-(butyl)ethylbenzene.
The barium pyrophosphate catalyst of this invention can be prepared by calcining the corresponding barium monohydrogen phosphate in accordance with the following: ##STR1## It is preferred to carry out the calcination between about 500° and about 650° C. Too high or too low a calcination temperature can be detrimental to the catalytic properties of the solid as is well-known to those skilled in the art.
Another route for preparing the barium pyrophosphate is to heat the alkaline earth monoammonium phosphate eliminating H 2 O and NH 3 . This process is characterized by the following equation: ##STR2## The preferred calcination temperature range is about the same as above.
A third procedure for preparing the barium-containing catalyst is to react a water soluble barium salt with NH 4 H 2 PO 4 , (NH 4 ) 2 HPO 4 or H 3 PO 4 . The amount of the mono or diammonium phosphate or phosphoric acid should be in excess of that needed to form the orthophosphate and at least sufficient to form the pyrophosphate. The precipitate which forms in the reaction is filtered, dried and calcined. In this procedure the PO 4 3- /barium ratio should preferably be less than 2. Calcination is preferably done above about 500° C. until the material loses no further water, however, too high a calcination temperature can be detrimental as can be understood by one skilled in the art.
The KFe 3 H 14 (PO 4 ) 8 .4H 2 O precursor to the potassium iron pyrophosphate material can be made by the method found in J. Agr. Food Chem. 14, (1) 27-33 (1966). After drying the material it is calcined at about 400° to about 650° C., more preferably at about 450° to about 550° C., until further weight loss is minimal. Calcination produces a substance which is essentially the compound KFe 3 H 6 (P 2 O 7 ) 4 . Again, too high or too low a calcination temperature can be detrimental as can be understood by one skilled in the art. The barium pyrophosphate and pyrophosphate calcination product of KFe 3 H 14 (PO 4 ) 8 .4H 2 O can be used neat or supported on a material such as silica, alumina, silica-alumina or magnesia. Preferably, they are used without a support.
An improved preparation of the above compound which avoids the production of a large amount of hydrogen chloride involves using Fe 2 O 3 as the iron source. Conveniently, the Fe 2 O 3 can be slurried with an aqueous solution made from phosphoric acid, preferably concentrated phosphoric acid, a potassium carbonate such as K 2 CO 3 or KHCO 3 , heating the slurry for up to about five or six days at a temperature between about 80° to about 120° C., preferably about 90° to 110° C., for up to about 5 or 6 days. The KFe 3 H 14 (PO 4 ) 8 .4H 2 O can then be isolated as a solid by filtration and washed and dried.
In the inventive process, the molar ratio of oxygen to alkyl aromatic compound fed into the dehydrogenation reactor can range from about 0.5 to about 4.0 mols of oxygen per mol of aromatic hydrocarbon, but a preferred range is from about 0.5 to about 2.5 mols. Most preferred is the use of about 1.1 to about 1.4 mols oxygen per mol of aromatic compound.
The oxygen can be pure oxygen, but it is preferred to use oxygen diluted with an inert diluent such as nitrogen. Most commonly, air is used as the oxygen source and further diluted with an inert gas if desired. Diluents when used can be one of the rare gases, nitrogen, carbon dioxide or steam and the like.
The space velocity (wt/wt/hr) used in the dehydrogenation reaction can range from about 0.01 to about 10, but a preferred range is from about 0.1 to about 5. Most preferred is the use of a range from about 0.1 to about 1 hr -1 . The pressure at which the reaction can be run is in the range from about 0.5 psi to about 300 psi, but it is preferable to operate in the pressure range of about 15 to about 100 psi for optimal results. The oxidative dehydrogenation reaction can be effected in a temperature range from about 300° to about 700° C., but a preferred range is from about 450° to about 600° C. Care should be exercised to avoid explosive mixtures when feeding the alkyl aromatic compound and oxygen into the reactor as can be understood by one skilled in the art. Generally, the dehydrogenation reaction produces only small amounts of by-products which can be separated by conventional means. When p-(t-butyl)ethylbenzene is used, small amounts of isopropenylstyrene and isobutenylstyrene form. The isopropenylstyrene can be separated from the desired product by active carbon adsorption.
The following Examples will serve to illustrate certain embodiments of the herein disclosed invention. These Examples should not, however, be construed as limiting the scope of the novel invention as there are many variations which may be made thereon without departing from the spirit of the disclosed invention, as those of skill in the art will recognize.
EXAMPLES
General
In each of the dehydrogenation Examples below a 25 ml charge of catalyst pellets was loaded in a 0.75 in stainless steel tubular reactor and the body temperature of the reactor was raised to 500° C. in a single-zone furnace. The gas flow was 7% by volume oxygen in nitrogen used at a total flow rate of 55 ml/min. The molar diluent ratio:nitrogen/t-butylethylbenzene was 18.4 and the liquid t-butylethylbenzene flow was 0.024 ml/min. The weight hourly space velocity was 0.04/hr -1 . Liquid products were determined quantitatively by gas chromatography to give selectivities and conversions so that the yields and selectivities are based upon conversion to liquid products. When total conversions (to gaseous products as well) are calculated they are about 4% higher and selectivities to the alkylstyrene are about 8% lower. All percentages are in weight percent.
EXAMPLE 1
A 151.4 g portion of barium nitrate was added to 2000 ml of distilled H 2 O and the pH adjusted to 6.3 using NH 4 OH. A solution of ammonium hydrogen phosphate dibasic (89.3 g in 500 ml distilled H 2 O) was prepared and the pH adjusted to 7.2 using HNO 3 . The barium nitrate solution was added to the ammonium hydrogen phosphate solution dropwise with vigorous stirring. The pH was kept monitored and kept in the range 5.5 to 6.5. The final pH was 6.1. The precipitate which formed over the course of addition was filtered and rinsed with distilled H 2 O. The resulting white solid was vacuum dried at 125° C. for 16 hr. The dried powder (69.2 g) was combined with 1.8 g of Sterotex (2.53%) and then pelletized into 1/8 in diameter pellets. The pellets were calcined at 550° C. for 8 hr and used as the barium pyrophosphate catalyst below.
EXAMPLE 2
Magnesium, calcium and strontium pyrophosphates were made in pellet form by the procedure of Example 1 and used as catalysts as below in Example 7.
EXAMPLE 3
Preparation of KFe 3 H 6 (P 2 O 7 ) 4 was as follows. A 2 1 beaker was charged with 1001 g of 85% phosphoric acid. While stirring the phosphoric acid with an overhead mechanical stirrer, a 233.3 g portion of powdered FeCl 3 .6H 2 O was slowly added followed by a 23.33 g portion of KCl. After stirring the mixture for about 20 min, the mixture was filtered through a coarse glass frit to remove any insoluble material. The filtrate was then transferred to a 1 1 beaker and covered with a watch glass. After standing for 4 days, the precipitate which had collected along the walls of the beaker was scraped off and the entire mixture manually stirred. After standing an additional day, the mixture was filtered on a coarse glass frit. The filter cake was reslurried with 350 ml methanol and filtered, a washing technique which was repeated 3 times. The light pink solid was then dried in a vacuum oven overnight at 300° F., affording a 192.3 g quantity of KFe 3 H 14 (PO 4 ) 8 .4H 2 O.
Approximately 2/3 of the dried material was ground and sieved to 8/12 mesh size. Total weight of 8/12 mesh size KFe 3 H 14 (PO 4 ) 8 .4H 2 O equaled 123.94 g. This material was calcined at 500° C. for 12 hr resulting in a weight loss of 15.46 g or 12.47% (theoretical weight loss corresponding to conversion to KFe 3 H 6 (P 2 O 7 ) 4 is 13.69%). Analysis showed Fe, 18.0% (18.44%); K, 4.7% (4.30%); P, 25.2% (27.28%). Theoretical values for the formula KFe 3 H 6 (P 2 O 7 ) 4 are in the parentheses.
EXAMPLE 4
The solid product of Example 3 was calcined at 500° C. for 12 hr, crushed, and sieved to 8/12 mesh size.
EXAMPLE 5
The solid product of Example 3 was calcined at 800° C. for 12 hr, crushed, and sieved to 8/12 mesh size.
EXAMPLE 6
The catalyst of Example 1 was used to oxidatively dehydrogenate p-(t-butyl)ethylbenzene to p-(t-butyl)styrene. The results are shown below in Table 1.
TABLE 1______________________________________% Selectivity and Conversion in theOxidative Dehydrogenation of p-(t-butyl)ethylbenzeneOn StreamTime (hr) % Conversion % Selectivity**______________________________________16 56 9721 55 9737 55 9745 56 9661 56 9781 56 97105 55 98115 56 98131* 42 98______________________________________ *Space velocity was changed by a factor of 2.5. **Major dialkenylbenzene product impurities are isopropenylstyrene (about 0.045%) and isobutenylstyrene (about 0.085%).
COMPARATIVE EXAMPLE 7
Various alkaline earth pyrophosphates were used to oxidatively dehydrogenate p-(t-butyl)ethylbenzene to p-(t-butyl)styrene. The results are shown below in Table 2.
TABLE 2______________________________________Comparison of % p-(t-butyl)ethylbenzene Conversionsand p-(t-butyl)styrene Selectivities forSeveral Alkaline Earth Pyrophosphate Catalysts On StreamCatalyst* Time (hr) % Conversion % Selectivity______________________________________Mg.sub.2 P.sub.2 O.sub.7 89 47 94Ca.sub.2 P.sub.2 O.sub.7 91 43 95Sr.sub.2 P.sub.2 O.sub.7 93 51 96Ba.sub.2 P.sub.2 O.sub.7 105 55 98______________________________________ *Catalysts used were made according to Examples 1 and 2.
EXAMPLE 8
The catalyst of Example 3 was used to oxidatively dehydrogenate p-(t-butyl)ethylbenzene to p-(t-butyl)styrene. The results are shown below in Table 3.
TABLE 3______________________________________% Selectivity and Conversion in theOxidative Dehydrogenation of p-(t-butyl)ethylbenzeneOn StreamTime* (hr) % Conversion % Selectivity**______________________________________ 5 56 97 23 52 98 29 50 97 47 50 97 53 50 97 70 50 97 77 52 97 95 52 91101 62*** 68122 46 96144 53 97167 52 97173 52 97192 42*** 97196 45 97______________________________________ *WHSV for this catalytic run was 0.077 hr.sup.-1. **% isopropenylstyrene (IPS) and % isobutenylstyrene (IBS) impurities in the product were about the same as in Example 5. ***Variation due to temperature fluctuations during the run.
EXAMPLE 9
The catalyst of Example 4 was used to oxidatively dehydrogenate p-(t-butyl)ethylbenzene to p-(t-butyl)styrene. The results are shown below in Table 4.
TABLE 4______________________________________% Selectivity and Conversion in theOxidative Dehydrogenation of p-(t-butyl)ethylbenzeneOn StreamTime* (hr) % Conversion % Selectivity______________________________________18 49 9723 49 9642 48 9748 49 9766 49 9671 49 9693 49 96117 47 96138 47 96144 49 96163 49 95______________________________________ *WHSV for this catalytic run was 0.077 hr.sup.-1.
EXAMPLE 10
The catalyst of Example 5 was used to oxidatively dehydrogenate p-(t-butyl)ethylbenzene to p-(t-butyl)styrene. The results are shown below in Table 5.
TABLE 5______________________________________% Selectivity and Conversion in theOxidative Dehydrogenation of p-(t-butyl)ethylbenzeneOn StreamTime (hr) % Conversion % Selectivity______________________________________ 6 37 3522 13 9530 22 91______________________________________
EXAMPLE 11
A 2 1, 3-neck round-bottomed flask equipped with a reflux condenser,thermometer, mechanical stirrer, and electric heating mantle was charged with 1472 g of 85% phosphoric acid, 100.7 g of Fe 2 O 3 , and 31.4 g of K 2 CO 3 . The mixture was heated at 97°-99° C. with stirring for 5 days. After cooling, the mixture was filtered and the product washed and dried as described in Example 3, affording 365 g of KFe 3 H 14 (PO 4 ) 8 .4H 2 O (82.5% yield based on the amount of iron used). The product was analyzed and the following results were obtained:
Calculated for KFe 3 H 14 (PO 4 ) 8 .4H 2 O (K, 3.7%; Fe, 15.9%; P, 23.5%). Found (K, 3.3%; Fe, 15.5%; P, 22.8%). The surface area of the product using the BET procedure employing nitrogen was less than 5 m 2 /g. Scanning electron microscopy revealed a homogeneous matrix of well-formed, distorted hexagonal block crystals.
A 306.5 g sample of KFe 3 H 14 (PO 4 ) 8 .4H 2 O as made above (8/12 mesh particles) was calcined in air at 500° C. for 12 hr yielding 268.4 g of light tan KFe 3 H 6 (P 2 O 7 ) 4 . The product was analyzed and the following results were obtained:
Calculated for KFe 3 H 6 (P 2 O 7 ) 4 (K, 4.3%; Fe, 18.4%; P, 27.3%). Found K, 4.3%; Fe, 18.4%; P, 27.6%). Calculated weight loss was 13.7% versus an observed weight loss of 12.4%. The surface area of the product using the BET procedure employing nitrogen was less than 5 m 2 /g. Scanning electron microscopy revealed a homogeneous matrix of fragmented, irregular platelike crystals.
EXAMPLE 12
The pyrophosphate of Example 11 was used to oxidatively dehydrogenate p-(t-butyl)ethylbenzene to p-(tbutyl)styrene. The results are shown below in Table 6.
TABLE 6______________________________________On StreamTime (hr) % Conversion % Selectivity______________________________________ 4 37 9723 37 9745 35 9777 35 97115 34 97______________________________________ | Catalyzed vapor-phase processes are taught for the oxidative dehydrogenation of a lower-alkyl-monosubstituted ethylbenzene to a lower-alkyl-monosubstituted styrene. Barium pyrophosphate and the pyrophosphate-containing calcination product of KFe 3 H 14 (PO 4 ) 8 .nH 2 O, n running between about 1 to about 4, are shown to effectively catalyze these dehydrogenations at a low enough temperature such that very little cracking of the lower alkyl group occurs which gives superior conversions and selectivities to the corresponding styrenes and lengthened catalyst lifetime. An improved method of preparation of KFe 3 H 14 (PO 4 ).nH 2 O is described as well as the new material which is essentially KFe 3 H 6 (P 2 O 7 ) 4 . | 2 |
FIELD OF THE INVENTION
[0001] The present invention relates to communication systems, and more particularly to a communication path that includes one or more latency-aligning transceivers.
BACKGROUND
[0002] FIG. 1 illustrates a prior art memory system that includes multiple integrated circuit memory devices 120 coupled to a memory controller 110 via a bidirectional communication channel 140 . Because each memory device 120 consumes physical space along the channel, the number of memory devices that can be coupled to the channel 140 , and to some extent the storage capacity of the memory system, is limited by the length of the channel 140 . The length of the channel 140 is itself limited by a number of practical considerations. For example, signals attenuate as they propagate down the channel 140 , constraining the channel length to one that provides a tolerable signal level at the memory IC farthest from the controller 110 . Similarly, channel capacitance increases with channel length, limiting the frequency response of the channel. Accordingly, the channel length usually must be limited to support the desired operating frequency of the memory system.
[0003] One technique for increasing the number of memory devices that can be used in a memory system without unacceptable loss in signaling margin or frequency response is to use buffering circuits to segment the communication path into multiple smaller channels. Unfortunately, buffers add latency that can be problematic, particularly in synchronous memory systems which rely on deterministic timing relationships. For example, in some memory systems, memory operations are pipelined by transmitting commands in the intervening time between transmission of an earlier command (e.g., a read command) and responsive transmission of the corresponding data (e.g., the read data). When buffers are positioned along the channel's length, however, the time intervals between command and response transmissions vary arbitrarily depending on the positions of the addressed memory devices (i.e., memory devices positioned downstream from one or more buffers or repeaters exhibit greater effective response delay than memory devices coupled directly to the memory controller). This significantly complicates command pipelining.
[0004] Thus, it is desirable to provide a memory subsystem that can support a large number of memory devices without degrading the reliability and performance of the memory system.
SUMMARY
[0005] A memory system including one or more transceivers with latency alignment circuitry is disclosed in various embodiments. The memory system includes a communication path that is segmented into a primary channel and one or more stick channels by appropriate placement of the latency aligning transceivers. In one embodiment, the transceivers buffer clock, control and data signals while also aligning the latency in the round-trip path between the memory controller and the stick channel driven by the transceiver to a clock cycle boundary. When memory devices that have adjustable response delays are coupled to the different stick channels in the memory system, the memory system can be configured so that the total response latency is substantially the same for each memory IC in the memory system. This simplifies command pipelining significantly, permitting commands to be packed densely within the available channel bandwidth. As discussed below, stick channels themselves can feed one or more additional transceivers, making any number of interconnection topologies possible.
[0006] These and other features and advantages of the present invention will be apparent from the accompanying drawings and from the detailed description that follows.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] The present invention is illustrated by way of example, and not by way of limitation, in the figures of the accompanying drawings and in which like reference numerals refer to similar elements and in which:
[0008] FIG. 1 illustrates a prior art memory system.
[0009] FIG. 2 is a block diagram of a memory system according to one embodiment of the present invention.
[0010] FIG. 3A is a timing diagram of a data transfer operation in the memory system of FIG. 2 .
[0011] FIG. 3B is a timing diagram of the data transfer from a master device to a memory device.
[0012] FIG. 3C is another timing diagram of a data transfer from the master device to a memory device.
[0013] FIG. 4 illustrates the response latency of a memory transaction according to one embodiment.
[0014] FIG. 5 illustrates the scaleability of a memory system according to one embodiment.
[0015] FIG. 6 is a block diagram of a transceiver according to one embodiment.
[0016] FIG. 7 illustrates the synchronization and transceiver logic of a transceiver 220 according to one embodiment.
[0017] FIG. 8 is a diagram of a transceiver that includes circuitry for preventing a latch-up condition.
DETAILED DESCRIPTION
[0018] FIG. 2 is a block diagram of a memory system 200 according to one embodiment of the present invention. The memory system 200 includes a master device 210 (e.g., a memory controller) coupled to a plurality of memory devices 260 A- 260 I via a communication path formed by a primary channel 215 and stick channels 275 A- 275 D. In one embodiment, the master device, transceivers and memory devices transmit signals on the communication path through current-mode signaling. That is, each conductor in a given channel 275 A- 275 D is pulled up to a predetermined voltage level through a termination impedance and may be driven to at least one lower voltage level by sinking an appropriate amount of current. Although the termination impedances are depicted in FIG. 2 as being coupled to the ends of the channels 275 A- 275 D, the termination impedances may alternatively be placed at any point along their respective channels, including within the master device 210 , or within a transceiver or memory device coupled to the channel.
[0019] In an alternative embodiment, voltage mode signaling may be used in which the master device, transceivers and memory devices output digital voltage levels to the bus to effect digital signaling. In voltage mode embodiments, the bus may be allowed to float or the bus may be pulled up or down through termination impedances.
[0020] In the embodiment of FIG. 2 , a clock generator 230 generates a clock signal 240 called clock-to-master (CTM) that propagates toward master device 210 . A second clock signal 250 , preferably having the same frequency as CTM 240 , propagates away from the master device 210 and is called clock-from-master (CFM). CTM 240 is used to clock the transmission of information to master device 210 on the primary channel 215 , while CFM 250 is used to clock transmission of information from the master device 210 to memory device 260 A and transceivers 220 A and 220 B. Together CTM and CFM provide for source synchronous transmission of data (i.e., data travels with clock) in both directions on the primary channel 215 . In one embodiment, CTM 240 and CFM 250 are the same signal, with the conductors that carry CFM 250 and CTM 240 being coupled to one another at or near the master device 210 (e.g., within the master device 210 , at a pin of the master device 210 or at another point just outside the master device 210 ). In alternative embodiments, clock signals CTM 240 and CFM 250 may be separately generated. For example, master device 210 may include a clock generator circuit that generates CFM 250 in a predetermined phase relationship to CTM 240 .
[0021] Regardless of whether CTM 240 and CFM 250 are the same signal or separately generated, CTM 240 and CFM 250 will have a different phase relationship at different points along the primary channel due to the fact that they are traveling in different directions. For example, if CFM and CTM are in phase at master device 210 , then at transceiver 220 B, they will be out of phase by the amount of time it takes for CTM 240 to travel from the transceiver 220 B to the master 210 plus the time it takes for CFM 250 to travel from the master 210 to the transceiver 220 B. This phase difference between CTM and CFM, referred to herein as t TR , is different at each point along the primary channel.
[0022] Each of transceivers 220 A- 220 C serves as a bi-directional repeater between a host channel (i.e., a channel used to deliver signals from the master device 210 ) and at least one stick channel. More specifically, transceiver 220 B serves as a bi-directional repeater between host channel 215 (the primary channel) and stick channel 275 C; transceiver 220 C serves as a bi-directional repeater between host channel 275 C and stick channel 275 D; and transceiver 220 A serves as a bi-directional repeater between host channel 215 and each of stick channels 275 A and 275 B. In one embodiment, each of the transceivers 220 A- 220 D provides regenerative gain and drive capability and resynchronizes signal transmissions between the clock domain of the host channel and the stick channel. It should be noted that the channel topology depicted in FIG. 2 is merely an example—numerous alternative channel topologies may be constructed without departing from the spirit and scope of the present invention.
[0023] By using transceivers 220 A- 220 D to segment the overall communication path into multiple segments, the resistive and capacitive loading of any given length of the communication path may be kept below a tolerable threshold. This permits the communication path to be extended to support more memory devices without unacceptable loss of signal margin due to resistive or capacitive loading.
[0024] Although each of transceivers 220 A- 220 C is shown in FIG. 2 as supporting one or two stick channels, a given transceiver may support any number of stick channels up to a practical limit. Also, though the primary channel 215 and stick channels 275 A- 275 D are each shown as supporting one or two memory devices, more memory devices may be supported by the channel segments in alternate embodiments. Similarly, any number of transceivers up to a practical limit may be hosted by a given channel segment.
[0025] In one embodiment, each of the transceivers uses the clock signals that correspond to its host channel to generate one or more clock signals for the stick channel (or channels) that it serves. For example, transceiver 220 B generates a clock signal “clock-to-end” (CTE) 270 C based on clock signals CTM 240 and CFM 250 . CTE 270 C is folded back at the end of stick channel 275 C to provide clock signal “clock-to-transceiver” (CTT) 280 C, which in turn is used to generate clock signal “clock-from-transceiver (CFT) 290 C. Similarly, transceiver 220 C generates clock signals CTE 270 D, CTT 280 D and CFT 290 D based on clock signals CTT 280 C and CFT 290 C, and transceiver 220 A generates clock signals CTE 270 A, CTT 280 A, CFT 290 A, CTE 270 B, CTT 280 B and CFT 290 B from clock signals CTM 240 and CFM 250 .
[0026] The relationship between CTM 240 and CFM 250 described above applies to the clock signals CTT and CFT generated for each stick channel. For example, in the embodiment of FIG. 2 , CTT and CFT for a given stick channel are the same signal, with their respective conductors being coupled together at or near the transceiver for the stick channel (e.g., within the transceiver, at a pin of the transceiver or at another point just outside the transceiver). In alternative embodiments, CTT and CFT may be separately generated. For example, a given transceiver may include a clock generator circuit that generates CFT in a predetermined phase relationship to CTT.
[0027] Regardless of whether CTT and CFT are the same signal or separately generated, CTT and CFT will have a different phase relationship at different points along the stick channel they serve. This phase difference between CTT and CFT for a given stick channel is analogous to the phase difference, t TR , between CTM 240 and CFM 250 discussed above, and is referred to herein as t-stick TR . As discussed below, transceivers 220 A- 220 D perform a latency alignment function by adjusting the transfer latency from host channel to stick channel according to the phase difference between the host channel's clocks (i.e., t TR when the host channel is the primary channel 215 and t-stick TR when the host channel is a stick channel).
[0028] In one embodiment, the CFT and CTT clocks on stick channels (stick clocks) are synchronized to CTM 240 on the primary channel 215 . Requests/commands from the master device 210 are received with CFM and resynchronized to CFT for retransmission on the stick channel. This timing relationship is discussed below in further detail.
[0029] FIG. 3A is a timing diagram of a data transfer operation in the memory system 200 of FIG. 2 . More specifically, FIG. 3A illustrates the timing of a data transfer from memory device 260 G to master device 210 . Data C is available on stick channel 275 C at the falling edge of StickClk 330 . In the embodiment shown, T×Clk 320 is the equivalent of CTM 240 and StickClk 330 is 180 degrees out of phase with T×Clk 320 . Data C is transferred onto the primary channel 215 at the second falling edge of T×Clk 320 at time T 2 . The overall propagation delay from the primary channel 215 to the stick channel 275 (i.e., the latency incurred crossing transceiver 220 B) is t LAT(SP) . In the embodiment shown, t LAT(SP) is 1.5 clock cycles in duration.
[0030] FIG. 3B illustrates the timing of a data transfer in the opposite direction—from master device 210 to memory device 260 G. The primary channel 215 has data A on it at a first time, at a falling edge of R×Clk 310 . For one embodiment, R×Clk 310 is equivalent to CFM 250 . CFM 250 lags CTM 240 by time t TR so that R×Clk 310 lags T×Clk 320 by time t TR . As discussed above, time t TR is twice the time of flight down the bus, which is the difference in phase between CTM and CFM at the pin of the slave device (transceiver). Generally period t TR should be less than one cycle (e.g. 0.8 t CYCLE , otherwise the timing relationship may be confusing (i.e. 2.2 cycles looks just like 0.2 cycles). In alternative embodiments, circuitry for tracking multiple cycles may be used so that t TR need not be limited to less than a clock cycle.
[0031] At the falling edge of R×Clk 310 , data A is available to the transceiver. For one embodiment, transceiver latches data A at this time. The data A is available on the stick channel 275 C on the falling edge F of stick clock 330 , after the rising edge 2 R. The overall propagation delay from the primary channel 215 to the stick channel 275 C is t LAT(PS) .
[0032] FIG. 3C is a timing diagram of a data transfer from the master device 210 to the memory device 260 G when t TR is relatively large (e.g., 0.8 tcycle). As shown, data B is available on primary channel 215 at a falling edge of R×Clk 310 and then on the stick channel 275 C at time T 2 , the first falling edge after the second rising edge 2 R of StickClk 330 . The overall propagation delay from the primary channel 215 to the stick channel 275 is t LAT(PS) .
[0033] Referring to FIGS. 3B and 3C , it can be seen that the transfer latency from primary channel to stick channel (t LAT(PS) ) is dependent upon the time t TR . More specifically, t LAT(PS) is given by a predetermined number of clock cycles less the round trip time on the channel between the transceiver and the master device, t TR . In an embodiment having the timing characteristic shown in FIGS. 3B and 3C , the latency incurred crossing the transceiver in the direction of the stick channel may be expressed mathematically as t LAT(PS) =2.5 cycles−t TR . Accordingly, when t TR is larger, t LAT(PS) is smaller (compare FIGS. 3B and 3C ). Thus, the transceiver 220 B effectively adjusts the time delay to repeat signals from the primary channel 215 on the stick channel 275 C to compensate for the flight time down the primary channel in each direction. The result of this compensation is that the roundtrip latency between the master device and a stick channel (not counting t-stick TR or the latency required for the target memory device to respond) is aligned to a clock cycle boundary. Said another way, the round-trip latency between the master device and a stick channel is independent of the distance on the primary channel between the transceiver and the master device 210 .
[0034] FIG. 4 illustrates the response latency of a memory transaction in greater detail. As shown, the overall response latency perceived by the master device is made up of the following latencies:
1. Flight time on primary channel 215 from 0.5t TR master device 210 to transceiver 220 2. Time to cross transceiver 220 from primary t LAT(PS) = channel 215 to stick channel 275 (X cycles) − t TR 3. Flight time on stick channel from transceiver 0.5tstick TR 220B to memory device 260G 4. Response latency of memory device t DEVLAT 5. Flight time on stick channel from memory 0.5tstick TR device 260G to transceiver 220B 6. Time to cross transceiver 220 from stick t LAT(SP) = Y cycles channel 275 to primary channel 215 7. Flight time on primary channel 215 from 0.5t TR transceiver 220B to master device 210 Total (X + Y) cycles + t-stick TR + t DEVLAT
[0035] Note that, because the time to cross the transceiver 220 from primary channel 215 to stick channel 275 is compensated to account for the round trip flight time on the primary channel (t TR ), the primary channel flight time does not appear in the expression for total latency. More specifically, the round-trip latency between the master device 210 and the stick channel 275 (i.e., node N) is equal to X+Y cycles. By selecting X and Y to add to a whole number of clock cycles, the round-trip latency between the master device 210 and the stick channel 275 is effectively aligned with a clock for the primary channel (CTM 240 in the embodiment of FIG. 2 ). That is, the round-trip time from the master device 210 to a given stick channel is aligned on a clock cycle boundary. As discussed below, this latency alignment simplifies timing in the memory system significantly, allowing more efficient bandwidth utilization on the primary channel and stick channels than is achieved with the above-described prior art techniques. Referring to FIG. 2 , for example, by choosing X to be 2.5 clock cycles and Y to be 1.5 clock cycles (the timing shown in FIGS. 3A and 3B ), the roundtrip latency between master device 210 and any one of stick channels 275 A, 275 B and 275 C is aligned with every fourth clock cycle of CTM 240 . Consequently, the master device 210 may use the four clock cycles which follow a transmission to any of memory devices 260 B- 260 I to transmit or receive other information on the primary channel 215 .
[0036] FIG. 5 illustrates the scaleability of the above-described latency alignment technique and the manner in which programmable latency registers may be used in conjunction with latency-aligning transceivers to establish a flat response latency over an entire memory system. Memory system 700 includes a number of transceivers (T 1 -T 5 ) that each serve as bi-directional repeaters for respective stick channels ( 775 A- 775 E). Transceivers T 1 , T 3 and T 5 are each coupled to the primary channel 715 and include latency alignment circuitry that aligns the round-trip latency between the master device and stick channels 775 A, 775 C and 775 E, respectively, to an integer number of clock cycles, N. Transceivers T 2 and T 4 are hosted by stick channels 775 A and 775 C, respectively, and include latency alignment circuitry that aligns the round-trip latency between the respective masters (T 1 and T 3 ) for their host channels and stick channels 775 B and 775 D to the integer number of clock cycles, N. In one embodiment, N is equal to four so that the round-trip latency between master device 210 and stick channel 775 A is four clock cycles and the round-trip latency between master device 210 and stick channel 775 B is eight clock cycles. More generally, the latency from the master device 210 to a given stick channel is M×N, where M is the number of transceivers that must be crossed to reach the stick channel, and N is the latency-aligned, round-trip time from a master of a given host channel to a stick channel that is coupled to the host channel through a single transceiver.
[0037] Note that no matter how many transceivers must be crossed in the memory system of FIG. 5 , the overall round-trip time between master device 210 and any stick channel in the memory system is aligned with the transmit clock of master device 210 (e.g., CFM 250 in FIG. 2 ). This enables construction of memory systems having large numbers of memory devices (“MEM” in FIG. 5 ) without loss of determinism in system timing. The intervals between command and response transmissions are well defined and may therefore be used for command and response pipelining.
[0038] Another benefit of the above-described latency-aligning tranceivers is that they may be used in conjunction with programmable-latency memory devices to provide a memory system with flat latency response. That is, the response latency of all memory devices may be made substantially equal, regardless of their proximity to the master device 210 . Referring to FIG. 5 , for example, memory devices hosted by stick channels 775 A, 775 C and 775 E may be programmed to delay their outputs by four clock cycles so that the overall response latency for all memory devices in the memory system is substantially equal (with sub-clock cycle variance due to relative positions of memory devices on their stick channels). Expressed analytically, the total response delay perceived by the master device 210 is:
(N×M)+t-stick TR +t DEVLAT +t DEV - PROG ,
[0039] where t DEV - PROG is the number of additional cycles of delay programmed within a given memory device, M is the number of transceivers that must be crossed to reach the stick channel that hosts the target memory device, and N is the latency-aligned, round-trip time from a master of a host channel to a stick channel coupled to the host channel through a single transceiver. Thus, to provide a flat response latency throughout the memory system, the delay time (t DEV - PROG ) for each memory device in the memory system may be set as follows:
No. Transceivers Separating Memory Device From Master Device 210 t DEV — PROG M 0 M-1 N M-2 2N . . . . . . 1 (M-1) × N 0 M × N
[0040] In this way, the total response latency will be substantially the same for each memory device in the memory system, regardless of the number of memory devices or stick channels in the memory system.
[0041] FIG. 6 is a block diagram of a transceiver according to one embodiment. The transceiver 220 receives the CTM 240 and CFM 250 clock signals from the master device. The transceiver 220 further receives host channel 410 . Host channel 410 transmits address and data information from the master device to the transceiver 220 . For one embodiment, host channel 410 is a parallel bus, having multiple conductors. For another embodiment, host channel 410 is a serial communication path. For another embodiment, host channel 410 may include multiple buses, such as an address bus and a separate data bus, or even multiple control paths.
[0042] The transceiver 220 acts as a slave device toward the master device 210 and includes a slave interface 420 to receive data and control signals from the master device via host channel 410 . To the master device, the transceiver 220 appears to be a memory device. Requests from the master device arrive at the transceiver in the CFM 250 timing domain, and responses are sent back to the master in the CTM 240 timing domain. The master device 210 does not need to be modified to interact with the transceiver.
[0043] On the stick channel 490 , the transceiver 220 functions as a master device, providing a master interface 430 to retransmit the requests/commands from the master device to the memory devices (or transceivers) coupled to stick channel 490 , and to forward responses from the memory devices to the master device via the slave interface 420 and host channel 410 . The memory devices perceive no difference in system operation resulting from the presence of transceiver 220 and therefore require no design modification.
[0044] The transceiver 220 provides the clock-from-transceiver (CFT) 290 and clock-to-transceiver (CTT) 280 signals to the memory devices and transceivers coupled to channel 490 . In one embodiment, CTE 270 is routed to the end of the stick channel where it is folded back to provide CTT 280 . As discussed above, CTT 280 is folded back away from the transceiver 220 to provide CFT 290 .
[0045] Data is transmitted to devices coupled to stick channel 490 in the CFT 290 clock domain and received from devices coupled to stick channel 490 in the CTT 280 clock domain.
[0046] For one embodiment, the transceiver 220 includes a stick transceiver 440 and a host transceiver 450 . The stick transceiver 440 transmits and receives data on the stick channel 490 . The host transceiver 450 transmits and receives data on the host channel 410 .
[0047] The transceiver 220 further includes a first synchronizing unit 460 . The synchronizing unit 460 synchronizes data transmitted from the memory channel to the stick channel to the CFT 290 . For one embodiment, the transceiver 220 may also include a second synchronizing unit 470 for synchronizing signals transmitted from the stick channel 490 to the host channel 410 with CTM 240 . For one embodiment, the second synchronizing unit 470 may be omitted if the CTT clock is synchronized with one of the clocks on the memory channel (e.g., in an embodiment in which the stick clocks CTT and CFT are synchronized with CTM 240 ).
[0048] The transceiver 220 further includes an isolation unit 480 that operates to prevent the transceiver 220 from repeating signals onto either the host channel 410 or the stick channel 490 . For one embodiment, the isolation unit 480 asserts an isolate signal 595 to force both sets of bus driver circuits into a high-impedance (non-driving) state. Using the isolate feature, the transceiver 220 can effectively split a memory system into two partitions. In normal operation (not isolated), the transceiver 220 passes packets between the two partitions and the channel functions normally. When the transceiver's isolation unit 480 is enabled, the two partitions become electrically isolated and, if desired, each individual section can operate independently. This may be advantageous in certain graphics applications, for example with a frame buffer and normal (code and data) DRAMs sharing a single channel partitioned by a transceiver.
[0049] The transceiver 220 further includes a power logic 485 for turning off the transceiver 220 when it does not need to transmit. In one embodiment, power logic 485 merely turns off the stick transceiver 440 , so that signals received via host channel 410 are not retransmitted on stick channel 490 . Circuitry may be provided to interpret incoming addresses to determine whether they decode to memory devices coupled to stick channel 490 (or downstream stick channels). Stick transceiver 440 may then be selectively enabled and disabled depending on whether memory devices coupled to stick channel 490 are being addressed. For example, if a certain amount of time passes (or transactions detected) without memory devices coupled to stick channel 490 being addressed, power unit 485 may disable stick transceiver 440 to save power. Alternatively, transceiver 220 may power down stick transceiver 440 and other circuitry within transceiver 220 in response to a power-save command received on the host channel 410 . Also, in alternative embodiments, transceiver 220 may remain fully enabled at all times and power unit 485 may be omitted altogether
[0050] For one embodiment the transceiver 220 does not interpret incoming transmissions on the host channel and therefore does not respond to commands. That is, the transceiver 220 cannot be “addressed” by a master device (e.g., device 210 of FIG. 2 ). Consequently, in this embodiment the transceiver 220 does not include registers which may be read or written by a master device. In alternative embodiments, the transceiver 220 include command interpretation circuitry for parsing packetized commands or other transmissions received on the host channel. In these embodiments, the transceiver 220 may perform timing adjustments or other operations in response to commands from a master device. For example, the transceiver 220 may perform output driver calibration or other signal parameter calibration operations in response to commands from the master device. Also, instead of calibration, the transceiver 220 may receive control parameters from the master device and install them in appropriate registers to provide master-specified signal adjustments (e.g., adjustments to slew rate, drive strength, receive and transmit timing, equalization, reference voltage adjustment, clock duty cycle correction and so forth). Moreover, as discussed above, the transceiver 220 may enter a power-saving state in response to commands received on the host channel.
[0051] FIG. 7 illustrates the synchronization and transceiver logic of a transceiver 220 according to one embodiment. The transceiver 220 receives a host channel 570 that couples the transceiver 220 to a master device along with signal lines for clock signals CTM 240 and CFM 250 . Though not shown, the transceiver 220 may also include isolation circuitry and power saving circuitry as described above in reference to FIG. 6 .
[0052] The transceiver 220 also receives signal lines for clock signals CTE 580 , CTT 585 and CFT 590 along with a stick channel 575 that couples the transceiver 220 to memory devices and/or other transceivers.
[0053] The transceiver 220 includes a phase locked loop (PLL) 510 which performs a clock recovery function, generating a buffered output 512 in phase alignment with CFM 250 . This recovered version of CFM 250 is input to the primary receiver 515 where it is used to time reception of signals from the host channel 570 . The transceiver 220 also includes PLL 525 to generate a recovered version of CTM 240 (i.e., buffered output 527 ) for clocking primary transmitter 520 . A PLL 550 is used to generate CTE 580 for the stick channel such that CTT 585 arrives at the transceiver 180 degrees out of phase with CTM 240 . This inverted version of CTM 240 is designated “stick clock” in FIG. 7 . PLL 545 is also used to generate a clock signal 529 that is 180 degrees out of phase with CTM 240 (i.e., in phase with the stick clock) for clocking the secondary receiver 540 . The 180 degree phase offset between CTM 240 and the stick clock permits the latency between reception of signals in secondary receiver and retransmission of the signals at the primary transmitter 520 to be aligned on half-clock cycle boundaries (e.g., 1.5 clock cycles as shown in FIG. 3A ).
[0054] Because transceiver 220 receives data from the host channel 570 in response to edges of CFM 250 and then retransmits the data on the stick channel in response to edges of CTM 240 , the time required to cross the transceiver in the direction of the stick channel (t LAT(PS) ) is compensated by the amount of time by which CFM 250 lags CTM 240 . That is, t LAT(PS) is equal to the number of cycles of CTM 240 that transpire during the transceiver crossing, less t TR . By contrast, data crossing the transceiver in the direction of the host channel 570 is both received and retransmitted in response to clock edges aligned with edges of CTM 240 (StickClk being an inverted version of CTM 240 ). That is, t LAT(SP) is equal to the number of cycles of CTM 240 consumed crossing the transceiver without compensation for t TR . This asymmetry between t LAT(PS) and t LAT(SP) results in a bidirectional transceiver crossing time that includes compensation for t TR , thus causing the round-trip latency between the master device and a given stick channel to be aligned to the CTM 240 clock.
[0055] Transceiver 220 also includes a re-timing circuit 530 that delays the data transfer between the primary receiver 515 and the secondary transmitter 535 when t TR becomes so small that half clock cycle boundary may be crossed. More specifically, re-timing circuit 530 determines the phase difference (t TR ) between the recovered versions of CTM 240 and CFM 250 and selects between a delayed and a non-delayed path for transferring data from primary receiver 515 to secondary transmitter 535 , ensuring that the overall t LAT(PS) is a fixed number of clock cycles less t TR .
[0056] FIG. 8 is a diagram of a transceiver that includes circuitry for preventing a latch-up condition. Latch-up occurs when data received from a first channel and transmitted to the second channel is detected on the second channel, and promptly retransmitted to the first channel. This feedback latches the device into a state.
[0057] Portions of the transceiver have been omitted from FIG. 8 for simplicity. Only the primary receiver 515 , primary transmitter 520 , secondary transmitter 535 , secondary receiver 540 , and re-timer 530 are shown.
[0058] A latch-up prevention logic 610 is placed between primary receiver 515 and primary transmitter 520 . A similar latch-up prevention logic 620 is placed between secondary transmitter 535 and secondary receiver 540 . The latch-up prevention logic 610 receives an input from the primary receiver 515 and from the secondary receiver 540 . The output of the latch-up prevention logic 610 is coupled to a disable logic (DL) 630 in the primary transmitter 520 . Similarly, the latch-up prevention logic 620 receives an input from the secondary receiver 540 and the primary receiver 515 . The output of the latch-up prevention logic 620 is coupled to a disable logic (DL) 640 in the secondary transmitter 535 . Pin 680 is coupled to the host channel 570 (not shown), while pin 690 is coupled to stick channel 575 (not shown).
[0059] When the primary receiver 515 receives data from the host channel 570 , it sends a disable signal through node 517 to the latch-up prevention logic 610 . The latch-up prevention logic 610 sends a disable signal to the primary transmitter's disable logic 630 . The disable logic 630 prevents the primary transmitter 520 from transmitting information received from the secondary transceiver 540 for a period of time. The disable signal is also sent to the disable logic (DL) 625 of latch-up prevention logic 620 . The disable signal turns off the latch-up prevention logic 620 . The data received by the primary receiver 515 is transmitted, through the secondary transmitter 535 to the stick channel. When the secondary receiver 540 receives the same data from the stick channel, the latch-up prevention logic 620 is already disabled, preventing the turning off of the secondary transmitter 535 . Furthermore, the primary transmitter 520 is already disabled, preventing the retransmission of the data to the host channel. In this manner, the latch-up prevention logic 610 prevents the system latch up.
[0060] The latch-up prevention logic 610 , 620 releases their transmitter, 520 and 535 respectively, after the entire data is transmitted by the primary receiver 515 .
[0061] Similarly, if data is first received on the stick channel by the secondary receiver, latch-up prevention logic 620 disables secondary transmitter 535 through disable logic 640 . The disable signal further disables latch-up prevention logic 610 through disable logic 615 . Using the above-described latch-up prevention logics, the danger of latch-up is avoided.
[0062] For one embodiment, the latch-up prevention logic 610 may be implemented as an AND gate and an inverter, such that the output of the secondary receiver 540 is inverted, and coupled as an input to an AND gate. The other input to the AND gate is the logic from the primary receiver 515 . In this way, only when the output of the primary receiver 515 is on, while the output of the secondary receiver 540 is off, does the latch-up prevention logic 610 output its disable signal.
[0063] Although the exemplary embodiments of latency-aligning receivers and systems and methods for incorporating latency-aligning receivers have been described in terms of memory systems. It will be appreciated that the concepts and principles disclosed are not limited to memory systems, but rather may be applied in any system where it is desirable to increase the number of devices attached to a communication path without overloading the communication path or complicating system timing. More generally, though the invention has been described with reference to specific exemplary embodiments thereof, it will be evident that various modifications and changes may be made thereto without departing from the broader spirit and scope of the invention as set forth in the appended claims. The specification and drawings are, accordingly, to be regarded in an illustrative rather than a restrictive sense. | A transceiver comprises a first interface to receive a first signal, through a first channel, from a memory device. A transmitter transmits a second signal that represents the first signal, through a second channel, to a master device. A plurality of registers stores a plurality of values provided by the master device. The plurality of values includes a first value that specifies a transmit timing adjustment to the second signal to transmit to the master device by the transmitter. | 6 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates, in general, to microwave amplitude commutation feed devices, but more specifically it relates to a coaxial waveguide amplitude commutation network configured to operate compatibly with a scanning circular array antenna.
2. Description of the Prior Art
RF feed network implementation has been recognized as a critical problem area in scanning circular array antenna systems. A fundamental requirement of the rf feed network is the capability to commutate a desirable low-sidelobe amplitude distribution about the periphery of the circular array antenna in such a manner that a given number of radiating elements in a 180° or smaller sector is excited at any instant of time. The rf feed implementation trade-off is usually one of physical complexity with the accompanying insertion-loss and tolerance control problems versus the ultimate desire of complete commutation capability of the ideal complex amplitude distribution, i.e., the desirable amplitude distribution magnitude and the requisite phase characteristics for plane-wave generation from a circular sector boundary. The network implementation problem is one of practical rather than theoretical realizability and a number of rf feed networks have been developed to cope with the circular array antenna geometry. Among these have been the R-2R lens feed [1], the Butler Matrix feed [2], the transfer switch matrix feed [3], and the waveguide commutator feed [4]. Various other feasible circular array feed configurations have also appeared in the prior art but they can essentially be categorized as one or a combination of the basic four feed types aforementioned.
The referenced feed networks all possess the desired capability of performing the amplitude commutation function, but each configuration is associated with one or more undesirable physical or performance attributes which most frequently reside in the areas of design complexity, rf output amplitude and phase tolerance control, insertion loss, or bandwidth limitations. The coaxial waveguide commutation feed network, according to the present invention, is characterized by simplicity of configuration with a resultant significant overall improvement in the critical cited performance areas. A key element of the coaxial waveguide commutation feed network is a coaxial waveguide commutator similar in performance capability to the radial waveguide design developed previously [4] but without the bandwidth limitations inherent in this nonuniform transmission-line device [5]. Some unique features of the coaxial waveguide commutation feed network are a simple coaxial input probe excitation implementation technique and the capability of an rf bandwidth in excess of 30-percent with respect to the mid-band frequency at which the coaxial waveguide commutator is tuned. The tuning devices of the present invention can be employed to tune to different mid-band frequencies while maintaining the 30-percent rf bandwidth operation. A dominant TEM mode and a pair of orthogonal TE 11 modes excited within the coaxial waveguide commutator are employed to generate a commutatable low-side-lobe amplitude distribution about the periphery at its output ports.
An exemplary sample of a network for supplying rf power to a plurality of radiators in a phased array according to a desired distribution pattern is disclosed in U.S. Pat. No. 4,005,379 to Lerner entitled "R.F. Distribution Network for Phased Antenna Array," issued on Jan. 25, 1977 from application Ser. No. 628,469, filed Nov. 4, 1975. In Lerner, a TEM mode and a pair of selectively phase shifted TE 11 modes are derived and applied to input ports of a cavity resonator to produce the desired rf power distribution at a plurality of output ports. The cavity resonator is a cylindrical member in which the output ports are arranged circumferentially about the periphery and axially spaced from the TE 11 mode input ports.
Lerner uses a single probe to excite the dominant TEM mode in the coaxial section of the cavity resonator, and a pair of probes to excite a single TE 11 mode, plus another pair of probes to excite an orthogonal TE 11 mode. Using only a single probe pair to excite a TE 11 mode limits the bandwidth capability compared to four-probe excitation in a coaxial waveguide. Consequently, there is a need in the prior art to configure a coaxial waveguide commutation network to including four-port feeding to inhibit the higher order TE modes thereby increasing the bandwidth capability.
Lerner also uses a 3db coupler, a pair of phase shifters, and a pair of baluns to achieve the excitation of the pair of TE 11 modes. This arrangement appears to be inherently more difficult to align and to control so as to produce the selective phasing required between the pair of TE 11 modes and the TEM mode so that the low-sidelobe amplitude distribution can be rotated about the output ports. Hence, there is a need in the prior art to configure networks of the kind discussed to have broadband capability while maintaining simplicity in configuration and alignment, and reliability in performance.
Additionally, Lerner does not incorporate any special impedance matching techniques to provide a smooth impedance transition for the dominant TEM mode from the input ports to the output ports of the commutator. Thus, there is a need in the prior art to provide a smooth impedance transition to further enhance bandwidth.
The prior art, as indicated hereinabove, include some progress in implementing feed networks to cope with the special problems inherent in the circular array antenna geometry. However, insofar as can be determined, no prior art network or method incorporates all of the features and advantages of the present invention.
OBJECTS OF THE INVENTION
Accordingly, an important object of the present invention is to configure, in an improved manner, a broadband version of a coaxial waveguide commutation feed network.
Another important object of the present invention is to be able to interface the improved coaxial waveguide commutation feed network to a scanning circular phased array antenna while maintaining the broadband operation.
Yet another important object of the present invention is to increase the bandwidth of the coaxial waveguide commutation feed network while maintaining its inherent low insertion loss.
A further important object of the present invention is to configure the improved coaxial waveguide commutator portion of the present invention to include a tapered inner conductor to produce a smooth impedance transition for the dominant TEM mode thereby enhancing bandwidth.
Still a further object of the present invention is to configure the coaxial waveguide commutation feed network to include balanced four-port feeding to inhibit the higher order TE modes thereby increasing the bandwidth capability.
Yet a further important object of the present invention is to carry-out the foregoing objects while maintaining simplicity in configuration and alignment, and reliability in performance.
SUMMARY OF THE INVENTION
The coaxial waveguide commutation feed network, according to the present invention, by which the foregoing and other objects, features and advantages are accomplished is characterized, inter alia, by a K db coupler, a variable power divider and a monopulse bridge comparator in combination with a coaxial waveguide commutator.
An rf input is divided into two outputs via the K db coupler. One of these outputs is the input to the sum port of the monopulse bridge comparator. The four outputs of the monopulse bridge comparator are connected to four symmetrically disposed input ports (probes) of the coaxial waveguide commutator. Thus, the sum port input to the monopulse bridge comparator excites the TEM mode in the coaxial waveguide commutator. The second output from the K db coupler is the input to the variable power divider. The variable power divider outputs are the inputs to the difference ports of the monopulse bridge comparator. Consequently, the variable power divider excites a pair of spatially orthogonal TE 11 modes in the coaxial waveguide commutator.
BRIEF DESCRIPTION OF THE DRAWINGS
The foregoing and other objects, novel features and advantages of the present invention will be more apparent from the following more particular description of the preferred embodiment as illustrated in the accompanying drawings,in which:
FIG. 1 is a pictorial and schematic representation of the coaxial waveguide commutation network, including a K db coupler, a variable power divider, a monopulse bridge comparator, and a coaxial waveguide commutator, according to the present invention;
FIG. 2 is a perspective view of the coaxial waveguide commutator of FIG. 1 in partial section and partially cut-away to show in more detail the pertinent parts and their interconnects, according to the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The following is a brief description of the coaxial waveguide commutation feed network, according to the present invention, for use with a scanning circular phased array antenna.
Referring then to FIG. 1, coaxial waveguide commutation feed network 10 comprises a K db coupler 12 having an input port 14, a pair of output ports 16 and 18, and a suitably terminated isolated port 20. Output port 16 of K db coupler 12 is coupled to an input port (sum port) 22 of a monopulse bridge comparator 24, via a suitable transmission line 26. The other output port 18 of K db coupler 12 is operatively coupled to the input port 28 of a variable power divider 30, via a suitable transmission line 32. A pair of output ports 34 and 36 of variable power divider 30 are operatively connected to input ports (difference ports) 38 and 40, respectively, of monopulse bridge comparator 24, via suitable transmission lines 42 and 44, respectively. Variable power divider 30 further includes a suitably terminated difference port 46, and monopulse bridge comparator 24 further includes a suitably terminated isolated port 48. Four output ports 50, 52, 54, and 56 of monopulse bridge comparator 24 are coupled to four corresponding symmetrically disposed input ports 58, 60, 62 and 64, respectively, of a coaxial waveguide commutator 66, via suitable transmission lines 68, 70, 72 and 74, respectively. Coaxial waveguide commutator 66 is terminated in a plurality of symmetrically disposed (with respect to input ports 58, 60, 62 and 64), output ports 76.
Referring now to FIG. 2, coaxial waveguide commutator 66 further comprises a uniform tube outer conductor 78, a linearly tapered inner conductor 80 coaxially disposed within uniform tube outer conductor 78, defining therebetween a central region of linear taper 82. The aforementioned conductors are affixed at their input ends to an input endplate 84 and at their output ends to an output endplate 86. For purposes of tuning at the input port plane defined by input ports 58, 60, 62 and 64, an input annular shorting ring 88 is disposed contiguously between uniform tube outer conductor 78 and linearly tapered inner conductor 80 in a non-tapered input region 90 defined thereby. Input annular shorting ring 88 is slidable and acts to short out a portion of coaxial waveguide commutator 66 at its input end. Input annular shorting ring 88 is connected to a movable input mounting plate 92 via a plurality of operatively connected and symmetrically disposed connecting rods 94. An input tuning adjustment screw 96 is threadedly journaled into both input endplate 84 and movable input mounting plate 92. Input tuning adjustment screw 96 is also fixedly connected to an input tuning knob 98 which, in turn, is fixedly and rotatably attached to movable input mounting plate 92. Consequently, when input tuning knob 98 is turned clockwise, movable input mounting plate 92 moves inward thereby moving input annular shorting ring 88 inward. The converse is true when input tuning knob 98 is turned counter-clockwise. An optimum impedance match occurs at the input port plane when input annular shorting ring 88 is approximately one-quarter of a TEM mode wavelength at mid-band frequency from the aforementioned input port plane.
Still referring to FIG. 2, for purposes of tuning at the output port plane defined by plurality of output ports 76, an output annular shorting ring 100 is disposed contiguously between uniform tube outer conductor 78 and linearly tapered inner conductor 80 in a non-tapered output region 102. Output annular shorting ring 100 is slidable and acts to short out a portion of coaxial waveguide commutator 66 at its output end. Output annular shorting ring 100 is connected to a movable output mounting plate 104 via a plurality of operatively connected and symmetrically disposed output connecting rods 106. An output tuning adjustment screw 108 is threadedly journaled into both output endplate 86 and movable output mounting plate 104. Output tuning adjustment screw 108 is also fixedly connected to an output tuning knob 110 which, in turn, is fixedly and rotatably attached to movable output mounting plate 104. Thus, when output tuning knob 110 is turned clockwise, movable output mounting plate 104 moves inward thereby moving output annular shorting ring 100 inward. The converse is true when output tuning knob 110 is turned counter-clockwise. Here also, an optimum impedance match occurs at the output port plane when output annular shorting ring 100 is approximately one-quarter of a TEM mode wavelength at mid-band frequency from the aforementioned output port plane.
It should be noted that input probes 112 and output probes 114 of input ports 58, 60, 62 and 64, and plurality of output ports 76, respectively, are contoured, as shown, to facilitate impedance matching.
STATEMENT OF THE OPERATION
Details of the operation, according to the present invention, are explained in conjunction with FIGS. 1 and 2 viewed concurrently. The rf input at sum port 14 is divided into a TEM path signal and a TE 11 path signal at output ports 16 and 18, respectively, of K db coupler 12. The TEM path signal at output port 16 is the input to sum port 22 of monopulse bridge comparator 24. The four output ports 50, 52, 54 and 56 of monopulse bridge comparator 24 are connected to four symmetrically disposed input ports 58, 60, 62, and 64, respectively, of coaxial waveguide commutator 66. The TEM path signal at sum port 22 of monopulse bridge comparator 24 excites the TEM mode in coaxial waveguide commutator 66 because the signals on output ports 50,52,54 and 56 are split into equal parts having the same amplitudes and phases. The TE 11 path signal at output port 18 of K db coupler 12 is the input signal to variable power divider 30. Variable power divider 30, for purposes of the present invention, can be equivalent to the device of reference [6] which employs a magic tee, a 90° hybrid, and a pair of differential phase shifters for controlling the relative magnitudes of the rf outputs. A special and desirable feature of variable power divider 30 is that output ports 34 and 36 phase track each other. The output signals at output ports 34 and 36 of variable power divider 30, which are variable amplitude TE 11 path signals, are the inputs to difference ports 38 and 40, respectively, of monopulse bridge comparator 24. The TE 11 path signal at difference port 38 of monopulse bridge comparator 24 excites a TE 11 mode in coaxial waveguide commutator 66 because, inter alia, the signals on the output ports 50,52,54 and 56 are split into equal parts having the same amplitudes. The pair of signals at output ports 50 and 52 have equal phases and the pair of signals at output ports 54 and 56 have equal phases. But the phase difference between the pair of signals is 180°. Conversely, the other TE 11 path signal at difference port 40 excites another TE 11 mode in coaxial waveguide commutator 66 because although the signals of the aforementioned output ports are split into equal parts having the same amplitudes and the pair of signals at output ports 50 and 56 have the same phases and the pair of signals at output ports 52 and 54 have the same phases, the phase difference between the pair of signals is 180°. Consequently, variable power divider 30 excites a pair of spatially orthogonal TE 11 modes in coaxial waveguide commutator 66.
For purposes of the present invention, coaxial waveguide commutator 66 is a traveling wave device which is terminated in a plurality of output ports 76 (for example sixteen ports) symmetrically disposed with respect to input ports 58, 60, 62 and 64. In the output port plane defined by output ports 76 of coaxial waveguide commutator 66, a radial electric field intensity of the form ##EQU1## will exist by a superposition of the functionally orthogonal TEM and TE 11 mode pairs. The first term on the right of (1) is the constant contribution from the TEM mode. The remaining two terms are characterized by the sin φ, cos φ, angular variation of the spatially orthogonal TE 11 modes with the magnitude proportionality factors sin α, cos α arising from the differential phase shift settings ##EQU2## of variable power divider 30. Equation (1) can be rewritten in the more recognizable consine-squared-on-a-pedestal form as
V(φ)=A+(1-A)cos.sup.2 1/2(φ-α) (2)
where the pedestal magnitude A is related to the coupling coefficient of K db coupler 12 as ##EQU3##
An inspection of (2) reveals that a low-sidelobe amplitude distribution proportional to V(φ) may be continuously commutated about the output periphery in the output port plane by a continuous variation of α. Since a primary function of coaxial waveguide commutator 66 is to feed a circular array antenna, a variation of α in a digital manner will provide the necessary coarse commutation. The rf outputs of coaxial waveguide commutator 66 can be interfaced with an rf switch and phase shifter network as indicated (but not shown) in FIG. 1 prior to final termination at radiating element inputs of a circular array antenna (not shown). The rf phase shifters are employed for the dual functions of plane wave collimation of the cylindrical wavefront and a fine beam steering capability between the coarse discrete beam positions provided by the present invention. A monopulse tracking capability may be added to coaxial waveguide commutation feed network 10 by employing isolated difference port 46 of variable power divider 30.
A L-band model of a coaxial waveguide commutation feed network 10 including a coaxial waveguide commutator 66, according to the present invention, was designed, fabricated and tested verifying the disclosed circular array feed technique. The results of the test program, including coaxial waveguide commutator 66 measurements, array antenna pattern performance predictions and specific design criteria, are disclosed in [7].
While the present invention has been particularly described with reference to the preferred embodiment thereof, it will be understood by those skilled in the art that various changes in form and detail can be made therein without departing from the spirit and scope thereof.
REFERENCES
[1] J. E. Boyns, et. al., "A Lens Feed for a Ring Array", IEEE Trans. on Ant. and Prop., Vol. AP-16, No. 2 pp. 264-267, Mar. 1968.
[2] B. Sheleg, "A Matrix-Fed Circular Array for Continuous Scanning", Proc. of IEEE, Vol. 56, pp. 2016-2027, Nov. 1968.
[3] R. S. Giannini, "An Electronically Scanned Cylindrical Array Based on a Switching and Phasing Technique", IEEE Int. Symp. Ant. and Prop. Digest, pp. 199-207, Dec. 1969.
[4] B. F. Bogner, "Circularly Symmetric RF Commutator for Cylindrical Phase Arrays", IEEE Trans. on Ant. and Prop., Vol. AP-22, No. 1, pp. 78-81, Jan. 1974.
[5] N. Marcuvitz, "Waveguide Handbook", MIT Radiation Laboratory Series, Vol. 10 McGraw Hill Book Co., 1951.
[6] A. R. Dion, L. J. Ricardi, "A Variable Coverage Satellite Antenna System", IEEE Proceedings, Vol. 59, No. 2, Feb. 1971, pp. 252-262.
[7] E. P. Irzinski, "A Coaxial Waveguide Commutator Feed for a Scanning Circular Phased Array Antenna", IEEE Trans. on Microwave Theory and Techniques, Vol. MTT-29, No. 3, pp. 266-270, Mar. 1981. | A dominant TEM mode and a pair of spatially orthogonal TE 11 modes suitably excited at the input ports of a coaxial waveguide commutator portion of a coaxial waveguide commutation feed network are employed to generate a commutatable low-sidelobe amplitude distribution at symmetrically disposed peripheral output ports of the coaxial waveguide commutator. The resulting low-sidelobe amplitude distribution can be used to feed radiating elements of an associated circular phased array antenna. The coaxial waveguide commutator is configured, inter alia, with a linearly tapered inner conductor surrounded by a uniform tube outer conductor to achieve a smoother TEM-dominant mode characteristic impedance transition from the input port plane to the output port plane thereof. Employment of this feed geometry, in conjunction with balanced four-port feeding of the coaxial waveguide commutator which inhibits the higher order TE modes, increases the bandwidth capability while maintaining low insertion loss. | 7 |
FIELD OF THE INVENTION
[0001] The present invention relates generally to the field of software development using a software framework. More particularly, the present invention relates to giving a framework module access to the call stack of the operating system in order to ensure proper functioning of the framework module.
BACKGROUND
[0002] Software developers frequently look to reuse portions of old computer code when developing new software applications. Reusing software speeds up development of new programs and leads to unified solutions that have similar behavior and exhibit similar problems, thus making the processes of debugging and updating easier. Prior to writing new applications, software developers may research and identify existing software that might have reusable portions. When writing new applications without the use of old software, a developer may do so with the intent of developing central services or frameworks that can be used for later products.
[0003] Software developers use frameworks to aid in software development by eliminating a need for redeveloping portions of code for features that appear in multiple applications. For example, a developer might design customized databases for its customers. Although every database will be unique depending on a particular customer's desires, certain features, such as saving data, printing screens, navigating from one screen to another, and so on, will be apparent in all or most of the databases. Rather than recoding this functionality every time the developer creates a new database, it would be more efficient to develop a framework for handling these features. Any given new database program may be a combination of application modules and framework modules, with the application modules being unique to each particular database program and the framework modules being common between multiple database programs.
[0004] When a framework module or other type of coding is reused, the reused portions of the code need to be correctly accessed, meaning they must be accessed in the way they were intended to be accessed or else they might not function properly. For example, a framework module may have dependencies such as a single module must have been executed before, a sequence of modules must have been executed before, different sequences of modules must have been executed before, a certain module must not have been executed before, or a certain module must not have been executed in a certain order before. Embodiments of the present invention provide an improved system and method for determining if these dependencies have been met, thus improving the efficiency and ease associated with using a software framework to develop new computer programs.
BRIEF DESCRIPTION OF THE DRAWINGS
[0005] FIG. 1 is a block diagram showing an example computer network in accordance with an embodiment of the present invention.
[0006] FIG. 2 is a block diagram showing an example structure of a workstation which may be a part of the example computer network of FIG. 1 .
[0007] FIG. 3 is a flow chart showing an example method in accordance with an embodiment of the present invention.
[0008] FIG. 4 is a flow chart showing an example method in accordance with an embodiment of the present invention.
DETAILED DESCRIPTION
[0009] Embodiments of the present invention may include giving framework modules access to the call stack of an operating system in order to ensure proper functionality of the framework module. Embodiments of the present invention may include storing images of call stacks as framework modules are called so that future framework modules can analyze prior call stacks. Embodiments of the present invention may be implemented on a single computer or over a computer network.
[0010] FIG. 1 shows the components of a computer network architecture that may be used implement embodiments of the present invention. The system may contain a user terminal 110 and one or more remote terminals 120 connected through a network 130 . The various components and modules described in the present application may be centrally located on the user terminal 110 or may be distributed over the network on the remote terminals 120 . Additionally, the various modules and components can be accessible from any of the remote terminals 120 as well as the user terminal 110 .
[0011] One or more of the terminals 110 , 120 may be personal computers, computer workstations, handheld personal digital assistants (“PDA”), or any other type of microprocessor-based device. The network 130 may be a local area network (LAN), wide area network (WAN), remote access network, an intranet, or the Internet, for example. Network links for the network 130 may include telephone lines, DSL, cable networks, T1 or T3 lines, wireless network connections, or any other arrangement that implements the transmission and reception of network signals. However, while FIG. 1 shows the terminals 110 , 120 connected through a network 130 , the terminals 110 , 120 may be connected through other means, including directly hardwired or wirelessly connected. In addition, the terminals 110 , 120 may be connected to other network devices not shown, such as wired or wireless routers and servers. The terminals 110 , 120 may also be connected to one or more peripheral devices, such a local or network printer, mouse, display, storage drives, etc.
[0012] FIG. 2 illustrates a possible configuration of a user or remote terminal 110 , 120 A terminal may include a controller/processor 210 , memory 220 , display 230 , database interface 240 , input/output device interface 250 , and network interface 260 , connected through a bus 270 .
[0013] The controller/processor 210 may be any programmed processor known to one of skill in the art. However, the concepts of the present invention can also be implemented on a general-purpose or a special purpose computer, a programmed microprocessor or microcontroller, peripheral integrated circuit elements, an application-specific integrated circuit (ASIC) or other integrated circuits, hardware/electronic logic circuits, such as a discrete element circuit, a programmable logic device, such as a PLD, PLA, FPGA, or PAL, or the like. In general, any device or devices capable of implementing a framework based software application can be used to implement aspects of the present invention.
[0014] The Input/Output interface 250 may be connected to one or more input devices that may include a keyboard, mouse, pen-operated touch screen or monitor, voice-recognition device, or any other device that accepts input. The Input/Output interface 250 may also be connected to one or more output devices, such as a monitor, printer, disk drive, speakers, or any other device provided to output data.
[0015] The memory 220 may include volatile and nonvolatile data storage, including one or more electrical, magnetic or optical memories such as a RAM, cache, hard drive, CD-ROM drive, tape drive or removable storage disk.
[0016] The network interface 260 may be connected to a communication device, modem, network interface card, or any other device capable of transmitting and receiving signals over a network 130 . The components of the terminals 110 , 120 may be connected via an electrical bus 270 , for example, or linked wirelessly.
[0017] Client software and databases may be accessed by the controller/processor 210 from memory 220 or through the database interface 240 , and may include, for example, database applications, word processing applications, the client side of a client/server application such as a billing system, as well as components that embody the decision support functionality of the present invention. The terminals 110 , 120 may implement any operating system, such as Windows or UNIX, for example. Client and server software may be written in any programming language, such as ABAP, C, C++, Java or Visual Basic, for example.
[0018] A system embodying aspects of the present invention is configured to assure proper framework access by creating a call stack by the operating system, providing the call stack to framework modules, and having the framework module evaluate the call stack to assure a correct sequence order of calls.
[0019] An operating system can be configured to log all modules that are called during program execution on a call stack stored in RAM. Whenever a module is called, the name of the module can be put on top of the call stack, and whenever the module is exited, it can be “popped,” or removed, from the call stack. In a prior art system, the call stack is usually stored in a local memory area, giving the called modules no access to it.
[0020] An embodiment of the present invention includes making the call stack available to the framework modules. A kernel function can be provided so that the framework module might call to retrieve the current call stack from the operating system. The framework module can receive a list of all modules being called on the path to the current module and can store that list in RAM, as a file on a hard drive, or in any other form known in the art. For example, assume, the following modules might be called in the following sequence order: A-B-C-D, meaning module A calls module B, which calls module C which calls Module D. In such an example, module D would retrieve from the operating system the following call stack:
[0000]
Level
Module
1
A
2
B
3
C
4
D
[0021] Module B would only have two hierarchy levels and would retrieve the following call stack:
[0000]
Level
Module
1
A
2
B
[0022] After receiving the call stack from the operating system, the called module can evaluate the call stack to check which other modules were called prior to the module itself. For example, if framework module X (F-X) evaluates the call stack, it might find a list of modules on the call stack that either belong to the framework as well (i.e. modules, which are known to module X, because they belong to the same framework—in the following donated with prefix “F”) or do not belong to the framework, but instead belong to the application using the framework. Thus a call stack might for example look like as follows:
[0000]
Level
Module
Framework/application
1
A
application
2
B
application
3
C
application
4
F-U
framework
5
D
application
6
F-V
framework
7
F-X
framework
[0023] Module F-X might implement certain functionality. This functionality might only work correctly if another framework module (e.g. F-U) has been called in advance. An embodiment of the present invention allows module F-X to check if module F-U has already been called by evaluating the call stack. If module F-U has not been called, then module F-X can react accordingly, for example by showing an error message or raising a proper system exception.
[0024] Module F-X might have multiple dependencies and multiple prerequisites necessary for proper functionality. For example, a prior call to a certain framework module might be required but missing, a framework module called before must not be called because it is incompatible with module F-Z, multiple required framework modules were called prior but in a wrong sequence order, or the call stack level of a prior framework module call is wrong (i.e. the module call is required, but on a different call stack level).
[0025] If a module such as F-X could not evaluate the call stack and had to continue with its functionality assuming that module F-U had been called, the system behavior would not be well defined. Depending on circumstances, the system might work as excepted; however, it might be that the system runs into a system exception because necessary data is missing. In a particularly undesirable scenario, everything might seem to be working correctly for a period of time but result in a malfunction of the system at a much later point in time. Such a situation may be particularly undesirable when developing software because errors of this nature can be difficult to identify and debug. For example, an error caused by one portion of code might not manifest itself until a much later time when a different portion of code is being developed. An embodiment of the present invention includes allowing a module to access the call stack, and thus verify the prerequisites for proper functionality at the time the module is called rather than having errors manifest themselves later in time.
[0026] FIG. 3 shows an example of a process embodying aspects of the present invention. The process might start when a program or sub-program is initialized (block 300 ). An application module (INITIALIZATION) might send a first screen to the computer display. After the user performs some functions on the first screen, the software might call a framework module (INVOKE_SCREEN) to trigger the displaying of a second screen (block 3 10 ). The INVOKE_SCREEN module might check to see if the second screen replaces the currently displayed first screen, and if it does, it might store all the properties of the currently displayed first screen in order to enable backward navigation. The INVOKE_SCREEN module can then call another application module (SCREEN 2 ) (block 320 ). The SCREEN 2 module can store data, user interface elements, and functions as a parameter. The SCREEN 2 module can then call a framework module (DISPLAY_SCREEN) to actually show the screen (block 330 ). The DISPLAY_SCREEN module can produce a screen based on the parameters passed from the SCREEN 2 module. When the user executes a function on the second screen, the DISPLAY_SCREEN module can call an application module (HANDLE_FUNCTION) to execute the function (block 340 ). The HANDLE_FUNCTION module of the application can evaluate the function executed by the user and perform some actions before ending. The HANDLE_FUNCTION module can provide a return parameter to the DISPLAY_SCREEN module telling the framework, to hide the current screen and replace it with the previous screen. When the DISPLAY_SCREEN module detects that backward navigation should occur, it can retrieve the parameters of the previous screen that were stored during the method INVOKE_SCREEN and deliver those parameter to the DISPLAY_SCREEN module (path 345 ).
[0027] The process described above is summarized in the chart below:
[0000]
level
FW/A
Module
1
A
INITIALIZATION
2
FW
INVOKE_SCREEN
3
A
SCREEN2
4
FW
DISPLAY_SCREEN
5
A
HANDLE_FUNCTION
4*
FW
DISPLAY_SCREEN
[0028] The first column shows the call stack, i.e. the level of the current module call. Level 4* in the last row means, that level 5 was completed and control was given back to the DISPLAY_SCREEN module which belongs to level 4 again (i.e. after the HANDLE_FUNCTION module was exited, it was popped from the call stack). In level 4* the second screen should be closed and the first screen should be displayed again (with exactly the same data as it had before). Therefore the information about the first screen that was stored when the INVOKE_SCREEN was called has to be retrieved. If the application would not have called the INVOKE_SCREEN module before calling the DISPLAY_SCREEN module, the information would not be stored and backward navigation would not be possible. Therefore, when the application calls the DISPLAY_SCREEN module, it is essential that the INVOKE_SCREEN module has been called before it.
[0029] In accordance with embodiments of the present invention, the DISPLAY_SCREEN can access the call stack or an image of the call stack to check for the presence of the INVOKE_SCREEN module. If the INVOKE_SCREEN module is not present, then a suitable error message might be delivered to the user. In the context of developing and debugging new software applications, this error message can be extremely helpful to the software developers because it alerts them immediately to errors or bugs in the code that might otherwise not manifest themselves until later.
[0030] FIG. 4 shows another example of a process embodying aspects of the present invention. The process might start when a program or sub-program is initialized (block 400 ). An application module (INITIALIZATION) might initialize the application and perform some functions before calling a framework module (UPDATE_SETTINGS) to update some central settings (block 410 ). The UPDATE_SETTINGS module might verify that the user calling the module is authorized to apply the new settings, and if he is, call another framework module (UPDATE_DATABASE_W_SETTINGS) (block 420 ). The UPDATE_DATABASE_W_SETTINGS module might store the settings on the database. The process described above is described in the chart below:
[0000]
level
FW
Module
1
—
INITIALIZATION
2
X
UPDATE_SETTINGS
3
X
UPDATE_DATABASE_W_SETTINGS
[0031] The UPDATE_DATABASE_W_SETTINGS module can store the settings provided by the caller on the database making the settings globally available. However, for some kind of settings, the user might need a certain authorization to apply them. This authorization is checked in method UPDATE_SETTINGS. Thus, for certain kinds of settings, the application is not allowed to call the UPDATE_DATABASE_W_SETTINGS module directly, but has to call the UPDATE_SETTINGS module first. The UPDATE_DATABASE_W_SETTINGS module can verify this by evaluating the call stack. If the UPDATE_SETTINGS module is on the call stack just before the UPDATE_DATABASE_W_SETTINGS module, then the necessary prerequisites have been fulfilled for the UPDATE_DATABASE_W_SETTINGS module to execute.
[0032] An embodiment of the present invention includes giving a module access to not only the current call stack but also to call stacks from earlier calls of other framework modules. For example, a framework module F-V might access the following call stack and verify that framework module F-U has been previously called.
[0000]
Level
Module
Framework/application
1
A
application
2
B
application
3
C
application
4
F-U
framework
5
D
application
6
F-V
framework
[0033] If, however, the methods are finished and popped from the call stack, then the call stack may then look as follows:
[0000]
Level
Module
Framework/application
1
A
application
2
B
application
3
C
application
[0034] Later on, the application may call another framework module (F-W) and access the following call stack:
[0000]
Level
Module
Framework/application
1
A
application
2
B
application
3
C
application
4
F-W
framework
[0035] With this call stack, the framework module cannot verify anything because it only sees application methods on the call stack, and the framework does not know anything about application modules. However, it might be that framework module F-W only works correctly, if framework modules F-U and F-V have been previously called. As they are already finished, framework modules F-U and F-V are no longer on the call stack, but if the call stack was stored when the F-V module was last called, it may be made available to module F-W.
[0036] Storing a call stack can be done during each call of a framework method making all information of previously called modules available for later call stack evaluations when other modules are called. If certain framework modules do not have any dependency on other framework modules, then storing the call stack may not be necessary for those modules.
[0037] The foregoing description of embodiments is provided to enable a person skilled in the art to make and use the present invention. Various modifications to these embodiments will be readily apparent to those skilled in the art, and the generic principles and specific examples defined herein may be applied to other embodiments without the use of inventive faculty. For example, some or all of the features of the different embodiments discussed above may be deleted from the embodiment or may be combined with features of alternate embodiments. Therefore, the present invention is not intended to be limited to the embodiments described herein but is to be accorded the widest scope defined only by the claims below and equivalents thereof. | A computer program product, system and method for verifying a call stack is provided and includes framework modules accessing an image of a call stack, verifying the call stack is compatible with a called framework module, and performing a default operation if the call stack is not compatible with a called framework module. | 6 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a divisional of U.S. patent application Ser. No. 10/043,553, filed Jan. 11, 2002, which claims the benefit under 35 U.S.C. § 119(e) of Provisional Application, Serial No. 60/261662, filed on Jan. 11, 2001, entitled “Process and System for Sparse Vector and Matrix Representation and Computations,” both incorporated herein by reference.
FIELD OF THE INVENTION
[0002] The invention relates to the field of mathematics, and more particularly the computation of sparse matrixes. In mathematical terms, a vector is a sequence of integral keys and corresponding numeric values. A matrix is a two-dimensional grid of key-pairs with corresponding values, or equivalently a vector of vectors. In common practice, many matrices are “sparse,” meaning that the majority of the numeric values are zero. The building and manipulation of vectors and matrices is a common mathematical task. The amount of memory consumption and processor time is of critical interest in performing these tasks.
[0003] The word-indexing of a set of documents, such as those used in document search engines, can be modeled as a sparse matrix. Because it is desired to both build and query such matrices quickly, and because there data is essentially dispersed at random, they are particularly susceptible to any number of speed tradeoffs made in current sparse matrix implementations. Typically, a large set of documents are indexed by words they contain. The purpose of the index is to speed up the lookup of words. The words and the documents containing them are represented by a unique identifier, generally an integer. Such an index is a matrix wherein the word is the primary key, yielding vectors in which the document is the secondary key, and finally yielding values such as the occurrence frequency of said word. The invention presents a novel data structure representation for vectors and matrices. Further, the invention presents numerous implementations of common methods on such vectors and matrices. Finally, the invention is applied to improving the performance of document index building and querying.
BACKGROUND AND PRIOR ART
[0004] Manipulation of large sparse matrices is a common mathematical task. There are many applications that require a space and time efficient data structure and related methods to perform these computations. However, existing implementations suffer from poor performance in particular tasks, or are specific to matrices of a particular pattern.
[0005] To analyze the computational time and memory requirements required for processing an algorithm, standard asymptotic notation (O) will be used. “M” and “N” will represent vectors. “m” and “n” will represent the number of elements in the vectors, respectively.
[0006] Many data structures and methods have been used for sparse matrix tasks. The classic method is to simply use arrays to implement vectors, and two-dimensional arrays to implement matrices. There are several benefits to this approach. First and foremost, it is conceptually simple. The vector indices map conveniently onto the array indices, and the adjacency of the values stored in memory is pleasingly similar to how a human would represent them visually. Furthermore, it allows quick, i.e., constant, access time to each value. The usual primitive operations on vectors: addition, multiplication, etc., can all be implemented efficiently—in linear time with respect to the number of values.
[0007] However, the memory consumption of arrays is proportional to the product of the matrix dimensions. In other words, arrays store zero values and hence do not take advantage of the sparsity of the matrices. A word-document index may contain a large number of documents, as well as a large number of words. However, a majority of words in the language(s) do not occur in any particular document. Hence such an index is generally a large, but sparse, matrix. For this reason, there is considerable interest in other representations that only require memory allocation proportional to the actual number of nonzero values, while still achieving acceptable operation times.
[0008] One such representation make use of “compressed vectors”, which are generally stored as parallel arrays of key-value pairs. Pointers are eschewed, as they require additional memory to store the addresses. The key-value pairs can be sorted (by key) or unsorted. The usual tradeoffs apply. Sorted vectors yield a binary search algorithm resulting in O(log(n)) access time. Unsorted vectors requires a linear search algorithm, resulting in O(n) time. But maintaining sorted vectors result in extra overhead for insertion and deletion of entries; the worst-case being O(n) time. A search engineer then needs to process the vector of documents for each word in the query. In order to generate results that are more relevant from a search, it is typically desired that search engines be queried with multiple words, combined with an “AND” or “OR” operation. This in turn results in the merging of multiple word vectors, with a set-like operation of intersection or union. Keeping the vectors sorted thus yield much faster merging for multiple word queries, at the expense of more computation being done during the building of the index.
[0009] Compressed matrices consist of an array of compressed vectors keys, with a corresponding full array of compressed vector values. However, unless all the vectors of matrix have similar length, this will still result in a large amount of wasted memory. Such a representation is poor for document indexes because their vectors cannot be expected to be of similar size.
[0010] Compressed Sparse Row (or Column) is another common method for sparse matrix representation. The vectors are compressed in the usual manner and concatenated in an order according to their own key. A third array stores the start position of each vector. Access to a given vector is constant, access to a value is O(log(n)), and insertion/deletion is O(n{circumflex over ( )}2). Several variants with the same basic tradeoffs are available.
[0011] Storing the matrix relative to a Diagonal (or Skyline) method is also common. Generally these are used if values can be expected to be concentrated along the main diagonal of the matrix. Otherwise, memory reduction is not significant.
[0012] All of the above methods offer relatively slow value lookups: O(log(N)) or worse, and extremely poor modification penalties: at least O(n) and generally O(n{circumflex over ( )}2). Furthermore, irrespective of the data structure choice for matrices, unsorted compressed vectors and temporary full-size vectors are generally used in practice.
[0013] When a word-document index is queried, generally an entire vector is desired, not just one word-document value. Thus the relatively slow lookup times for individual values is not an issue. However, constructing such an index with O(n) insertion time results in an excruciatingly slow build time. Consequently, it is common to build a forward index first—document by word—and then invert the index—to word by document—for querying. By compiling all the values first, they can be sorted by word, thereby building the inverted index without the O(n) insertion hit.
[0014] But this common solution has several drawbacks. It requires a second pass through all the data, thus increasing the time to build the index. It also results in two distinct phases of indexing, a “build” phase and a “query” phase. Hence, the index cannot be effectively used while it is being built, and any updates to the documents cannot be quickly integrated into the index.
[0015] In addition to the above shortcomings, querying using compressed vectors can also yield sub-optimal performance times. A query is answered by acquiring the appropriate word vectors, and then merging them together. The merging operation may be as simple as adding the scores for each word-document value. Irrespective of what function is used to merge to values however, there is the overhead of the set operation used to combine the values at issue. Assume there are M query words each of which have any average word vector length of N. If the query is an OR of the words, these vectors must be unioned together. Hence, there are potentially O(M*N) result documents, which is a convenient lower bound for how long such a union operation can take. Unfortunately, if the vectors must be kept in a standard compressed format—even if they are sorted by document—the union operation can be shown to take O((M{circumflex over ( )}2)*N). It is typical to unpack each vector into an uncompressed format to overcome this. However, this workaround assumes there is sufficient memory to unpack a vector. It may be the case that the range of possible vector values is orders of magnitude larger than the actual size of the vectors, making this unreasonable in practice.
[0016] The situation is even worse in an AND operation, where the vectors need to be intersected. It can be easily shown that the intersection operation must take at least O(M*N) time, as all the values need to be scanned. In practice it may be even longer, depending on small the resulting vector is. Surprisingly, O(M*N) is not optimal in this case: all the values don't have to be scanned. Only the smallest vector remaining needs to be scanned to intersect it with another, and the result vector continues to get smaller. However, the standard algorithm cannot take advantage of this fact, nor does uncompressing the vector help the situation, because than the larger range of possible values must again be scanned.
[0017] In conclusion, it has been shown that the prior art methods of vector and matrix representation have several shortcomings, especially as related to common search engine operations. Both indexing and querying have sub-optimal operations with respect to time. It is therefore desirable to create a new implementation which improves operations to their optimal limits, while keeping the amount of memory consumed to be proportional to existing methods. This new implementation will require the use of an existing data structure: a hash table.
[0018] A hash function refers to mapping from an arbitrary domain to a restricted range, usually consisting only of integers and of smaller size. It performs a transformation that takes an input m and returns a fixed-size string, which is called the hash value h (that is, h=H(m)). Though the function cannot be one-to-one, it is desirable to have a minimal number of collisions (i.e., having more than one key map to the same position). Furthermore, it is generally desirable that the output of the function be statistically random, so that the hash values aren't clustered. Hash functions almost always end with a modulo operation, thereby yielding an integer in the desired range. For some applications, merely a modulo hash function is adequate.
[0019] Hash tables are a well-known data structure, in which keys are mapped to array positions by a hash function. The table is simply an array of key-value slots. Keys are processed through a hash function that yields an index of a slot in the table. Values are then inserted, deleted, or modified in the slot as necessary after a key lookup. The result is constant access time, albeit a higher constant than with arrays.
[0020] Collisions occur if two different keys hash to the same slot. There are generally two ways of resolving collisions. “Changing” refers to putting multiple values together, linked to the slot. As this requires the use of pointers, which result in additional memory and time overhead, it is often not preferred. “Open addressing” (or “open indexing”) is the alternate method of resolving collisions. In addition to the initial hash, there is a probe sequence based on the hash value that iterates until the correct slot, or an empty slot, is found. This probe sequence must be deterministic and never repeat a slot. There are several well-known algorithms for implementing such a sequence. Although collisions naturally increase access time, it can be shown the statistical expectation of look-up time is constant with reasonably sized hash tables. It is typical to keep the hash table half full, and double its size when growing, to achieve acceptable performance. Deletion is handled by inserting a dummy key into the empty slot. A dummy key is necessary to be distinguished from a null key, so that the probe sequence will continue if necessary.
OBJECT OF THE INVENTION
[0021] It is an object of the invention to present a novel data structure and applicable methods for sparse vectors and matrices computations with optimal operation limits, while keeping the amount of memory consumed to be proportional to existing methods. It is another object of the invention to present the following features: Modification of values occurring in constant time; Operations on vectors occurring in linear time as appropriate; and total memory consumption being linear with respect to the number of nonzero values.
[0022] It is a further object of the invention to combine these features to enable the sparse matrix representation to be used for a searchable word-document index to produce fast build and query times for document retrieval. The index could be built in linear time (with respect to the number of nonzero values), and can be queried in constant time. Furthermore, no conversion between build or query modes would be necessary. The index can be queried even as it is being built.
SUMMARY OF THE INVENTION
[0023] A new data structure and algorithms is presented which offer performance at least equal to the prior art in common sparse matrix tasks, and improved performance in additional tasks. Further, this representation is applied to a word-document index to produce fast build and query times for document retrieval.
[0024] Under this new data structure, matrices and vectors are represented as dictionaries of key-value pairs. A vector is a dictionary of integral keys and corresponding numeric values. A matrix is a dictionary of integral keys and corresponding vector values. The dictionaries themselves are implemented using hash tables. When a key is looked up, it is hashed, and its corresponding slot (which may be empty) is found in the hash table. The value of the slot is then retrieved, inserted, or deleted as appropriate. The hash function used is a modulo of the key itself.
[0025] The departure from more traditional representations in the prior art is that the context of the values are no longer relevant. Values are not kept sorted, or even spatially organized at all. The tradeoff is the emphasis on constant time access and modification, which is generally unavailable in other methods. Though it is not surprising that such a dictionary could be used to build a vector, the fact that the random organization of the values will be shown to be advantageous to numerous computations is novel and non-obvious.
[0026] The resulting implementation yields memory use that is comparable or better than other known methods, and at the same time yielding computation efficiencies that are comparable or better than other known methods. Further, certain computations will be shown to be superior to all known methods.
[0027] The constant insert and access time will be shown to implement an extremely fast document index. Additionally, fast set operations on the vectors will be shown to implement multiple word queries efficiently. See FIG. 1.
BRIEF DESCRIPTION OF THE DRAWINGS
[0028] [0028]FIG. 1 is an abstract representation of a document represented as a word vector.
[0029] [0029]FIG. 2 is an abstract representation of an inverted word matrix.
[0030] [0030]FIG. 3. is a representation of indexing steps.
[0031] [0031]FIG. 4 is a representation of query steps.
DETAILED DESCRIPTION OF THE INVENTION
[0032] In the preferred embodiment of the invention, the dictionary implementation of vectors using hash tables with the indices as keys, and the entries as values. Vectors are hash tables of integer-number pairs. Matrices are hash tables of integer-vector pairs. Insertion and deletion of values are done in constant time, and memory requirement is linear with respect to the number of pairs—both within small constant factors. A unique word identifier is the primary key. A unique document identifier is the secondary key. The value is non-null if the given word appears in the given document.
[0033] Variations include scaling to higher dimensions. Caching of commonly used vectors can be done. Note that the matrix is transposed in a particular orientation, i.e. either its rows or columns are available as a unit. This is common in other implementations, however, and it is feasible if memory is adequate to maintain both orientations. Again constant time modification is what makes this possible. For a document index, just one orientation—word by document—is sufficient. Because queries are always done with words. See FIG. 2 for an abstract representation of an inverted word matrix.
[0034] Consider some primitive unary vector operations, where n is the number of nonzero elements in the vector. Any operation performed on a particular value of the vector is assumed to run in constant—O(1)—time. All operations are assumed to be destructive, i.e., altering the vector is allowed. When this isn't the case, the vector can be copied first.
[0035] Scan
[0036] Scanning a vector simply refers to iterating over its values. The table can be iterated just as any array, while ignoring null and deleted keys. And the hash table size is of course proportional to the number of elements. Thus this is trivially O(n) time, just as with any sparse vector representation.
[0037] Map
[0038] Mapping refers to apply a function to each value in a vector. The vector is scanned, while overwriting the values with the result of the function. O(n) time.
[0039] Filter
[0040] Filtering refers to remove some elements of the vector based on a conditional test. The vector is scanned, while deleting the keys of values which don't pass the condition. O(n) time.
[0041] Alternatively, a new vector can be constructed with the values that do pass the condition. This will also be O(n) time, but with higher constants due to memory allocation. The tradeoff is simply whether the deleted keys would cause sufficient performance degradation to warrant the memory allocation overhead. In practice, this is rare, but the option is available.
[0042] Reduce
[0043] Reduction refers to apply a binary function to pairs of values, recursively. So the result of the function is a single value, and the vector itself is unchanged. Again, the vector can be scanned with the function and one current value in O(n) time.
[0044] These few operations cover the basic primitives, from which common mathematical tasks can be trivially achieved. All of them run in O(n) time, just as with any normal implementation. A sampling follows.
[0045] Sum
[0046] The sum of a vector's value is implemented by Reduce with addition as the binary operator and 0 as the initial value.
[0047] Product
[0048] The product of a vector's value is implemented by Reduce with multiplication as the binary operator and 1 as the initial value.
[0049] Scalar Multiplication
[0050] Multiplying the vector's value with a scalar is implemented by Map, with the described scalar function.
[0051] Now we consider some primitive operations on two vectors. Destruction on the first vector is again assumed. Let the vectors M and N be sized m and n, respectively.
[0052] Union
[0053] The combination of two vectors such that values with matching keys are combined with a provided function, and non-matched values are retained. Scan N, and look up each key in M. If a value is found, then combine the two values and overwrite the value in M. If a values in not found, then insert N's key and value. Only N is scanned, and all other operations are constant, hence O(n) time.
[0054] Intersection
[0055] The combination of two vectors such that values with matching keys are combined with a provided function, and non-matched values are considered 0. Scan M, and look up each key in N. If a value is found, then combine the two values and overwrite the value in M. If a value is not found, then delete the value from M. O(m) time.
[0056] As with filtering, a deleting operation such as this has a nondestructive variation. Simply, surviving values are inserted in a new vector, as opposed to deleted values being removed from the old one. The same tradeoffs apply. However, another advantage presents itself in this case because the operation is binary. The nondestructive version is obviously commutative. Thus the smaller of M and N could be chosen to be scanned, yielding an improved O(min(m, n)) running time.
[0057] Addition
[0058] The addition of two vectors is implemented by Union with addition as the binary function. Running time is O(n).
[0059] Multiplication
[0060] The multiplication of two vectors is implemented by Intersection with multiplication as the binary function. Running time is O(m).
[0061] Dot Product
[0062] The dot product of two vectors is the sum of the products of their corresponding pairs. Thus is it implemented by Multiplication followed by Sum of the resulting vector. Running time is O(m).
[0063] Now we consider many of the basic operations performed on large groups of vectors, namely matrices. Let there be m vectors of average length n. A matrix will be implemented as a vector of vectors.
[0064] A vector is obviously only missing from the matrix if no values of that vector are present. Thus even if the matrix has a overall low density, its number of vectors will be considerably more. Hence, even a sparse matrix doesn't necessarily need a sparse representation for its vector, let alone the same representation. Hence, the invention described herein can be used in its vector form only, in conjunction with any number of matrix representations. For simplicity, we will assume the main vector of the matrix is itself a hash table implementation.
[0065] Sum
[0066] To sum the vectors of a matrix, create a new empty vector. Iterate over the input vectors, performing destructive addition from each. Running time is simply O(m*n).
[0067] Now consider vector summation of other implementations. If the vectors are kept compressed, then their binary addition is O(m+n), as both vectors must be scanned. As the result vector grows, the running time exhibits quadratic behavior, yielding a much slower O(m*n{circumflex over ( )}2). Thus, Sum is an order of magnitude faster than existing implementations.
[0068] If memory is available to expand the vector, then only successive vectors need to be to scanned each time. This results in the equivalent O(m*n) running time. But this comes at the cost of more memory, and the assumption that the vector key can reasonable be represented in an array. In the case of a document index, this depends on how the word and document identifiers were created, as well as how many there are. Certainly in many cases, the sheer number of documents will cause an expanded vector to be infeasible.
[0069] Product
[0070] To compute the product of the vectors, copy the first vector. Iterate over the remaining input vectors, performing multiplication from each. Running time is worst-case O(m*n). However, as the vectors are sparse, their values most likely do not overlap. Given normally distributed data, a running time is O(n) is expected as the result vector continues to reduce in size by its density factor with each iteration.
[0071] By contrast, standard implementations can regardless expect a running time of O(m*n) in all cases. Even uncompressing the result vector does not aid the situation, as it did with Sum, because the its the smaller vector that is scanned. Whereas this implementation can be optimized to a rare sublinear running time. The expected running time of Product is a full order of magnitude faster.
[0072] Gaussian Elimination
[0073] Gaussian elimination refers to solving a system of multivariate linear equations. The coefficients of these equations are commonly represented as vector values; the unknown variables of these equations are commonly represented as vector keys.
[0074] A standard method of gaussian elimination is as follows. Select a single vector and a single key-value pair of that vector to act as a pivot. A scalar multiple of the pivot vector is then added to every other vector such that the pivot value in the new sum will become zero. The process iterates until all vectors have been pivoted. The resulting sparse matrix should then consist of vectors of one value only, if there is a single consistent solution.
[0075] Let there be m vectors in the matrix, with an average length of n. Addition of vectors requires O(n) time and the vectors are scanned in a double nested loop. So standard gaussian elimination then requires O(n*m{circumflex over ( )}2) time. Note that gaussian elimination essentially makes a sparse matrix even sparser, by attempting to reduce the length of each vector to constant size. Furthermore, it is common practice to pivot around smaller vectors, thereby maximizing the amount of values removed from the matrix. Hence, the length of the pivot vector can be expected to approach constant size instead of linear size.
[0076] But existing vector representation can not take advantage of this because their addition takes time proportional to the total length of both vectors. Adding a hash-table vector of constant size, however, takes only constant time. Thus gaussian elimination can approach O(m{circumflex over ( )}2) time, a order of magnitude speedup.
[0077] These primitives are sufficient to demonstrate the implementation of a word-document index. As described, the index will be kept inverted at all times. The word and document identifiers may be any value which is practically hashable.
[0078] Building
[0079] First the text of document is processed in any conventional manner to produce a word vector. The word are keys, and the values are whatever is desired: often a frequency count. The word vector is Scanned, and each value is added to the index matrix. Since each insert is constant, the addition of a document is linear with respect to number of unique words in the document, as desired. See FIG. 3 for a representation of indexing steps.
[0080] Querying
[0081] For each word in the query, its document vector is retrieved from the matrix in constant time. If the words in the query are weighted, their weights can be applied with a linear time Scale operation on each vector.
[0082] Next, the vectors need to be combined to yield the total scores for each document. As demonstrated earlier, which actual binary function is used to combine two values is orthogonal to the set operation used to combine the vectors. Typically, a search engine will support some of three boolean operations: OR, AND, and NOT. OR means some of the words must appear in the document. AND means all the words must appear in the document. NOT means the words must not appear in the document. The OR operation translates into a Union set operation. The AND operation translates into an Intersection set operation. The NOT operation translates into a Filter operation, after the vectors have already been merged.
[0083] As describe under matrix Sum and Product, the merging of these vectors can be expected to be an order of magnitude faster than a representation of sorted document-value pairs. Furthermore, maintaining the values in sorted order is more time consuming than the hashed index. See FIG. 4 for a representation of query steps.
[0084] The result is now a single vector, whose keys are document identifiers and whose values are the merged data from each corresponding word vector. Those values can now have a function mapped across them to finish the scoring process. Finally the vector is used to actually display results to the user, as desired by the search engine. The document-score pairs can be removed from vector form whenever constant time access is no longer desired. For example, a list of results can be generated and sorted by score, so the user sees the best results first. Note also, the number of results can be cut by score first before sorting. Partitioning a group of documents by score will generally be faster than sorting all of them. And generally the document key is just some unique identifier which is used to retrieve other data of the document from a database, e.g., title, summary, location. These document objects are then displayed in whatever manner desired.
[0085] Updating
[0086] Often search engines must respond to changed or deleted files from their index set. This is especially true on local machines, where a user may expect their document changes to be reflected in their operating system's find utility virtually instantaneously.
[0087] This presents no problem for index as it can be queried and built simultaneously. The text of the deleted or old document is removed from matrix in linear time. And the text from the added or new document is inserted in linear time.
[0088] Storage
[0089] Though the implementation of the vectors and matrices was discussed as if they were in memory, the analogous data structure can be kept on disk. This may be necessary if the machine does not have enough main memory to hold the entire index.
[0090] The foregoing merely illustrates the principles of the present invention. Those skilled in the art will be able to devise various modifications, which although not explicitly described or shown herein, embody the principles of the invention and are thus within its spirit and scope. | A new data structure and algorithms which offer at least equal performance in common sparse matrix tasks, and improved performance in many. This is applied to a word-document index to produce fast build and query times for document retrieval. | 8 |
BACKGROUND OF THE INVENTION
The invention relates to a series-parallel-series digital system with at least one storage function, comprising a first number of n (n>1) series-parallel-series digital units, each of which comprises a second number of k(k>1) elements, a further number r (1≦r≦k) thereof being defective in each unit, each digital unit comprising a serial input and a serial output for connection to a bus which comprises at least p(p>1) channels for the serial transport of a data stream of digital bits via each channel.
Such a series-parallel-series digital system is known from the article "Multiplexed partial-good chip scheme employing defective loops as selectors for all-good chips" by F. J. Aichelmann, Jr., published in I.B.M. T.D.B., Vol. 22, No. 1, June 1979, pp. 138-139. The series-parallel-series digital system described therein is a series-parallel-series shift register system in which each memory unit comprises at least one defective memory element. Consequently, it is not possible to store information in said defective memory element in a reliable manner. In order to enable reliable information storage, however, the system includes an additional memory unit which comprises only memory elements which are not defective. When such a defective memory element is addressed, the relevant address is converted into an address for the additional memory unit in order to read or write information from or into the additional memory unit.
However, the total capacity of the system will not be required in given circumstances or for given applications. This is the case, for example when not all channels of the bus are used, for example in digital television where only 7 of 8 bus channels are used. It may also be that operations need be performed only on words which are transported via given channels of the bus, or that the supply of information requires only a part of the capacity of the system. It may also be that, for example when multibit words are used, unreliability occurs in the least-significant bit due to a defective element which, however, has no adverse effects on the further processing of the relevant word. For this type of circumstances and applications it is feasible to use only digital units which comprise one or sometimes more than one defective element and which are cheaper than all-good digital units.
SUMMARY OF THE INVENTION
It is the object of the invention to provide a series-parallel-series digital system which utilizes units comprising one or more defective elements and in which the data stream is on the output of the digital system affected to only a minor degree by the presence of the defective elements, the part of the data stream which has become unreliable due to said defective elements being situated in an accurately defined location on the bus.
To achieve this, a series-parallel-series digital system in accordance with the invention is characterized in that each digital unit comprises at least (p-r) (1≦p-r<k) non-defective elements, the serial input of each digital unit being connected to a respective serial connection point of a respective data traffic control system which comprises p parallel connection points for connection to a respective one of the p channels of the bus, said data traffic control system being suitable for redistributing the data stream originating from the bus by successively fetching, within a given period, a number of bits from each channel and for conducting, in cooperation with the relevant digital unit, the bits originating from (p-r) different channels through the (p-r) non-defective elements, the serial output of each digital unit being connected to a respective serial connection point of the respective data traffic control system which is also suitable for redistributing the data stream on said serial output by rearranging the bits on said serial output into a pattern which substantially corresponds to the pattern of the bits on the bus. Due to the redistribution of the data stream from the bus as performed by the data traffic control systems it is ensured that the various bits which are transported via r different channels are conducted through r defective elements which are spread over the various digital units, the bits which are transported via the other channels being conducted through (p-r) non-defective elements per digital unit. The data traffic control systems also ensure that the data stream on the serial outputs of the digital units is reorganized so that the bits which are conducted through the defective elements are applied to the same channels. Consequently, the system can be used for p-r channels channels whose position on the bus is accurately known.
A preferred embodiment of a series-parallel-series digital system in accordance with the invention is characterized in that each data traffic control system comprises a first and a second data traffic control sub-system, each of which comprises a respective serial connection point and p respective parallel connection points, the serial connection point of the first data traffic control sub-system being connected to the serial input of its respective digital unit, the serial connection point of the second data traffic control sub-system being connected to the serial output of its respective digital unit. The use of a first and a second data traffic control sub-system optimizes the flow of data bits through the digital system because the data traffic on the serial input and the serial output of the digital unit thus has independent access to the bus.
A further preferred embodiment of a series-parallel-series digital system in accordance with the invention is characterized in that the first and the second data traffic control sub-system comprise a first and a second switching system, respectively, comprising p switching positions which are successively activated in order to establish a connection between one of the parallel connection points and the serial connection point, the n digital units being positioned with respect to the successive switching positions of their first switching system in such a manner that the defective elements each time receive bits originating from the same r channels. In this system the defective elements may be situated in different locations with respect to the sequence in which data bits are present thereto. However, it is important to ensure that the digital units are included in the system in accordance with the switching positions of their respective switching systems.
Another preferred embodiment of a series-parallel-series digital system in accordance with the invention is characterized in that the data stream presented to the serial input of each digital unit can be distributed among the various elements of the relevant unit in a well-defined sequence, the (p-r) non-defective elements in each digital unit being situated each time in the same location with respect to said sequence, the first and the second data traffic control sub-system comprising a first and a second switching system, respectively, comprising p switching positions which are successively activated in order to establish a connection between one of the parallel connection points and the serial connection point, in series with each digital unit there being connected at least one delay element for delaying the data stream between said first and said second switching system by at least one period. However, this is subject to the condition that the defective elements must always be situated in the same location with respect to the sequence in which data bits are presented thereto. However, in this case there is no requirement to be satisfied as regards correspondence to the position of the switching systems.
Preferably, the number of defective elements per digital unit amounts to one. The usability of the system then remains substantially unaffected.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be described in detail hereinafter with reference to the accompanying drawing; therein:
FIG. 1 shows a first embodiment of a series-parallel-series digital system in accordance with the invention, and
FIG. 2 shows a second embodiment of a series-parallel-series digital system in accordance with the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 shows a first embodiment of a series-parallel-series digital system in accordance with the invention. A shift register memory system has been chosen as the digital system for this first embodiment. The shift register memory system is connected between a first data bus 1 and a second data bus 22, each bus comprising n channels. The first and the second data bus are or can be essentially the same; herein the distinction has been made only for the sake of clarity. The present embodiment comprises n=4 channels which are denoted by the letters A, B, C and D. Data bits are serially transported via each of said channels. Four switching systems 2, 3, 4 and 5, and 18, 19, 20 and 21, respectively, are connected to the first bus 1 and the second bus 22, respectively. These switching systems are formed, for example by T.I. 74 LS 153 (T.I.=Texas Instruments) integrated circuits. Each switching system has four feasible switching positions (A, B, C, and D), in each position a connection being established to a respective channel.
The shift register memory system furthermore comprises n digital memory units (10, 11, 12 and 13) which are series-parallel-series memory units. The memory unit 10 comprises an input which is connected, via a delay element 6 (for example, T.I. 74 LS 164) to the switching system 2, and an output which is connected to the switching system 18 via a delay element 14. The switching system and the delay element together form a data traffic control sub-system. Analogously, the memory units 11, 12 and 13 are connected to their respective switching systems via respective delay elements 7, 8, 9 and 15, 16, 17.
Each memory unit comprises k (k>1) memory elements (I, II, III, IV), k being equal to 4 in the present embodiment. Each memory unit also comprises a demultiplexer (D) and a multiplexer (M). The demultiplexer (D) distributes the incoming serial data stream in parallel among the various memory elements and the multiplexer (M) combines the data bits on the outputs of the various elements in order to form a data word which is subsequently serially output on the serial output of the memory unit.
It is assumed that the distribution of the data stream between the various memory elements of the same memory unit is the same for all memory units of the memory system. However, it will be apparent that the invention is by no means restricted thereto.
In a memory unit which comprises a plurality of memory elements it often occurs that one or more memory elements are defective due to manufacturing faults so that they do not satisfy the relevant specifications. However, this does not necessarily mean that the entire memory unit is unusable. The memory elements which are defective can be determined by means of known test and measurement methods.
For the embodiment shown in FIG. 1 it is assumed that it has been determined for each memory unit 10, 11, 12 and 13 that the memory element II is defective. The memory elements can still be used, but the information of the data bits conducted through the memory elements II are presented to the serial output of the memory units has become unreliable. By cooperation of the switching systems and the delay elements in the shift register memory system shown in FIG. 1 it is achieved that a signal is supplied on the second data bus 22, unreliable information being supplied by only one channel (in this case the channel B), while reliable information is supplied by all other channels.
The switching systems 2, 3, 4 and 5 are controlled by a control system (not shown in the Figure) which ensures that each time when 2 bits from the data stream in a channel have passed through a switching system, the relevant switching system is switched to the next position. Because the switching system has four switching positions, it outputs an 8-bit word on its output after one complete rotation. This 8-bit word contains 2 bits from each of the channels; the various bits of the various words will be denoted by lower-case letters a i , b i , c i , d i (1≦i≦8), the letter denoting the channel of origin and the index the time sequence in which the bits are output on the output of the switching system. The direction of rotation of the switching system is denoted by an arrow.
It is also assumed that the switching systems 2, 3, 4 and 5 have a starting position as shown in FIG. 1. In this starting position, the switching system 2 conducts the bits a 1 and a 2 originating from the channel A to the delay element 6. The switching system 3 conducts the bits b 1 and b 2 originating from the channel B to the delay element 7 in its starting position. The same is applicable to the switching systems 4 and 5 which conduct the bits c 1 and c 2 and d 1 and d 2 to the delay elements 8 and 9, respectively, in their starting position (see table). Subsequently, the switching systems 2, 3, 4, and 5 are switched one position further. Consequently, the switching system 2 then conducts the bits b 3 and b 4 originating from the channel B to the delay element 6. The respective switching systems 3, 4, 5 conduct the bits c 3 and c 4 , d 3 and d 4 , a 3 and a 4 to the associated delay element 7, 8, 9 respectively. This process of conducting two bits from a channel to a respective delay element and subsequently switching the switching systems one position further is continued for the various positions of the switch in a switching system.
When the switches of the switching system 2, 3, 4 and 5 reach their starting position again, they have performed one complete rotation, which means that from each channel 8 bits have been taken up by the system. However, due to the switching operation the various bits of the various channels have been distributed among the four memory units. The first column of the table at the end of this description contains data words as applied to the input of their respective delay elements.
As soon as a bit originating from a channel has passed through a switching system, it is applied to a delay element. The bits are presented to an output of each switching system at a well-defined bit frequency (f b ). The delay elements have a delay time which corresponds to an integer multiple of the bit period (T b =1/f b ). In the present embodiment, the delay elements have the following delay times:
delay element 6: 0×T b
delay element 7: 2×T b
delay element 8: 4×T b
delay element 9: 6×T b .
The second column of the table contains data words as output by the respective delay elements. The first and the second column of the table represents an instantaneous situation, which means that, for example bit b 1 is output on the output of the switching system 3 at substantially the same instant as the bit a' 7 on the output of the delay element 7. The accent denotes that the relevant bits originate from the preceding word.
The delay element 6 has a delay time of 0×T b which is the same as if the bits were applied directly to the memory unit 10. In a practical embodiment of the system such a delay element 6 can be dispensed with. The delay element 7 has a delay time of 2×T b . Consequently, the data stream on the output of the delay element 7 exhibits a delay of 2 bits with respect to the input data stream. Therefore, when for example the bit b 1 is output on the output of the switching system 3, the bit a' 7 is output on the output of the delay element 7. The delay elements 8 and 9 delay the data stream by 4 and 6 bits, respectively, as indicated in the first and the second column of the table. The effect of the delay elements 6, 7, 8 and 9 consists in that the data stream on the input of the memory units 10, 11, 12 and 13 now exhibits a pattern which is uniform in time as appears from the second column of the table.
The data words as shown in the second column of the table are now presented to the respective memory units 10, 11, 12 and 13. Under the influence of the demultiplexer D, in the memory unit 10 the bits a 1 and a 2 are conducted through the memory element I, the bits b 3 and b 4 through the memory element II, the bits c 5 and c 6 through the memory element III and the bits d 7 and d 8 through the memory element IV. The data stream is conducted through the various memory elements of the other memory units 11, 12 and 13 in the same manner. It is assumed that the demultiplexers of the various memory units operate in synchronism with the given numbering of the elements.
Under the influence of the delay elements 6, 7, 8 and 9 and the demultiplexers of the various memory units, the various bits of the data stream originating from the channel B of the first bus 1 are conducted each time to the memory element II. As has already been stated, the memory elements II in each of the memory units are defective. This means that on the output of the various memory units unreliable information will be present each time at the location of the bits b i in the data stream. This is indicated by means of dashes in the data words as shown in the third column of the table. Thus, it appears from the third column that, due to the defective memory elements II, the data stream originating from the channel B is mutilated so that it no longer contains reliable information. However, only the data stream originating from the channel B has become unreliable and the data streams originating from all other channels still contains reliable information. Vis-a-vis the environment, i.e. on the connections of a system as shown in FIG. 1, only the data stream via channel B has become unreliable.
In order to conduct the various bits to the appropriate channel of the second data bus 22, the data stream as presented to the output of the memory units requires some reorganization. This is inter alia provided by the delay elements 14, 15, 16 and 17 and the switching systems 18, 19, 20 and 21. The delay elements 14, 15, 16 and 17 and the switching systems 18, 19, 20 and 21 form a data traffic control system. In the present embodiment, these delay elements have the following delay times:
delay element 14: 8×T b
delay element 15: 6×T b
delay element 16: 4×T b
delay element 17: 2×T b ,
in which T b again represents the bit period. The fourth column of the table contains the data stream output on the output of the delay elements 14, 15, 16 and 17.
The switching systems 18, 19, 20 and 21 operate in the same way and at the same rotary speed as the previously described switching systems 2, 3, 4 and 5. The switching systems 18, 19, 20 and 21 conduct the bits output on the output of the delay elements 14, 15, 16 and 17 to the appropriate channel again, i.e. to the channel from which they originate. In addition to the internal delay caused by the memory units, the passage of the data stream through a system as shown in FIG. 1 introduces a delay of the outgoing data stream (on data bus 22) by 8 bits with respect to the incoming data stream (on data bus 1) under the influence of the delay elements. The latter can also be seen in the table.
FIG. 2 shows a second embodiment of a series-parallel-series digital system in accordance with the invention. The digital system is again formed by a series-parallel-series shift register memory system. Parts which correspond to parts shown in FIG. 1 are denoted by corresponding reference numerals. However, in the system shown in FIG. 2 the defective memory element is not always situated in the same location with respect to the demultiplexer rotation in the memory unit. The demultiplexer rotation is assumed to be the same for all memory units. By a suitable choice of the memory units comprising one defective memory element, the delay elements (as shown in FIG. 1) have become superfluous in the present embodiment, so that the data traffic control system comprises merely a switching system. In the embodiment shown in FIG. 2 the defective memory elements are situated in the following locations:
memory unit 10: memory element I
memory unit 11: memory element IV
memory unit 12: memory element III
memory unit 13: memory element II.
The data streams as output on the output of the switching systems 2, 3, 4 and 5 are shown in the Figure. Under the influence of the demultiplexer D of the memory unit 10 the bits a 1 , a 2 which are output on the output of the switching system 2 are conducted to the defective memory element I. Consequently, the bits on the output of the memory unit 10 which originate from the memory element I will contain unreliable information. Because the other memory elements are not defective, the bits b 3 , b 4 , c 5 , c 6 , d 7 , d 8 will contain reliable information. The bits a 7 and a 8 are conducted to the defective memory element IV of the memory unit 11. Consequently, no reliable information will be present on the output of the memory unit 11 at the location of the bits a 7 and a 8 . For the memory units 12 and 13 the bits a 5 , a 6 and a 3 , a 4 will be conducted to the defective memory elements III and II, respectively, in the same manner. The data stream in the channel A of the second data bus 22 thus contains unreliable information, while reliable information is present in the other channels. The passage of the data stream through the system as shown in FIG. 2 involves no delay other than the internal delay introduced by the memory units.
It will be apparent that the invention is not restricted to series-parallel-series shift register units as shown in FIG. 1 or 2. The invention can be used in any series-parallel-series digital system and for the digital units use can be made equally well of microprocessors, ALU's as well as any other series-parallel-series digital unit.
It has already been stated that the various elements of the digital unit need not always be activated in the same sequence by the associated demultiplexer. The sequence within the units may in principle differ from one unit to another, because the routing through the non-defective and defective elements is performed by cooperation of the demultiplexer of the unit and the respective data traffic control system.
CCD (Charge Coupled Devices) or bubble memories are series-parallel-series digital units in which defective elements occur regularly. Therefore, the use of the invention represents an attractive solution for such memories.
TABLE__________________________________________________________________________delayword presented to the word output on theelementinput output__________________________________________________________________________6 a.sub.1 a.sub.2 b.sub.3 b.sub.4 c.sub.5 c.sub.6 d.sub.7 d.sub.8 a.sub.1 a.sub.2 b.sub.3 b.sub.4 c.sub.5 c.sub.6 d.sub.7 d.sub.87 b.sub.1 b.sub.2 c.sub.3 c.sub.4 d.sub.5 d.sub.6 a.sub.7 a.sub.8 a.sub.7 ' a.sub.8 ' b.sub.1 b.sub.2 c.sub.3 c.sub.4 d.sub.5 d.sub.68 c.sub.1 c.sub.2 d.sub.3 d.sub.4 a.sub.5 a.sub.6 b.sub.7 b.sub.8 a.sub.5 ' a.sub.6 ' b.sub.7 ' b.sub.8 ' c.sub.1 c.sub.2 d.sub.3 d.sub.49 d.sub.1 d.sub.2 a.sub.3 a.sub.4 b.sub.5 b.sub.6 c.sub.7 c.sub.8 a.sub.3 ' a.sub.4 ' b.sub.5 ' b.sub.6 ' c.sub.7 ' c.sub.8 ' d.sub.1 d.sub.214 a.sub.1 a.sub.2 -- -- c.sub.5 c.sub.6 d.sub.7 d.sub.8 a.sub.1 ' a.sub.2 ' -- -- c.sub.5 ' c.sub.6 ' d.sub.7 ' d.sub.8 '15 a.sub.7 ' a.sub.8 ' -- -- c.sub.3 c.sub.4 d.sub.5 d.sub.6 -- -- c.sub.3 ' c.sub.4 ' d.sub.5 ' d.sub.6 ' a.sub.7 ' a.sub.8 '16 a.sub.5 ' a.sub.6 ' -- -- c.sub.1 c.sub.2 d.sub.3 d.sub.4 c.sub.1 ' c.sub.2 ' d.sub.3 ' d.sub.4 ' a.sub.5 ' a.sub.6 ' -- --17 a.sub.3 ' a.sub.4 ' -- -- c.sub.7 ' c.sub.8 ' d.sub.1 d.sub.2 d.sub.1 ' d.sub.2 ' a.sub.3 ' a.sub.4 ' -- -- c.sub.7 ' c.sub.8 '__________________________________________________________________________ | One or more defective elements regularly occur in series-parallel-series digital units comprising several elements. The described system offers a solution for the construction of a series-parallel-series digital system by means of a number of series-parallel-series digital units comprising one or more defective elements; in this system only a part of the data stream passing through the system appears as being unreliable on the output thereof. Moreover, said unreliable part will always be situated within the same serial data stream, while the other serial data stream on the output will not be affected thereby. | 7 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to substantially colorless, thermally colorable, indigo compounds. The compounds find use as color reactants in thermal sensitive materials.
The invention particularly relates to certain colorable dehydroindigo di(alkyl acylate) compounds and to their use in thermal sensitive marking materials.
This invention relates to thermal sensitive materials in film and sheet form, transparent and non-transparent. The invention more particularly relates to transparent marking materials incorporating colorable dehydroindigo di(alkyl acylate) compounds as a thermal sensitive color reactant. The invention more particularly relates to substantially opaque marking materials coated by dehydroindigo di(alkyl acylate) compounds.
The invention even more particularly relates to certain dehydroindigo di(alkyl acylate) compounds used in thermal coloration reactions in combination with certain color intensifying additives.
2. Description of the Prior Art
U.S. Pat. No. 3,666,525 discloses a heat sensitive copying sheet which utilizes a spiro compound and an organic sulfonic acid in a thermofusible material. A dispersion of the spiro compound, acid, and thermofusible material is coated onto a support material and marks are generated by application of sufficient heat to melt the thermofusible material and place the spiro compound and the acid in reactive contact.
U.S. Pat. No. 3,594,208 discloses a heat sensitive transparency sheet for light projection wherein two color reactant components are individually coated onto a substrate carrier using different polymeric binder materials. Solvents are selected to eliminate reactive contact of the components during coating operations.
U.S. Pat. No. 3,914,510 issued Oct. 21, 1975 discloses a heat sensitive transparency sheet having individual color reactant layers including a base layer of binder and acid reactant and a surface coating of binder and chromogen. The binder of the base layer is hardened by crosslinking to improve qualities of the transparency.
SUMMARY OF THE INVENTION
Thermal sensitive record materials are known in the art. Typically, colorless mark-forming components such as crystal violet lactone and a phenolic material are arranged in juxtaposition in a single support sheet. Application of heat to the sheet causes a migration of liquefied or vaporized material to a juxtaposed mark-forming component to produce a mark, as the mark-forming components generally react upon contact to produce a color. Often, these known thermal sensitive copy sheets prematurely color before or without the application of heat. Another problem is the development of color in areas of the sheet where heat for marking is not applied.
Once colored, some heat sensitive record materials of the prior art fade or undergo an alteration in the developed hue. A fog or haze sometimes forms on heat sensitive record materials of the prior art.
A thermal sensitive material has now been developed which exhibits greatly improved stability. Underdeveloped or uncolored areas remain uncolored until heat is supplied to the area in greater than a certain threshold amount. Colored areas remain unfaded with constant hue. Sheets of the material do not become hazy in humid or otherwise adverse storage conditions.
The thermal sensitive material of this invention utilizes dehydroindigo di(alkyl acylate) material as the primary color former. The dehydroindigo di(alkyl acylate) material is used as the sole color former and it is used in combination with additive, intensifying, compounds.
The material of this invention is transparent or not and may be in a single layer form or it may involve a construction having more than one layer.
Accordingly, it is an object of this invention to provide a thermal sensitive dehydroindigo di(alkyl acylate) material.
It is an object of this invention to provide a thermal sensitive recording material having stable colored and uncolored states. It is, further, an object of this invention to provide a thermal sensitive sheet material utilizing dehydroindigo di(alkyl acylates). It is, further, an object of this invention to provide a thermal sensitive material utilizing dehydroindigo di(alkyl acylates) and additive, intensifying, compounds.
In accordance with the present invention, there is provided a dehydroindigo di(alkyl acylate) having the following structure wherein R is alkyl acylate having three to nine carbon atoms: ##SPC1##
and there is provided a thermal sensitive material comprising a substrate and a dehydroindigo di(alkyl acylate) associated therewith.
The substrate serves as a carrier for color forming compounds and associated additive compounds. The substrate can include color forming and additive compounds within the body of the substrate or such compounds can be present in at least one layer on the substrate. The substrate can be thick or thin, flexible or not, and transparent, opaque or in gradations thereof. The usual substrate is flexible and has a thickness of about 0.005 to 0.50, preferably 0.01 to 0.25 millimeters. Transparent and non-transparent substrates are equally eligible; and layered combinations of transparent and non-transparent materials are used.
Non-transparent substrates include non-woven fibrous materials such as papers, spun-bonded synthetic polymeric sheets, and the like; woven fibrous materials such as cloth of natural or synthetic polymeric sources; pigmented or otherwise opacified polymeric webs of cast or extruded sources; and layered combinations thereof.
Transparent substrates can vary widely and are generally synthetic polymeric materials, cast or extruded, exemplified by the following:
cellulosics such as ethylcellulose, cellulose acetate, nitrocellulose, and cellulose acetate butyrate; polystyrene; polyvinylacetate; polyvinylchloride; polyvinylidene chloride; polyalkylacrylates, methacrylates, ethacrylates, and the like, such as polymethylmethacrylate and polybutylmethacrylate; polyacrylonitriles; polycarbonates; polyethylenes; polypropylenes; polyethylene terephthalates; copolymers of the above; and the like. Although water soluble polymeric materials are eligible, preferred materials are insoluble in water.
Binder is a polymeric material which holds the color forming and additive compounds in location on or in the thermal sensitive material. The binder can be the same polymeric materials as are used for the substrate. In the case of a single layer construction, the color forming and additive compounds are distributed and bound in the single layer. When the substrate of the single layer is fibrous, the binder can be a polymeric impregnant for the substrate fibers and the color forming and additive compounds. The substrate can also be a synthetic polymeric material which binds the color forming and additive compounds; and, in that case, the binder is the substrate.
The binder can be water soluble or not and need not be thermoplastic. The color forming compounds of this invention generate color spontaneously in the presence of adequate thermal energy and, therefore, are not required to be bound in a fusible matrix for reactive, color-forming, contact with another material. When a combination of color forming compounds and intensifying compounds are present in undissolved form, a thermofusible binder is helpful in obtaining contact between the compounds. When either or both of the compounds are molecularly dispersed in the binder, however, compound contact is achieved without melting the binder.
In addition to the materials listed above as eligible substrate materials, binder can also be materials such as polyvinyl alcohol, gelatin, polyvinyl butyral, and the like.
Binder is generally added to substrates as a liquid solution or dispersion of polymeric material and some combination of color former or additive or both. The binder system can be absorbed into the substrate to yield a single layer recording material or the binder can be coated onto the substrate to yield an additional layer. When desired or required for some particular purpose, color former and additives such as intensifier, can be present in individual layers.
Intensifiers are sulfonic acids and phenols which aid in the heat development of color in the thermal sensitive material of this invention. Intensifiers increase the sensitivity of color formers by providing an acid environment more conducive to dehydroindigo di(alkyl acylates) color formation. Moreover, the use of intensifiers permits color formation at a considerably reduced temperature when compared with the temperature of color formation using color former alone.
Intensifiers often cause color formers to develop a hue different from the hue of a color former developed alone. As previously mentioned, the intensifiers can be dissolved (molecularly dispersed) in the binder system along with the color former or can be dispersed therein undissolved or can be located in an adjacent, contacting layer. When intensifier and color former are molecularly dispersed together, there is sometimes a light, preliminary, hue developed. The preliminary hue is usually in high contrast with the thermally developed color and reasons for the existence and formation of the preliminary hue are not well understood.
Intensifiers have been found to be useful in any small amount. To the extent that an intensifier is present, benefit from intensifiers is realized. Intensifiers are generally used in an amount of from about 0.10 to 10 weight parts per weight part of color former and about 0.50 to 4.0 parts is preferred. More than 10 parts per part of color former is not recommended except when the color former and the intensifier are in separate layers.
The color formers of this invention are derivatives of [Δ2,2'-Biindoline]-3,3'-dione, commonly known as indigo. The derivatives are commonly known as dehydroindigo di(alkyl acylates) and bear the proper chemical name of 2,2'-diacyloxy-2,2'-biindoline-3,3'-dione. Indigo is a colored dye and is not thermally colorable. Unmodified dehydroindigo compounds are thermally colorable and develop from nearly colorless through yellow and green to blue at less than 25 degrees centigrade. Moreover, such dehydroindigo compounds are very sensitive to humidity changes and tend to develop color in humid environments.
Eligible dehydroindigo color former compounds are symmetrical diesters having increasing carbon numbers from propionate through heptylate and octylate. The diester functionality reduces the coloration tendency and raises the coloration temperature to provide eminently effective thermal sensitive material. The color former is generally associated with the substrate in an amount of about 0.3 to 0.7 grams of color former per square meter of substrate surface area. As little as 0.1 grams per square meter can be used and more than 1.5 grams per square meter might be required or desired in some instances. A larger amount of color former might be required where the effect of an intensifier is desired and the color former and intensifier are in separate layers.
DESCRIPTION OF PREFERRED EMBODIMENTS
All parts are weight parts and all percents are weight percents, unless otherwise specified.
EXAMPLE 1
0.05 parts of dehydroindigo dihexanoate is dissolved in 4.0 parts of a solution of 10 percent polystyrene in toluene to make a thermal sensitive liquid binder system with color former. The binder system is coated onto a polyester film substrate to a wet film thickness of about 10 millimeters. A dried sheet of the above-made material undergoes coloration in areas where the temperature is increased to about 170° centigrade.
The Example is also conducted using paper and cellulose acetate as substrates and polycarbonate and styrene-acrylonitrile copolymer as binders.
EXAMPLES 2-7
Example 1 is repeated substituting each of the several color formers specified below for the color former of Example 1; and with and without 0.05 parts of 2,3-dihydroxynaphthalene (DHN). An excellent color forming thermal sensitive recording material is formed. The DHN is used as an intensifier. Examples incorporating DHN are imaged by exposure in any commercially available heat copying machine.
__________________________________________________________________________Coloration Temperature (°centigrade)ExampleDi(alkyl acylate) with DHN without DHN__________________________________________________________________________2 acetate forms no color 230 decomposes)3 propionate 117 2224 2-methyl propionate 111 185(butyrate)5 2-ethylhexanoate 97 173(octanoate)6 hexanoate 99 1837 heptanoate 92 175__________________________________________________________________________
The indicated coloration temperatures, without DHN, are actually melting points of the corresponding di(alkyl acylate) compounds. Without DHN, color can be expected to form at about 30° to 40° centigrade below the melting points. Note that the diacetate forms no color with DHN and that it decomposes at about 230° centigrade, without DHN.
EXAMPLE 8
0.10 parts of dehydroindigo diheptanoate is dissolved in 10 parts of a solution of 7.0 percent cellulose acetate butyrate and 1.0 percent d-10-camphorsulfonic acid in toluene:butanol:ethanol 80:10:10 to make a liquid binder system. The binder system is cast onto a silicone-coated, stainless steel, plate to a wet thickness of about 10 millimeters and dried. The sheet is removed from the plate and is used as a transparent thermal sensitive copying material useful, among other things, as a transparency in overhead light projection.
The sulfonic acid serves as an intensifier. Other eligible sulfonic acids include:
catechol-3,5-disulfonic acid;
2-chloroaniline-5-sulfonic acid;
2-chloro-6-methylaniline-4-sulfonic acid;
4-chloroaniline-3-sulfonic acid;
m-benzenedisulfonic acid;
p-chlorobenzene sulfonic acid;
2-naphthalenesulfonic acid;
xylenesulfonic acid;
toluenesulfonic acid;
4-nitrotoluene-2-sulfonic acid;
2,4,6-trinitrobenzenesulfonic acid; and
2,4-dinitro-1-naphthol-7-sulfonic acid and the like.
EXAMPLES 9-41
Example 1 is repeated and 0.05 parts of a variety of phenol intensifiers is added to the thermal sensitive binder system. Each thermal sensitive material is coated onto a substrate and dried. The dried thermal sensitive material is sometimes slightly colored but is usually nearly colorless and, in every case, develops color at a characteristic temperature. Particulars of these examples are listed following:
__________________________________________________________________________ DevelopedExampleIntensifier Initial Color Color__________________________________________________________________________ 9 bis-(2-hydroxyphenyl)methane light green blue10 6,6'-isobutylene-bis-2,4'-xy- nearly colorless bluelenol11 2,7-dihydroxynaphthalene light green blue12 catechol green dense blue13 2,2'-methyl-bis(4,6-di- colorless bluetertbutylcresol)14 p-tritylphenol colorless blue15 6,6'-methylene-bis(4-tert- green bluebutyl-o-cresol)16 2,2'-methylene-bis(6-tert- light green bluebutyl-4-chlorophenol)17 p-nitrophenol yellow green18 phenol colorless dark blue19 2,4,6-trimethylphenol green blue20 2,2'-methylene-bis(4-chloro- nearly colorless bluephenol)21 p-tertbutylphenol colorless blue22 2,4,6-tri-tertbutylphenol nearly colorless purple23 m-pentadecylphenol colorless dark blue24 3-methyl-4-nitrophenol colorless blue-green25 2-methyl-4-tertoctylphenol light green dark blue26 2,2'-methylene-bis(6-tert- green dark purplebutyl-4-ethylphenol)27 m-nitrophenol colorless blue-green28 4-chloro-2-methylphenol nearly colorless blue29 p-methoxyphenol blue-green blue30 p-bromophenol colorless blue31 2-methylene-bis(4-chloro- light green blue6-methylphenol)32 o-hydroxybiphenyl colorless dark blue33 4-iodophenol colorless blue34 4,4'-methylene-bis(2-tert- light green dark greenbutyl-6-methylphenol)35 p-(1,1-dimethylpropyl)phenol nearly colorless blue36 2,6-dichlorophenol light green dark blue37 4,4'-isopropylidene-bis(2- light green dark blueisopropylphenol)38 p-p'-(p-phenylenediisopropyl- colorless dark blueidene)diphenol39 4,4,6,6-tetratertbutyl-o,o- light green purplebisphenol40 4,4'-isopropylidene-bis(6- colorless bluechloro-o-cresol)41 4,4'-isopropylidene-di-o- light green bluecresol__________________________________________________________________________
EXAMPLE 42
0.2 parts of finely powdered dehydroindigo dihexanoate and 0.4 parts of finely powdered p-tert-butylphenol, intensifier, are thoroughly dispersed in a 5.0 percent solution of polyvinyl alcohol in water to yield a thermal sensitive liquid binder system. Ethylhydroxyethylcellulose is also an eligible binder. That dispersion is coated onto a substrate and cast onto a silicone-coated sheet, as in previous examples, to make opaque and translucent thermal sensitive recording material.
EXAMPLE 43
Dehydroindigo di(alkyl acylate) are prepared as follows: Indigo is reacted with an appropriate carboxylic acid in the presence of a catalyst such as lead tetracetate. As a preferred method, the carboxylic acid is in excess and can be used as the vehicle in which to conduct the reaction.
For instance, in making dehydroindigo dipropionate, about 0.01 mole of indigo (2.6 grams) and about 0.01 mole of lead tetracetate (4.7 grams) are stirred into about 100 grams of propionic acid. Agitation is continued for about 15 to 30 minutes and, if desired or required, the mixture can be warmed to maintain fluidity of the system.
As it is formed, the dipropionate product precipitates from solution in the propionic acid. The product is separated by filtration, washed with water to remove residual components, and purified by recrystallization from benzene or toluene.
Others of the di(alkyl acylate) compounds are made in similar fashion using appropriate carboxylic acids. The melting points of representative compounds have been listed in Examples 2-7, above. | Thermal sensitive indigo compounds are disclosed.
A thermal sensitive sheet material is disclosed utilizing dehydroindigo di(alkyl acylates) as a color producing component. The material can be a copy medium and it can be transparent or non-transparent.
The indigo compounds are substantially colorless dehydroindigo di(alkyl acylates) colorable by thermal exposure. | 8 |
This application claims the benefit of U.S. Provisional Application Ser. No. 61/171,403, filed Apr. 21, 2009, which is incorporated herein by reference in its entirety.
FIELD
In one preferred aspects, methods are provided to produce a three-dimensional feature, comprising: (a) providing a nano-manipulator device; (b) positioning an article with the nano-manipulator device; and (c) manipulating the article to produce the three-dimensional feature. The invention relates to production of nanoscale systems that can be tailored with with specific physical, optical and/or electrical characteristics or need to have these characteristics modified. Methods and apparatus are presented that can construct three-dimensional nanostructures and can also modify existing nanostructures in three dimensions.
BACKGROUND
Nanoscale Systems are currently being fabricated using many techniques adopted from the semiconductor and MEMS fields. These fabrication techniques create three dimensional structures by layering materials and patterning each layer (photolithography). Although such a process can create devices in parallel and thus produce large numbers of identical devices it is limited in its vertical scale capability. The aspect ratio (AR) of most planar processes is limited to a factor of a few units in the vertical dimension over the lateral dimension (AR of 3:1, for example). As the lateral dimension shrinks, so does the vertical and is confined to no more than an aspect ratio of 5:1 or so.
Reactive Ion Etching (RIE) has been pushed to achieve large aspect ratio via milling in nanoscale systems but it is limited to certain materials and the vertical walls cannot be made perpendicular. Subsequent process steps have to conform to the shape of the RIE formed process.
The materials that lend themselves to creating these structures are also limited to a few compounds and elements (silicon and its compounds, aluminum, titanium, copper, etc). Some of these compounds or elements are also incompatible with each other and have to be processed in special ways. For example, copper will diffuse in silicon and silicon dielectrics so it has to be completely encapsulated in a different material before it can be used in electrical circuits. This limits the scalability of copper in photolithographic processes.
In the area of structure modification, a very valuable application is circuit edit. Electronic semiconductor circuits have been modified in functionality and logic by using particle beam processes. However, these processes can only generate materials that are far inferior from the manufactured material (such as copper and dielectrics). See, generally, U.S. Pat. Nos. 7,297,946 and 5,364,497.
SUMMARY
In one aspect, the present invention mimics building construction techniques adapted to the nanoscale.
In a preferred aspect, instead of the planar process, methods and systems of the invention employ a “pick and place” system that can place prefabricated nano-wires or other nano-articles in position for construction in a manner analogous to beams that are welded together to form the frame of a building.
Apparatus useful in methods and systems of the invention may comprise a vacuum chamber where a staging area will hold the materials for construction. A nanomanipulator can act as the crane that will place the materials in position and an imaging system will provide the navigation information and energy for welding in the case of beam based direct-write CVD processing. Electrical and other feedthroughs can permit electrical fusing of nanostructures as an alternate or additional welding technique. “Bottom-up Nanoconstruction by the Welding of Individual Metallic Nanoobjects Using Nanoscale Solder”, Yong Peng, Tony Cullis and Beverley Inkson. Nano Lett., 2009, 9 (1), pp 91-96
These nanostructures (e.g. beams and wires) can be suitably fabricated and be of any of a large number of materials or compounds customized to the needs of the specific structure of interest. The pre-fabricated segments are nano-manipulated into position and beam based chemical vapor deposition processes can be used to fuse them together. A two beam system (electron and ion beams coincident on the sample) is suitably employed and exemplified herein.
Suitably, processing in methods and systems of the invention can be accomplished through a combination of beam based chemistry, special environmental conditions and electrical/electrochemical processes. A preferred approach is electron beam based chemical vapor deposition process, see “Deposition of Narrow, High Quality, Closely Spaced, but Isolated Conductors, V. V. Makarov and R. K. Jain, Proceedings of the 33 rd International Symposium for Testing and Failure Analysis, Nov. 4-8, 2007, San Jose, Calif., pp 41-45. In situ sizing of raw material(s) can be easily done with one of the beams present and usually without any chemical assistance.
A specific application that will immediately benefit from such a methodology is circuit edit, the process of modifying the layout of an already fabricated integrated circuit.
In a preferred aspect, methods and systems of the invention can employ manufactured components in circuit edit thus providing identical quality of material to the manufactured component.
In a preferred aspect, methods for producing a three-dimensional feature are provided comprising: (a) providing a nano-manipulator device; (b) positioning an article with the nano-manipulator device; and (c) manipulating the article to produce the three-dimensional feature. Two or more articles may be suitably positioned with the nano-manipulator device. As discussed, in preferred aspects, semiconductor chip editing is performed with the nano-manipulator device.
As referred to herein a nano-sized feature or object will have a critical size (smallest dimension) that is less than 5,000 nm or 1000 nm, more typically less than 500 nm, even more typically 100 nm or less. For example, a wire that is 50 nm in diameter but several microns long is considered herein to be a nanowire. A layer of material that is many square microns in area but 100 nm thick is a nanolayer.
As referred to herein, “nano-manipulation” use of a “nano-manipulator device” or other similar term indicates modification, construction or creation of a three-dimensional structure, e.g. where at least two, three, four or more discrete members (e.g. nanotubes (including carbon nanotubes), nanowires) are rigidly affixed (e.g. affixing through a CVD, electrochemical process, and/thermal process). Such rigid affixing can increase volume and/or mass of each of the joined members. For instance, a first member (e.g. carbon nanotube or nanowire) upon nano-manipulation in accordance with the present invention may result in rigid affixing to one or more additional members and a volume and/or mass change of at least 5, 10, 20, 30, 40, 50, 60, 70, 80, 90, 100, 200, 300, 400, 500, 1000%. Nano-manipulation may be accomplished through incorporation of a variety of techniques (e.g. Computer Aided Design or CAD) but may include joint creation and/or volume and/or mass addition or subtraction to manipulated nano-objects.
Nano-manipulation as referred to herein may include (but is not limited to in the absence of a mass addition or subtraction) planar fabrication and processes involving moving nanoscale structures around for either imaging or to connect them to other nanostructures or to separate them from other nanostructures. For example, two nanowires grown apart can be nanomanipulated to either cross each other or make contact to electrical points in a circuit (such as pads). In another example, an electrical nano-probe is manipulated on to a metal pad or circuit line to electrically characterize it.
Other aspects of the invention are discussed infra.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 (includes FIGS. 1 a and 1 b ) shows a suitable nano construction apparatus where in FIG. 1( a ) an overview is depicted and in FIG. 1( b ) a process area with exemplary structure (beam with arc) is depicted.
FIG. 2 shows a prefabricated nanowire which has been welded to the nanomanipulator and is being moved to the area of interest.
FIG. 3 shows the nanowire has been placed into position and is ready for welding.
FIG. 4 shows the nanowire has been welded in position.
FIG. 5 shows beams crossed in air.
DETAILED DESCRIPTION
An apparatus and method for constructing complex nano-scale structures or modifying existing structures has been developed. This method uses integration of technologies such as nano particle beams (for example, SEM, FIB), beam based chemistry (CVD), nano-manipulators, environmental control, and computer aided design (CAD) files to construct, analyze and modify nanoscale systems.
Unlike the existing techniques that use planar fabrication methods extended to some limited three-dimensional capability, this nano-construction technique is capable of building complex three dimensional structures through building construction techniques adapted to nanoscale environments. For example, beams are made of nano tubes, cranes are nano-manipulators and welders are beam based CVD or electrochemical processing. The raw material can be for example carbon nanotubes, beams or lines cut out of bulk metal in-situ or ex-situ that can be curved or rectangular. Gaseous precursors are used for welding pieces together under the energy of the beam, etc.
In methods and systems of the invention, a variety of commercially available nano-manipulator devices (including e.g. nano-tweezers) may be employed including e.g. devices from Omniprobe (TEM sample prep device); Zyvex (Electrical Probing); Kleindiek (TEM sample prep and electrical probing); and Xidex (Nanomanipulation).
A wide nanoscale system can be created in accordance with methods and systems of the invention. More specifically, particularly suitably applications for methods and systems of the invention include
1) Circuit Edit; 2) Construction of nano-electrical mechanical systems (NEMS), including placing gears and electrical components together to assemble a NEMS; 3) Photonic systems. Construction of complex nanoscale structures for optical systems (optical guides, wave guides, fiber splicers etc.); 4) Construction of sensors. For example, an electrical system can have a sensor to measure electrical resistivity inside a cell. This sensor has to be attached to the electrical circuit; 5) Medical nanodevices (these are often called NEMS, but can be different than above discussed NEMS). For example, a fluidic device that separates different particles from within a fluid or mixes fluids etc.; 6) Synthetic biology.
In accordance with the invention, nano manipulators can position beams in such a way that they can be welded and structures built in a manner very similar to building construction. Overhanging, retrograde, high aspect ratio features are all easily built with this technique.
Several components of this invention have already been integrated into one system but others have to be further developed and integrated. Existing nanomanipulators lack the positioning accuracy for the finest range of nanoscale accuracy and electrochemical fusing processes are an alternative to CVD welding that show a lot of promise but not yet fully developed. “Nanomanipulation by Atomic Force Microscopy, F. J. Rubio-Sierra 1, W. M. Heckl 1 2, R. W. Stark *, 1Ludwig-Maximilians-Universität München, Kristallographie and Center for Nanoscience CeNS, Theresienstr. 41, 80333 Munich, Germany, Deutsches Museum, Museumsinsel 1, 80538 Munich, Germany, Advanced Engineering Materials, Volume 7 Issue 4, Pages 193-196, Published Online: 21 Apr. 2005. Also, temperature control can have a positive effect in beam based processing; consequently, that aspect of the environmental control may become important.
Referring now to the drawings, in one preferred method, a substrate is placed in a holder ( FIG. 1( a )) that incorporates at least one nano-crane and is placed inside a beam system with beam chemistry capability and CAD navigation. The holder is designed to be a complete construction site ready with beams of pre-cut metal, metal blocks for in-situ cutting of custom pieces, plates of insulator, a supply of carbon nanotubes (CNT's), spare nano-manipulator parts and space for custom supplies. The nano-crane may be any of a variety of nano-manipulation tools, including commercially available nano-manipulators, such as a Zyvex L100™, which may include an x-nano-positioner and a y-nano-positioner for nano-positioning of a nano-article in the x and y directions. The nano-manipulator may be used for manipulation of the specimen in any of x, y or z directions.
The length of wire needed in the construction is either immediately available or is cut to size with the system beam. It is then attached to the nano-manipulator, moved to the desired location and fused to the system under construction.
In one specifically preferred system, methods of the invention were conducted in a nanofabrication facility and in a two beam (FIB/SEM) system outfitted with a nanomanipulator. Using nanofabrication, wires are constructed as needed to connect the center of a disk to a pad so that the center of the disk could be grounded. The surface of the disk is covered with dielectric everywhere except the center where the doped silicon below is exposed.
As depicted in FIG. 2 , a prefabricated nanowire is moved to the disk area. The wire is suitably designed to have a tab for attachment to the nanomanipulator. The tab is cut off once the wire is attached to the system.
Next, shown in FIG. 3 , the wire is in position for welding and in FIG. 4 the wire has been welded using E-Beam CVD. As shown in FIG. 4 , the nanowire is welded in position.
The ability to connect additional structures to such a beam has been successfully carried out and with proper design structures can be built up into heights and complexities not attainable through planar processing. FIG. 5 depicts an example of a structure that would be impossible to build in planar processing where pillars are connected by crossing beams that are not touching.
As discussed above; circuit editing applications are preferred aspects of the invention. A specific application of nanoconstruction is for the editing of integrated circuits. The ultimate verification of a circuit design is in a system after the part is manufactured. Currently, FIB systems are routinely used to edit circuits once first silicon is produced so that fixes and improvements can be tested out without running through the manufacturing process. The nano-construction technique and system are adaptable to future generations of circuit editing because not only are dimensions scaling down but also material properties are becoming increasingly critical (for example, metal re-wiring resistance).
The following Table 1 is a summary of specifications that are currently state of the art and with existing techniques cannot be adequately bridged to meet the needs for many of the edits encountered already and will be even further behind in future generation of circuits.
TABLE 1
Comparison of critical specifications using extended state of the art
technologies and nanoconstruction
Figure of
Nanoconstruction
Objective
Merit
State-of-the-art
Capability
Metal
Line Width
100 nm
10 nm
Deposition
Line Pitch
200 nm
20 nm
Resistivity
200 μΩcm
2 μΩcm
Dielectric
Resistivity
10 9 μΩcm
10 15 μΩcm
Deposition
Dielectric
Unknown
~2
Constant (k)
Speed of
10 um × 1 um ×
15 minutes
5 minutes to
deposition
1 um
place and weld
Custom wires (e.g. metal nanowires such as copper nanowires, semiconductor nanowire such as a silicon nanowires and other such as an indinium-containing nanowire) can be cut from bulk metal and placed where the editing needs to be routed. Resistance can be as desired and only the ends are fused/welded with impure deposition material adding minimal resistance to the edit.
Nanowires or carbon nanotubes can be inserted directly into vias and make contact with metal interconnect or even active areas or circuit contacts. CNT's that are insulating on the outside and conductive on the inside are ideal for inserting in vias to connect to underlying metal. Alternatively, an insulating coating can be deposited in the via to insulate a nanowire inserted to contact underlying interconnect.
It is often desired to run multiple edit lines of interconnect with very tight pitch (sub 100 nm). Nanowires or CNT's can be layed out in such a fashion eliminating the issues that arise from direct write deposition techniques. Where wire might have to cross, a dielectric pad can be positioned between the crossing wires.
This technique can overcome limitations with interconnect material deposition and others. Edits that are speed sensitive can be done without adjustments or limitations that current technologies impose.
The following terms and abbreviations mean the following as used herein:
CVD—Chemical Vapor Deposition. In this context we are referring to a beam induced CVD using an organometalic precursor such as Tungsten Hexa Carbonyl FIB—Focused Ion Beam SEM—Scanning Electron Microscope CAD—Computer Aided Design. Electronic data file with structural information CNT—Carbon nanotube RIE—Reactive Ion Etching
All documents mentioned herein are incorporated by reference herein in their entirety. The following non-limiting Example is illustrative of the invention.
EXAMPLE 1
A 10 micrometer diameter disk on a pedestal had its center connected to a ground terminal using a prefabricated nanobridge. The center of the disk had to be connected to the ground terminal while avoiding any disturbance of the insulating material over the rest of the disk. A curved beam was fabricated from silicon and was then cut from the substrate using focused ion beam (FIB) milling and then lifted with a nanomanipulator after welding the beam to the nanomanipulator using electron beam (E-Beam) chemical vapor deposition. The beam was then placed in position to ground the center of the disk and was welded to the disk and the substrate again using E-Beam chemical vapor deposition. The beam was then cut loose from the nanomanipulator using FIB milling. | In one preferred aspects, methods are provided to produce a three-dimensional feature, comprising: (a) providing a nano-manipulator device; (b) positioning an article with the nano-manipulator device; and (c) manipulating the article to produce the three-dimensional feature. The invention relates to production of nanoscale systems that can be tailored with specific physical and/or electrical characteristics or need to have these characteristics modified. Methods and apparatus are presented that can construct three-dimensional nanostructures and can also modify existing nanostructures in three dimensions. | 1 |
TECHNICAL FIELD
The present invention relates to separators for oil and gas wells, and more particularly to a rotary, downhole, gas and liquid separator and a downhole method of separating gas and liquid from production fluid.
BACKGROUND ART
Liquids are substantially incompressible fluids while gases are compressible fluids. The production fluid in an oil or gas well is generally a combination of liquids and gases. In particular, the production fluid for methane production from coal formation includes the gas and water. Pumping such production fluid is difficult due to the compressibility of the gas. Compression of the gas reduces the efficiency of the pump and the pump can cavitate, stopping fluid flow. Downhole gas and liquid separators separate the gas and liquid in the production fluid at the bottom of the production string, before pumping the liquid up the production string, and thereby improve the efficiency and reliability of the pumping process. In some cases, the waste fluids from the production fluid may be reinjected above or below the production formation, eliminating the cost of bringing such waste fluids to the surface and the cost of disposal or recycling.
U.S. Pat. No. 5,673,752 to Scudder et al. discloses a separator that uses a hydrophobic membrane for separation. U.S. Pat. No. 6,036,749 to Ribeiro et al., U.S. Pat. No. 6,066,193 to Lee and U.S. Pat. No. 6,382,317 to Cobb disclose powered rotary separators. U.S. Pat. No. 6,155,345 to Lee et al. discloses a separator divided by flow-through bearings into multiple separation chambers.
DISCLOSURE OF THE INVENTION
A downhole separator includes a housing defining an interior cavity, a means for restricting fluid flow, an internal pump and a vortex generator. The means for restricting fluid flow is located in the housing and divides the interior cavity into a first chamber and a second chamber. The internal pump pumps production fluid into the first chamber and through the means for restricting flow. The means for restricting flow generates a pressure drop in production fluid entering the second chamber, causing the gas and liquid to separate. The vortex generator segregates the liquid to the outside and gas to the inside of the second chamber. The method of separating liquid and gas from production fluid includes pumping production fluid into a first chamber, generating a pressure drop in the production fluid as the production fluid flows from the first chamber into a second chamber, and generating a vortex in the production fluid in the second chamber.
BRIEF DESCRIPTION OF THE DRAWINGS
Details of this invention are described in connection with the accompanying drawings that bear similar reference numerals in which:
FIG. 1 is a side elevation view of a separator embodying features of the present invention.
FIG. 2 is a side cut away view of the separator of FIG. 1 .
FIG. 3 is a partially cut away view of the head of the separator of FIG. 1 .
FIG. 4 is a partially cut away view of the lower diffuser of the separator of FIG. 1 .
FIG. 5 is a partially cut away view of the upper diffuser of the separator of FIG. 1 .
FIG. 6 is a partially cut away view of the bearing housing of the separator of FIG. 1 .
FIG. 7 is a partially cut away view of the impeller of the separator of FIG. 1 .
DETAILED DESCRIPTION OF THE INVENTION
Referring now to FIGS. 1 and 2, a separator 10 embodying features of the present invention includes a housing 11 , a base 12 , and a head 14 . The housing 11 is a hollow, elongated, cylinder defining an interior cavity 15 . The separator housing 11 has spaced, internally threaded lower and upper ends 17 and 18 .
Describing the specific embodiments herein chosen for illustrating the invention, certain terminology is used which will be recognized as being employed for convenience and having no limiting significance. For example, the terms “top”, “bottom”, “up” and “down” will refer to the illustrated embodiment in its normal position of use. “Inward” and “outward” refer to radially inward and radially outward, respectively, relative to the axis of the illustrated embodiment of the device. Further, all of the terminology above-defined includes derivatives of the word specifically mentioned and words of similar import.
The base 12 has an upper portion 20 , an intermediate portion 21 and a lower portion 22 . The upper portion 20 is an externally threaded, hollow, cylinder sized and shaped to thread into the lower end 17 of separator housing 11 , and includes an upwardly opening, centered, generally cylindrical upper cavity 24 . The intermediate portion 21 has an exterior surface 25 that, in the illustrated embodiment, extends downwardly and inwardly from the upper portion 20 and has a centered lower bearing aperture 26 extending downward from the upper cavity 24 . A lower bearing 28 is mounted in the lower bearing aperture 26 . A plurality of circumferentially arranged inlet ports 27 extend from the exterior surface 25 upwardly and inwardly into the upper cavity 24 . The lower portion 22 is hollow and generally cylindrical, and extends downward from the intermediate portion 21 to an outwardly projecting flange 29 , with a lower cavity 30 extending from the lower bearing aperture 26 .
Referring to FIG. 3, the head 14 includes an upper portion 34 , an intermediate portion 35 extending downward from the upper portion 34 , and a lower portion 36 extending downward from the intermediate portion 35 . The upper portion 34 is generally cylindrical and includes a plurality of spaced, radially arranged, upwardly extending, threaded studs 38 . An external, circumferential channel 39 extends around the head 14 between the upper portion 34 and the intermediate portion 35 . The intermediate portion 35 is externally threaded, and sized and shaped to thread into the upper end 18 of the separator housing 11 . An upwardly opening, inwardly and downwardly tapering, generally conical upper cavity 40 extends through the upper portion 34 and the intermediate portion 35 .
The lower portion 36 has a downwardly and inwardly tapering exterior surface 41 , and a downwardly opening, downwardly and outwardly tapering lower cavity 42 that connects to the exterior surface 41 at a lower end 43 . An upper bearing aperture 44 extends between the upper cavity 40 and the lower cavity 43 , and has an upper bearing 45 mounted therein. A plurality of circumferentially arranged liquid outlet ports 47 extend upwardly and inwardly from the exterior surface 41 to the upper cavity 40 . A plurality of circumferentially arranged gas outlet ports 48 extend upwardly and outwardly from the lower cavity 42 to the channel 39 .
Referring again to FIG. 2, the separator 10 includes a lower diffuser 50 , an upper diffuser 51 , a first sleeve 52 , a means for restricting flow 53 , a second sleeve 55 and a third sleeve 56 , with each having a cylindrical exterior sized and shaped to fit into the interior cavity 15 of the separator housing 11 , and with each being assembled into the interior cavity 15 in the above listed order from the base 12 to the head 14 . In the illustrated embodiment the means for restricting fluid flow 53 is a bearing housing 54 . Other means for restricting fluid flow 53 are suitable for the present invention.
As shown in FIG. 4, the lower diffuser 50 is substantially cup shaped with a generally flat round bottom 58 , an outer wall 59 extending upward from the periphery of the bottom 58 , and a lower diffuser aperture 60 extending through the center of the bottom 58 . Referring to FIG. 5, the upper diffuser 51 includes an upper diffuser aperture 62 extending upwardly through the center of upper diffuser 51 , a cylindrical outer wall 63 , and a plurality of spaced, radially arranged, upwardly, inwardly and helically extending passages 64 between upper diffuser aperture 62 and the outer wall 63 , with passages 64 being separated by radial fins 65 . The outer wall 59 of the lower diffuser 50 extends upwardly and the outer wall 63 of the upper diffuser 51 extends downwardly to space the lower and upper diffusers 51 and 52 apart to define an impeller cavity 67 therebetween.
The bearing housing 54 , as shown in FIG. 6, is generally cylindrical with an intermediate bearing aperture 68 and a plurality of spaced, radially arranged passages 69 extending through the bearing housing 54 . An intermediate bearing 70 is mounted in the intermediate bearing aperture 68 . Passages 69 are configured to restrict fluid flow so that bearing housing 54 divides the interior cavity 15 into a first chamber 71 and a second chamber 72 . In the illustrated embodiment the passages 69 extend upwardly, inwardly and helically, so that the passages 69 initiate vortex generation in the production fluid as the production fluid flows into the second chamber 72 . Referring back to FIG. 2, the first, second and third sleeves 53 , 55 and 56 are each relatively thin walled hollow cylinders. The first sleeve 52 spaces the bearing housing 54 from the upper diffuser 51 . The second and third sleeves 55 and 56 together space the bearing housing 54 from the head 14 .
An elongated cylindrical shaft 74 extends through the interior cavity 15 with a splined lower end 75 extending into the lower cavity 30 of the base 12 and a spaced, splined upper end 76 extending into the upper cavity 40 of the head 14 . Lower, intermediate and upper bearing journals 77 , 78 and 79 are sized and spaced along the shaft 74 to fit the lower, intermediate and upper bearings 28 , 70 and 45 , respectively. A keyway 80 extends longitudinally along shaft 74 with a key 81 mounted therein. An internal pump 82 mounts on the shaft 74 . Internal pump 82 is shown in the illustrated embodiment in FIG. 7 as impeller 83 , in the impeller cavity 67 , having a hub 84 on shaft 74 secured by key 81 and a plurality of spaced, radially arranged, upwardly, outwardly and helically extending passages 85 around the hub 84 . Other styles of internal pump 82 , such as an auger pump, are suitable. A vortex generator 86 is shown in FIG. 2 as a paddle assembly 87 positioned in the second chamber 72 and having a hub 88 on shaft 74 secured by key 81 and a plurality of spaced vertical paddles 89 that extend radially from the hub 88 . Other styles of vortex generator, such as spiral or propeller, are also suitable.
In a typical installation of the separator 10 mounts between a motor on the flange 29 of the base 12 and a well pump secured to the head 14 by the studs 38 . The impeller 83 pulls production fluid into the first chamber 71 of the separator 10 through the inlet ports 27 and lower diffuser 50 and pumps the production fluid into the upper diffuser 51 . The upper diffuser 51 directs production fluid up to the bearing housing 54 .
The passages 69 restrict the flow of production fluid through the bearing housing 54 between the first and second chambers 71 and 72 , generating a pressure drop and rapid expansion of the production fluid enter the second chamber 72 . The rapid expansion of the production fluid causes gas in the production fluid to expand and separate from liquid in the production fluid. From the bearing housing 54 the liquid and gas travel upward to the vortex generator 87 . The paddles 89 push the liquid and gas in a circular direction and thereby centrifugally segregate the liquid at the outside and the gas at the inside of the second chamber 72 . The liquid passes upwardly to the liquid outlet ports 47 and into the well pump. Gas passes upwardly to the gas outlet ports 48 and out of the separator 10 at the channel 39 .
A method of separating gas and liquid from production fluid in a well, embodying features of the present invention, includes providing connected first and second chambers, pumping production fluid into the first chamber, generating a pressure drop in the production fluid as the fluid passes between the first and second chamber, and generating a vortex in the second chamber. More particularly, the first step of the method includes providing connected first and second chambers, a bearing housing between the first and second chambers, a rotary paddle in the second chamber, and gas outlet ports and liquid outlet ports connected to the second chamber, with the bearing housing having a plurality of restrictive passages extending helically between the first and second chambers. The next step includes pumping the production fluid into the first chamber. The next step includes passing said the production fluid through the passages to generate a pressure drop in said production fluid as the production fluid flows into the second chamber to separate the gas and the liquid. Passing the production fluid through the passages also imparts a helical flow to the production fluid and thereby initiates generation of a vortex. The next step includes rotating the paddle to continue vortex generation to further separate the gas and the liquid. The gas is then diverted out of the second chamber through the gas outlet ports, and the liquid is diverted out of the second chamber through the liquid outlet ports.
Although the present invention has been described with a certain degree of particularity, it is understood that the present disclosure has been made by way of example and that changes in details of structure may be made without departing from the spirit thereof. | A downhole separator has a housing defining an interior cavity divided into a first chamber and a second chamber by a flow restricting bearing housing. A shaft driven impeller pumps production fluid into the first chamber and to the bearing housing. The bearing housing generates a pressure drop in production fluid entering the second chamber, separating gas from liquid. A vortex generator in the second chamber segregates the liquid to the outside and the gas to the inside of the second chamber. A downhole separation method includes pumping production fluid into a first chamber, and generating a pressure drop in the fluid as the fluid enters a second chamber to separate gas and liquid. | 4 |
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority of European Patent Office application No. 11185021.0 EP filed Oct. 13, 2011. All of the applications are incorporated by reference herein in their entirety.
FIELD OF INVENTION
[0002] The illustrated embodiments refer to a device for passage measurement for the quick checking of the passability of holes, and to a method for it.
BACKGROUND OF INVENTION
[0003] High-temperature components, such as gas turbine blades, are often cooled from the inside by means of a cooling medium, wherein this discharges from the turbine blades and contributes to film cooling.
[0004] In this case, it is essential for the function and the service life of the turbine blades that the passage is not blocked since otherwise local temperature increases and breaking off of the ceramic coating system can occur during operation.
[0005] These holes can be partially closed off during operation or during reconditioning if the cooling air holes are provided in the substrate and if a subsequent coating on the cooling air hole was not completely removed. There are a number of methods for checking passability, such as infrared camera and hot air excitation, or for checking the water passability and for visually determining whether water discharges from each cooling air hole. This, however, requires costly apparatus and needs time.
[0006] In particular, the application on the plant in remote places requires a quick quality check.
SUMMARY OF INVENTION
[0007] It is an object herein to provide a means or a method with which the passability of cooling air holes can be quickly and simply checked.
[0008] The object is achieved by the features of the independent claims.
[0009] Further advantageous measures, which can be combined with each other as desired in order to achieve further advantages, are listed in the dependent claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] In the drawings:
[0011] FIGS. 1-4 show exemplary embodiments,
[0012] FIG. 5 perspectively shows a turbine blade,
[0013] FIG. 6 perspectively shows a combustion chamber,
[0014] FIG. 7 perspectively shows a gas turbine.
DETAILED DESCRIPTION OF INVENTION
[0015] The figures and the description represent only exemplary embodiments.
[0016] Shown in FIG. 1 is a device 1 for measuring passability of a through-hole 16 ( FIG. 2 ).
[0017] In one embodiment, the device 1 may have three sections, these being a front section 4 , which is inserted into, or seated upon, the through-hole 16 , a middle section 17 , as an option, for better gripping, and an inflatable balloon 10 at the end, which is connected by means of the middle section 7 to the front section 4 so that air can flow from the inlet 3 of the front section 4 , through the middle section 7 , into the balloon 10 .
[0018] The front section 4 consists of rubber, for example, and is sufficiently elastic so that it can be inserted into the through-hole 16 and can completely close it off around the circumference or can completely cover the through-hole 16 by being seated upon it.
[0019] In one embodiment, the front section 4 is may be of an at least partially concentric construction in a way that it does not penetrate too deeply into the through-hole 16 and can exactly surround and cover difficult through-holes.
[0020] Shown in FIG. 2 is how a method is implemented using such means 1 .
[0021] Compressed air 13 , which is provided during each operation and available at site, is introduced into the interior of the turbine blade 120 , 130 which is an exemplary component with a through-hole (a film cooling hole in this case). A corresponding adapter for the blade root or for an inlet opening of the component which is to be checked is used in this case.
[0022] The compressed air is turned on and compressed air discharges from all the through-holes 16 , providing they are not closed off. The device 1 is then applied point by point or depending upon where a constriction is assumed. The device 1 can first of all be inserted into, or seated upon, a through-hole 16 and then the compressed air can be turned on.
[0023] Shown in FIG. 3 is how the balloon 10 is blown up into the state 10 ′ when air discharges from the through-hole 16 at sufficient speed. In this case, the volume is dimensioned so that it does not fill too quickly if a constriction of the through-hole 16 is present, but not too slowly so as to avoid extending the measuring time unnecessarily.
[0024] If a constriction is present in the through-hole 16 , then the balloon 10 fills very slowly (state 10 ″) or hardly at all ( FIG. 4 ) and a visual rechecking and rectification is a specific possibility.
[0025] FIG. 5 shows in a perspective view a rotor blade 120 or stator blade 130 of a turbomachine, which extends along a longitudinal axis 121 .
[0026] The turbomachine can be a gas turbine of an aircraft or of a power plant for electricity generation, a steam turbine or a compressor.
[0027] The blade 120 , 130 has, in sequence along the longitudinal axis 121 , a fastening section 400 , a blade platform 403 adjoining the fastening section, and also a blade airfoil 406 and a blade tip 415 .
[0028] As a stator blade 130 , the blade 130 can have an additional platform (not shown) at its blade tip 415 .
[0029] A blade root 183 is formed in the fastening section 400 and serves for the fastening of the rotor blades 120 , 130 on a shaft or on a disk (not shown).
[0030] The blade root 183 is of inverted-T design, for example. Other designs as a fir-tree root or dovetail root are possible.
[0031] The blade 120 , 130 has a leading edge 409 and a trailing edge 412 for a medium which flows past the blade airfoil 406 .
[0032] In the case of conventional blades 120 , 130 , solid metal materials, for example, especially superalloys, are used in all the regions 400 , 403 , 406 of the blade 120 , 130 .
[0033] Such superalloys are known from EP 1 204 776 B1, EP 1 306 454, EP 1 319 729 A1, WO 99/67435 or WO 00/44949, for example.
[0034] The blade 120 , 130 can be produced in this case by means of a casting process, also by means of directional solidification, by means of a forging process, by means of a milling process, or by combinations thereof.
[0035] Workpieces with a single-crystalline structure, or structures, are used as machine components which are exposed to high mechanical, thermal and/or chemical loads during operation.
[0036] The production of such single-crystalline workpieces is carried out, for example, by directional solidification of the molten metal. In this case, it involves casting processes, in which the liquid metal alloy solidifies, or directionally solidifies, to form the single-crystalline structure, i.e. the single-crystalline workpiece.
[0037] In this case, dendritic crystals are oriented along the heat flux and form either a crystalline structure of columnar grains (columnar, i.e. grains which extend over the entire length of the workpiece and here, in accordance with language customarily used, are referred to as directionally solidified), or a single-crystalline structure, i.e. the entire workpiece consists of a single crystal. In this process, the transition to the globulitic (polycrystalline) solidification must be avoided since as a result of undirectional growth transverse and longitudinal grain boundaries are inevitably formed, nullifying the good properties of the directionally solidified or single-crystalline component.
[0038] If directionally solidified structures are spoken of in general, then both single crystals, which have no grain boundaries or at most have small angle grain boundaries, and crystalline structures with columnar grains, which possibly have grain boundaries extending in the longitudinal direction but no transverse grain boundaries, are meant by this. In the case of these secondly referred to crystalline structures, directionally solidified structures are also spoken of.
[0039] Such processes are known from U.S. Pat. No. 6,024,792 and from EP 0 892 090 A1.
[0040] Also, the blades 120 , 130 can have coatings against corrosion or oxidation, e.g. MCrAlX (M is at least one element of the group consisting of iron (Fe), cobalt (Co), nickel (Ni), X is an active element and stands for yttrium (Y) and/or silicon and/or at least one element of the rare earths, or hafnium (Hf)). Such alloys are known from EP 0 486 489 B1, EP 0 786 017 B1, EP 0 412 397 B1 or EP 1 306 454 A1.
[0041] In one embodiment, the density lies at 95% of the theoretic density.
[0042] On the MCrAlX layer (as an intermediate layer or as an outermost layer) a protective aluminum oxide layer (TGO=thermally grown oxide layer) is formed.
[0043] In one embodiment, the layer composition may feature Co-30 Ni-28 Cr-8 Al-0, 6 Y-0, 7 Si or Co-28 Ni-24 Cr-10 Al-0, 6 Y. In addition to these cobalt-based protective coatings, for example nickel-based protective layers, such as Ni-10 Cr-12 Al-0, 6 Y-3 Re or Ni-12 Co-21 Cr-11 Al-0, 4 Y-2 Re or Ni-25 Co-17 Cr-10 Al-0 4 Y-1, 5 Re, are also used.
[0044] Provision can additionally be made on the MCrAlX for a thermal barrier coating which may, for example, be the outermost layer and consists of ZrO2, Y2O3—ZrO2, for example, i.e. it is not stabilized, is partially stabilized or completely stabilized by yttrium oxide and/or calcium oxide and/or magnesium oxide.
[0045] The thermal barrier coating covers the entire MCrAlX layer.
[0046] By means of suitable coating processes, such as electron beam physical vapor deposition (EB-PVD), crystalline columnar grains are created in the thermal barrier coating.
[0047] Other coating processes are conceivable, e.g. atmospheric plasma spraying (APS), low-pressure plasma spraying (LPPS), vacuum plasma spraying (VPS) or chemical vapor deposition (CVD). The thermal barrier coating can have porous, microcrack- or macrocrack-affected grains for better thermal shock resistance. In one embodiment, the thermal barrier coating is therefore more porous than the MCrAlX layer.
[0048] Refurbishment means that components 120 , 130 have to be freed of protective layers if necessary after their use (e.g. by means of sand-blasting). Removal of anti-corrosive and/or anti-oxidation coatings or products is then carried out. If necessary, cracks in the component 120 , 130 are also repaired. After this, recoating of the component 120 , 130 and re-installing of the component 120 , 130 are carried out.
[0049] The blade 120 , 130 can be of a hollow or solid construction. If the blade 120 , 130 is to be cooled, it is hollow and, if necessary, has film cooling holes 418 (shown by dashed lines) in addition.
[0050] FIG. 6 shows a combustion chamber 110 of a gas turbine.
[0051] The combustion chamber 110 is designed as a so-called annular combustion chamber, for example, in which a multiplicity of burners 107 , which are arranged around a rotational axis 102 in the circumferential direction, open into a common combustion chamber space 154 and create flames 156 . To this end, the combustion chamber 110 is designed in its entirety as an annular structure which is positioned around the rotational axis 102 .
[0052] For achieving comparatively high efficiency, the combustion chamber 110 is designed for a comparatively high temperature of the operating medium M of about 1000° C. to 1600° C. In order to also enable a comparatively long operating period in the case of these operating parameters which are unfavorable for the materials, the combustion chamber wall 153 , on its side facing the operating medium M, is provided with an inner lining which is formed from heat shield elements 155 .
[0053] Each heat shield element 155 , consisting of an alloy, is equipped on the operating medium side with an especially heat-resistant protective layer (MCrAlX layer and/or ceramic coating) or is produced from high temperature-resistant material (solid ceramic tiles).
[0054] These protective layers can be similar to the turbine blades, that means consisting of MCrAlX, for example, wherein M is at least one element of the group consisting of iron (Fe), cobalt (Co), nickel (Ni), X is an active element and stands for yttrium (Y) and/or silicon and/or at least one element of the rare earths, or hafnium (Hf). Such alloys are known from EP 0 486 489 B1, EP 0 786 017 B1, EP 0 412 397 B1 or EP 1 306 454 A1.
[0055] Provision can additionally be made on the MCrAlX for a ceramic thermal barrier coating, for example, and consists of ZrO2, Y2O3—ZrO2, for example, i.e. it is not stabilized, is partially stabilized or completely stabilized by yttrium oxide and/or calcium oxide and/or magnesium oxide.
[0056] By means of suitable coating processes, such as electron beam physical vapor deposition (EB-PVD), crystalline columnar grains are created in the thermal barrier coating.
[0057] Other coating processes are conceivable, e.g. atmospheric plasma spraying (APS), low-pressure plasma spraying (LPPS), vacuum plasma spraying (VPS) or chemical vapor deposition (CVD). The thermal barrier coating can have porous, microcrack- or macrocrack-affected grains for better thermal shock resistance.
[0058] Refurbishment means that heat shield elements 155 have to be freed of protective coatings if necessary after their use (e.g. by means of sand-blasting). Removal of anti-corrosive and/or anti-oxidation coatings or products is then carried out. If necessary, cracks in the heat shield element 155 are also repaired. After this, recoating of the heat shield elements 155 and re-installing of the heat shield elements 155 are carried out.
[0059] On account of the high temperatures in the interior of the combustion chamber 110 , a cooling system can additionally be provided for the heat shield elements 155 or for their retaining elements. The heat shield elements 155 are then hollow, for example, and, if necessary, additionally have cooling holes (not shown) which open into the combustion chamber space 154 .
[0060] FIG. 7 shows by way of example a gas turbine 100 in a longitudinal partial section.
[0061] The gas turbine 100 has on the inside a rotor 103 , with a shaft 101 , rotatably mounted around a rotational axis 102 , which is also referred to as a rotor assembly.
[0062] In series along the rotor 103 are an intake housing 104 , a compressor 105 , a toroidal, for example, combustion chamber 110 , especially an annular combustion chamber, with a plurality of coaxially arranged burners 107 , a turbine 108 and the exhaust gas housing 109 .
[0063] The annular combustion chamber 110 communicates with an annular, for example, hot gas passage 111 . Four turbine stages 112 , for example, which are connected in series, form the turbine 108 there.
[0064] Each turbine stage 112 is formed from two blade rings, for example. A row 125 formed from rotor blades 120 follows a stator blade row 115 in the hot gas passage 111 , as seen in the flow direction of an operating medium 113 .
[0065] The stator blades 130 are fastened in this case on an inner housing 138 of a stator 143 , whereas the rotor blades 120 of a row 125 are attached by means of a turbine disk 133 , for example, on the rotor 103 .
[0066] A generator or a driven machine (not shown) is coupled to the rotor 103 .
[0067] During operation of the gas turbine 100 , air 135 is inducted by the compressor 105 through the intake housing 104 and compressed. The compressed air which is made available at the turbine-side end of the compressor 105 is directed to the burners 107 and mixed with a combustible medium there. The mixture is then combusted in the combustion chamber 110 , forming the operating medium 113 . From there, the operating medium 113 flows along the hot gas passage 111 , past the stator blades 130 and the rotor blades 120 . The operating medium 113 expands on the rotor blades 120 , transmitting an impulse, so that the rotor blades 120 drive the rotor 103 and this drives the driven machine which is coupled to it.
[0068] The components which are exposed to the hot operating medium 113 are subject to thermal loads during operation of the gas turbine 100 . The stator blades 130 and rotor blades 120 of the first turbine stage 112 , as seen in the flow direction of the operating medium 113 , are thermally loaded most of all next to the heat shield elements which line the annular combustion chamber 110 .
[0069] In order to withstand the temperatures which prevail there, these can be cooled by means of a cooling medium.
[0070] Also, substrates of the components can have a directional structure, i.e. they are single-crystalline (SX structure) or have only longitudinally-directed grains (DS structure).
[0071] As material for the components, especially for the turbine blades 120 , 130 and components of the combustion chamber 110 , iron-based, nickel-based or cobalt-based superalloys, for example, are used.
[0072] Such superalloys are known from EP 1 204 776 B 1, EP 1 306 454, EP 1 319 729 A1, WO 99/67435 or WO 00/44949, for example.
[0073] Also, the blades 120 , 130 can have coatings against corrosion (MCrAlX, wherein M is at least one element of the group consisting of iron (Fe), cobalt (Co), nickel (Ni), X is an active element and stands for yttrium (Y) and/or silicon, scandium (Sc) and/or at least one element of the rare earths, or hafnium). Such alloys are known from EP 0 486 489 B1, EP 0 786 017 B1, EP 0 412 397 B1 or EP 1 306 454 A1.
[0074] Provision can additionally be made on the MCrAlX for a thermal barrier coating and consists of ZrO2, Y2O3—ZrO2, for example, i.e. it is not stabilized, is partially stabilized or completely stabilized by yttrium oxide and/or calcium oxide and/or magnesium oxide.
[0075] By means of suitable coating processes, such as electron beam physical vapor deposition (EB-PVD), crystalline columnar grains are created in the thermal barrier coating.
[0076] The stator blade 130 has a stator blade root (not shown here), which faces the inner housing 138 of the turbine 108 , and a stator blade tip which lies opposite the stator blade root. The stator blade tip faces the rotor 103 and is fastened on a fastening ring 140 of the stator 143 . | A device for checking the passability of a through-hole of a component includes a front section and an inflatable balloon. The front section is configured so that it can be pressed into or onto the through-hole. The inflatable balloon is fluidically connected to the front section. In one embodiment, a middle section is provided, which is formed as a tube, wherein the inflatable balloon, is fluidically connected to the front section via the middle section | 5 |
BACKGROUND OF THE INVENTION
This invention relates to drill stem testing in oil and gas exploration which employ apparatus for placing instruments in a deep well bore in the earth for measuring parameters such as temperature and pressure.
It has been found that monitoring parameters such as temperature, pressure and flow rate provide useful information related to the type of material being drilled, drill bit wear, and presence of oil, natural gas or water in or adjacent the bore. Monitoring the above-mentioned parameters and characteristics of a well bore is generally referred to in the art as drill stem testing.
A difficulty associated with well logging is the requirement of removing the drill string to mount sensors thereto and then reinserting the drill string into the well bore. If more than one or two parameters are to be monitored, the problem is particularly exacerbated by the necessity of several removals and reinsertions of the drill string.
Apparatus used to introduce measuring and test instruments into well bores are known as bundle carriers. It would be desirable to use a bundle carrier which could simultaneously introduce a plurality of instruments into a well bore thereby minimizing the repetitive insertion and removal of the drill string. The bundle carrier is generally inserted into a drill string above the drill bit if simultaneous drilling and logging are to occur.
An especially difficult problem in well borehole logging is encountered in mounting instrument bundles to the exterior of a bundle carrier. The bundles and the mounting devices are exposed to the same environment as the exterior of the drill string, and must, therefore, have sufficient structural strength to prevent inadvertent removal and damage to the instruments during drilling operations. Previous instrument bundle carriers do not provide means for readily removing and replacing the instrument bundles in the field and are, therefore, inconvenient for use in many applications. Some previous bundle carriers have passages therein including sharply angled bends so that insertion of other instruments and equipment through such bundle carriers is very difficult and often impossible.
SUMMARY OF THE INVENTION
This invention is used in connection with a bundle carrier for carrying well borehole logging instruments that overcomes the deficiencies of prior art bundle carriers. The bundle carrier preferably includes an elongate body formed generally as a cylinder with an eccentric cavity formed therein. The eccentric cavity causes the bundle carrier body to have a thicker sidewall portion and a thinner sidewall portion. A plurality of longitudinal slots are formed in the thicker sidewall portion for carrying instrument bundles. Longitudinal pressure port passages extend from one end of the slots into the body of the bundle carrier to provide fluid communication between the interior of the bundle carrier and the instrument bundle.
According to this invention, radial passages provide fluid communication between the interior of the eccentric bore and the pressure port passages or between the well bore exterior to the drill string and the pressure port passages. The radial passages permit logging of drilling parameters inside and outside the drill string.
Also, according to this invention, one end of an instrument bundle is connected to a pressure port adapter, and the other end has a projection that extends into a corresponding cavity in a jig. The jig is formed to fit in the slot with the instrument bundle. The other end of the jig includes a projection that extends into a cavity at the end of the slot. A retaining ring has a notch that may be aligned with the cavity in the slot for insertion and removal of the jig. When the jig is inside the cavity, the retaining ring may be rotated to cover the end of the slot and the jig projection to securely retain the instrument bundle and the jig within the slot. The retaining ring preferably includes a pair of set screws for engagement in corresponding detents to prevent rotation of the retaining ring during drilling operations. The pressure port adapters, the jigs and the retaining ring cooperate to retain the instrument bundles in the slots.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 schematically represents a drill string having a bundle carrier according to the invention inside a deep well bore in the earth;
FIG. 2 is a perspective view illustrating the bundle carrier of the drill of FIG. 1 in an expanded scale;
FIG. 3 is a cross-sectional view about line 3--3 of FIG. 2 illustrating a pressure port at one end of the bundle carrier of FIGS. 1 and 2 for providing fluid communication between the hollow interior of the bundle carrier and an instrument mounted in a slot therein for monitoring the well bore and showing a first bore portion concentric with the drill string and a second bore portion eccentric to the drill string;
FIG. 4 is a perspective view of the other end of the bundle carrier;
FIG. 5 is an exploded perspective view of the apparatus of FIG. 4;
FIG. 6 is a cross-sectional view about line 6--6 of FIG. 3 showing passages between the slots and the eccentric bore;
FIG. 7 is a cross-sectional view of the bundle carrier according to the invention including a first pressure port for placing an instrument in one of the slots in fluid communication with the eccentric bore of FIG. 3; and
FIG. 8 is a cross-sectional view taken about line 8--8 of FIG. 6 showing a second pressure port for placing an instrument in fluid communication with the well bore exterior to drill string.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIG. 1, in deep subterranean drilling operations, a drill string 20 carrying a drill bit 21 extends into a well borehole 22. In order to monitor parameters such as temperature and pressure in the well borehole 22 during drilling operations, a bundle carrier 24 is mounted in the drill string 20 above the drill bit 21.
Referring to FIG. 2, the bundle carrier 24 includes a first end 26 and a second end 28 having male and female threaded portions, respectively, for mounting the bundle carrier 24 in the drill string, which is preferably standard 5.5 inch outer diameter drill string piping with a central bore (not shown) having a diameter of about 2.25 inch. As shown in the hidden lines of FIG. 3, the bundle carrier 24 includes a first frustoconical portion 32 adjacent the end 26 and a second frustoconical portion 34 adjacent the end 28. The frustoconical portions 32 and 34 are concentric with and about the same diameter as the central bore 30 in the drill string 20. The bundle carrier 24 preferably includes an eccentric bore portion 36 that is about the same diameter as the central bore. A first transition section and a second transition section, respectively, are formed as part of portions 32 and 34 and smoothly connect the frustoconical portions 32 and 34 with the eccentric bore portion 36.
Referring to FIG. 3 and 6, the eccentricity of the bore portion 36 causes a first portion 42 of the sidewall of the bundle carrier 24 to have a greater thickness than a second portion 44. A plurality of slots 46-49 are formed in the thicker wall portion 42 in longitudinal alignment with the eccentric bore 36. The slots 46-49 are preferably formed by machining the cylindrical outer surface of the bundle carrier 24. As best shown in FIGS. 6 and 7, a plurality of passages 51-54 extend from the slots 46-49, respectively, into the bundle carrier 24 axially aligned with the eccentric bore 36. The passages 51-54 are preferably formed in the slots 46-49 at the lower ends, respectively by machining processes known in the art.
Referring to FIGS. 2 and 7, a pressure port 62 is inserted into the passage 51. The pressure port 62 has a generally cylindrical body 64 having a passage 66 therein. A plurality of O-rings 60 are mounted to the body 64 to form seals with the walls of the passage 51. The pressure port 62 includes a side inlet 63 extending into the passage 66 at a narrowed portion 69, which is inserted into the passage 51. A radical bore 65 extends between the eccentric bore 36 and the passage 51 to provide fluid communication therebetween. When the pressure port 62 is fully inserted into the passage 51, the narrowed portion 69 cooperates with the walls of the passage 51 to form a small void 71 that is in fluid communication with the interior of the eccentric passage 36. The radial bore 65 is formed by drilling through the bundle carrier near the end 26 at a location 73. The passage 65 is plugged at the outer surface of the bundle carrier 24 by any suitable means such as welding. As shown in FIG. 6, the passages 52, 53 and 54 have radial bores 65A, 65B and 65C that are substantially identical to the radial bore 65.
A male threaded fitting 70 extends from an end 72 of the pressure port 62 for threaded engagement with an instrument carrier 74 positioned within the slot 36. An O-ring 76 is preferably positioned between the fitting 70 and the body 64 to provide a seal when the instrument carrier 74 and the pressure port 62 are engaged in a manner suitable for use in drill stem testing. The pressure port 62 also preferably includes a hexagonal flange 78 suitable for engagement by a wrench, (not shown) to threadedly engage the fitting 70 and the instrument carrier 74. When fully assembled, the passage 51 and the corresponding pressure port 62 with side inlet 63 cooperate to provide fluid communication between the eccentric passage 36 and the instrument carrier 74 mounted in the slot 46.
The passages 52, 53 and 54 are formed to be substantially identical to the passage 51 and to receive therein pressure ports similar to the pressure port 62.
FIG. 8 illustrates a second pressure port 82 that may be inserted into the passage 52 for providing fluid communication between the well borehole 22 outside the bundle carrier 24 and drill string 20 and the instrument carrier 74. The pressure port 82 includes a passage 83 having a side inlet 85. The pressure port 82 includes the O-rings 60 and 76, the flanged portion 78 and the threaded portion 70 of the pressure port 82.
The instrument carrier 74 is formed generally as an elongate cylinder having one end 84 threaded to engage one of the pressure ports 62 and 82. The other end of the instrument carrier 74 extends in its corresponding slot, for example, the slot 46 to a location near the end 28 of the bundle carrier 24. The instrument carrier 74 has a projection 88 extending therefrom toward the end 90 of the slot 46. As shown in FIG. 5, a jig 92 includes a cavity 94 formed to receive the projection 88. When the instrument carrier 74 and the jig 92 are positioned in the slot 46, a projection 95, which may be generally shaped as a semi-cylinder, extends into a cavity 96, which may be an extension of the slot 46.
A retaining ring 98 is preferably attached to a portion 99 of the bundle carrier 24 that has been machined to a reduced diameter. The retaining ring is preferably formed in two arcuate portions 98A and 98B, that are welded together to form the retaining ring 98 as an integral unit.
The retaining ring 98 is rotatably mounted to the bundle carrier 24 in a groove 99 that is preferably machined into the bundle carrier 24 adjacent the end 28 thereof. The retaining ring 98 includes a notch 100 having a width approximately equal to that of the slot 46 and the jig 92. The jig 92 with the instrument carrier 74 engaged therewith is placed in the cavity 46 with the projection 95 extending into the cavity 96 while the notch 100 is aligned therewith. After the jig 92 is in the desired position, the retaining ring 98 is rotated to cover the cavity 96 to retain the jig 92 and instrument carrier 74 in the slot 46. The retaining ring 98 is preferably formed of two portions 98A and 98B, best shown in FIG. 5, that are welded together.
The bundle carrier 24 as shown, comprises four slots 46-49 for holding instrument carriers. The ring 98 may have a plurality of angularly spaced notches 100 with a separate notch corresponding to each of the slots 46-49, which permits simultaneous locking of instrument carriers, such as the instrument carrier 74, into the bundle carrier 24. The retaining ring 98 may also have only the single notch 100, which simply requires that each of the slots 46-49 be loaded and locked in succession.
As shown in FIGS. 4 and 5, the retaining ring 98 preferably includes a passage 102 configured for engagement with a generally cylindrical rod (not shown), which is then used as a wrench for rotating the retaining ring 98 to a desired position. Referring to FIG. 4, a pair of set screws 104-105 are positioned in the ring 98. When all of the cavities 96 at the ends of the notches 46-49 are covered by the ring 98, the set screws 104-105 may be aligned with a corresponding pair of recesses 106-107. The set screw 104-105 preferably are configured for being driven by means such as an Allen wrench, not shown, into the recesses 106-107 for retaining the ring 98 against rotation in the slot 99. The heads of the set screws 104-105 should not project outwardly of the curved surface of the retaining ring 98.
The eccentric bore 36 is a particularly important feature of the present invention. The outer diameter of the bundle carrier 24 cannot exceed the diameter of an ordinary drill string, which has a typical outside diameter of 5.5 inches. The minimum interior diameter of the eccentric bore 36 is 2.25 inch in order to accomodate instruments and other equipment normally used in drilling operations. Therefore, if the bore 36 were centered in the bundle carrier 24, the wall thickness thereof would be only 1.125 inch uniformly around the circumference. It has been found that for many instruments, a wall thickness of 1.125 inch is insufficient for forming the slots 46-49 and the corresponding ports 51-54 to provide flush mounting with the outer surface of the bundle carrier 24 while providing adequate structural strength to withstand the pressures and axial loads encountered in drill stem testing.
In the present invention, the slots 46-49 are formed in the thicker walled portion 42 of the bundle carrier 24, which affords ample space for carrying instruments without unacceptable reduction of the torsional strength. By providing the bundle carrier 24 with an eccentric bore 36 matched to the bore 30 of the drill string by the frustoconical portions 32 and 34, the present invention advantageously permits well bore logging during drilling operations and insertion of equipment and other instruments via a cable through the drill string 22 to the drill bit 21, if desired.
Typical dimensions for the bundle carrier 24 of the invention include a length of about 8 feet. The thinnest portion of the wall portion 44 is about 0.330 inch, and the thickest portion is about 1.625 inches. The instrument carrier 74 is typically about five feet long and about 11/4 inch in diameter. The slots 46-49 are sufficiently long to accommodate the five foot long instrument carrier 74 and the jig 92. The width of the slots is slightly greater than the 11/4 inch outer diameter of the bundle carriers 74, that they may be easily inserted into the slots 46-49 and removed therefrom.
Although the present invention has been described with reference to a particular preferred embodiment, it is to be understood that those skilled in the art may made numerous modifications of the preferred embodiment without departing from the scope and spirit of the invention. Accordingly, all modifications and equivalents that are within the scope and spirit of the invention are included in the claims appended hereto. | This invention provides a bundle carrier for deep drill stem testing in oil well drilling. The bundle carrier has an eccentric passage for permitting instruments and other apparatus to be passed therethrough during drilling and logging operations. A plurality of slots are formed in the thicker wall portion of the bundle carrier for receiving instrument bundles therein for making measurments of well borehole parameters. A locking device for securing measuring instruments in the slots and parts for communicating fluid to the measuring instrument are provided by this invention. | 4 |
This is a continuation of application Ser. No. 08/250,797, filed May 27, 1994, now U.S. Pat. No. 5,572,940.
BACKGROUND OF THE INVENTION
This invention relates to a method and apparatus for producing finished sewn products from a roll of cloth. More particularly, the method and apparatus pertains to cutting predetermined lengths of fabric from a large roll of fabric and then performing various sewing operations on the fabric to produce articles such as lined drapes, sheets, valances, etc.
Heretofore, one of the major expenses in producing valances was cutting lengths of fabric to precise lengths and then sewing folded hems on the edge of the fabric prior to performing additional sewing operations. Such has been time consuming and labor intensive adding considerable cost to the finished products.
OBJECTS AND SUMMARY OF THE INVENTION
It is a principal object of the present invention to provide a method and apparatus for efficiently cutting fabric into predetermined lengths and automatically performing sewing operations thereon.
Another important object of the present invention is to provide a method and apparatus for automatically cutting fabric from a large roll and then automatically folding the edges of the fabric. The folded edges are then sewn into hems, and the fabric is transported to a folding station. After the fabric has been folded at the folding station, it is then transported to another sewing station for performing sewing operations thereon.
Still another important object of the present invention is to provide an efficient and automatic system for folding and sewing sheet material.
Still another important object of the present invention is to provide an efficient method and apparatus for automatically producing sewn valances from a roll of cloth.
Still another important object of the present invention is to provide an apparatus and method for automatically producing hemmed fabric for subsequent manufacture into drapes and the like.
Still another important object of the present invention is to provide a method and apparatus for cutting fabric in predetermined lengths, folding the edges of the fabric to produce precise hems and then transporting said fabric to a receiver.
A further object of the present invention is to provide a method and apparatus for precisely folding fabric of a predetermined length into a desired folded pattern for subsequent sewing.
Still another important object of the invention is to provide a method and apparatus for automatically sewing sockets and pockets into a folded fabric to produce valances.
Additional objects of the invention will be set forth in part in the description which follows, and in part will be obvious from the description, or may be learned by practice of the invention. The objects and advantages of the invention may be realized and attained by means of the instrumentalities and combinations particularly pointed out in the appended claims.
To achieve the objects and in accordance with the purpose of the invention, as embodied and broadly described herein, the apparatus of the present invention comprises a let off device which carries a large roll of fabric that is to be used for producing the finished product. The fabric is unwound by the let off device which is under the control of a dancer so as to maintain uniform tension in the fabric as it leaves the let off device. The open fabric then passes under a pair of spaced edge cutters which trim opposed edges of the fabric to a predetermined width.
After the fabric has been trimmed, the edges of the fabric are folded in by a hem forming and hem width control device. The folded edge of the fabric is maintained at a precise location by means of a photoelectric sensor and a hem shifting device. The photoelectric sensor includes a pair of laterally spaced photosensors which generate signals indicating when the edge of the fabric is at the precise location in between the two photodetectors. The photodetectors in turn control the hem shifting device to keep the edge of the hem properly aligned. After the hem has been folded onto the edges of the open cloth, the hem then passes through a curling device which curls the outer edge of the hem under so as to produce a double layer hem. This curl portion is then passed under a sewing head which advances the cloth and sews the hem into the edges of the fabric. The fabric is then fed into an accumulator which accumulates a predetermined length of fabric.
Following the accumulator is a length cutter which makes a transverse cut across the fabric to cut the fabric into predetermined lengths.
In order to cut the fabric into predetermined lengths, a cloth puller moves from the downstream end of the machine to adjacent the cutting head for gripping the edge of the fabric in order to pull the fabric from the accumulator when the cloth puller is moved back towards the downstream end of the machine. After the cloth puller pulls the cloth back towards the end of the machine, a predetermined length of cloth rests on a folding table and is ready for being folded into a desired pattern. In one particular embodiment, the apparatus is used for making valances. At the folding table it is desired to fold the open fabric so that it can be subsequently sewed with elongated stitching to produce the final product.
In order to fold the open length of fabric on the folding table, a pair of spaced dies are lowered down on top of the fabric. The dies are spaced a distance that corresponds to the ultimate width of the valance.
Once the dies are lowered onto the fabric carried on the folding table, the cloth puller which is still gripping the leading edge of the fabric is moved back towards the front end of the machine, folding the fabric over a first die. It then releases the leading edge of the cloth and moves back adjacent the end of the machine. The trailing edge of the cut cloth is then folded up over the second die and overlaps the edge of the cloth that was previously folded.
The cloth in this folded position is then transported to a sewing station wherein two sewing heads are provided for sewing a pair of elongated spaced stitching so as to form a socket in the folded fabric for receiving a curtain rod as well as a pocket in the fabric. This completes the construction of the valance.
The apparatus and machine can also be used for producing lined draperies. When being used to produce lined draperies, a second roll of fabric is carried on a second let off above the first let off which carries the facing layer of fabric. The fabrics are superimposed on each other under uniform tension. The superimposed liner and facing are then passed through the cutting and hem forming device as described above. The cloth puller is used for pulling the sewn liner and facing from an accumulator so that they can be cut to a desired length.
The folding operation discussed above takes place in a similar but wider spaced configuration when producing lined draperies.
The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate the embodiments of the invention and together with the description, serve to explain the principle of the invention.
It is to be understood that the invention is made up of a plurality of various elements. It is understood of course that equivalent components could be substituted for the elements shown in the drawings and described hereto in the specification without departing from the spirit or scope of the present invention.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side elevational view illustrating a portion of a machine constructed in accordance with the present invention.
FIG. 2 is an enlarged perspective view illustrating a cutting head used for cutting the edge of a fabric.
FIG. 3 is an enlarged perspective view illustrating an edge folding and positioning device.
FIG. 4 is an end view of the edge aligning and locating device.
FIG. 5 is an elevational view illustrating one of the sewing machines used for sewing the hem on one side of the fabric.
FIG. 6 is a sectional view illustrating the curl and double folded hem produced on the edge of the fabric.
FIG. 7 is an elevational view illustrating a sewing head positioned on the opposite side of the fabric from the sewing head of FIG. 5.
FIG. 8 is an enlarged perspective view illustrating one of the sewing heads used for sewing the hems into the fabric.
FIG. 9 is a perspective view illustrating another embodiment of the sewing head of FIG. 8.
FIG. 10 is a perspective view of a movable cutter which is used for cutting the cloth into predetermined lengths.
FIG. 11 is an enlarged perspective view illustrating the cutter head from part of the cutter of FIG. 10.
FIG. 12 is a cross-sectional view of a movable gripping head carried on the cloth puller shown in more detail in FIG. 21.
FIG. 13 is an end view partially in section illustrating a portion of the folding table and the cloth pulling mechanism.
FIG. 14 is an end view illustrating the cloth pulling mechanism in a position immediately prior to gripping the end of the cloth.
FIG. 15 is an end view partially in section of the cloth pulling mechanism gripping the cloth.
FIG. 16 is an end view of the cloth pulling mechanism after the cloth has been pulled back over the folding table.
FIG. 17 is an end view of the cloth pulling mechanism and the folding table showing the dies being placed down on the cloth.
FIG. 18 is an end view illustrating the folding table and the first fold of the fabric forming a folded valance.
FIG. 19 is an end view illustrating a folding table illustrating the trailing edge of the fabric being folded into a valance.
FIG. 20 illustrates an end view of the folding table showing the fabric in a folded condition immediately prior to being transported to a sewing mechanism.
FIG. 21 is an enlarged fragmentary perspective view illustrating a portion of the cloth pulling device.
FIG. 22 is an enlarged perspective view illustrating a pair of dies used for holding the cloth down on the folding table during the folding operation.
FIG. 23 is a cross-sectional view illustrating a gripping device for gripping and retaining the cloth prior to the cloth being cut into predetermined lengths.
FIG. 24 is an enlarged perspective view illustrating the folded cloth on the folding table prior to sewing.
FIG. 25 is a fragmentary perspective view illustrating part of the cloth processing apparatus.
FIG. 26 is a plan view illustrating a final sewing station for sewing valances.
FIG. 27 is a perspective view illustrating a valance that was sewn automatically on the apparatus of the present invention.
FIG. 28 is a perspective view with parts broken away for the purpose of clarity illustrating a sewn valance.
Repeat use of reference characters in the present specification and drawings is intended to represent same or analogous features or elements of the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring in more detail to the drawings, FIG. 1 is a side elevational view of the machine which is provided for hemming and cutting predetermined lengths of material from a large roll of material 10. The large roll of material 10 is carried on a let off A. The let off A includes a pair of idle rollers 14 and 16 which permit the roll 10 of cloth to be rotated when it is pulled by a power driven roll 18 which has a friction covering thereon. The power driven roll 18 is driven by an electric motor 20. The motor is a variable speed driven motor which is under control of a dancer roll 22. The dancer roll 22 is permitted to move up and down responsive to variations in tension in the cloth extending therearound. As the dancer roll 22 moves up and down, it varies the adjustment on a potentiometer that in turn varies the voltage applied to the motor drive board for varying the let off speed for the cloth. The cloth 24 is then fed from the let off A up over a guide roll 26 onto a sewing table 28. As the cloth enters the sewing table, it first passes through an edge cutting device B. There are two edge cutters B spaced on opposite sides of the table so as to cut the cloth to a predetermined width. The cloth then moves under an edge folding and positioning station C which forms a fold of a predetermined width in the edge of the cloth. This occurs on one or both sides of the cloth.
From the edge folding and positioning station C, the cloth is then fed to a hem folding mechanism D which folds the hem into a double fold. From the hem folder D, the cloth is then fed under to a hem sewing head and cloth advancer E for sewing the hem into the edge of the cloth.
The cloth is fed from the hem sewing head and cloth advancer E into an accumulator F which accumulates a cloth reserve. The cloth passes around an adjustable tension roll 30 provided in the accumulator and from the roll 30 proceeds up onto a cutting table.
Provided on the cutting table is a length cutter G which cuts the cloth from one side to the other.
The particular length of cloth that is cut at this point is controlled by a cloth puller H. To explain the operation to this point we will take up from the point where the cloth was previously cut. As a result, there is a leading edge of cloth 24 directly under where the transverse cutter blade severed the cloth.
The cloth puller H is brought up from the end of the machine into engagement with the leading edge of the cloth 24 directly under the path of the cutting blade. The cloth puller H then grips the edge of the cloth and pulls it back towards the end of the machine over a folding table 8. The cloth puller H pulls the cloth a predetermined length. Once the cloth 24 reaches that predetermined length, the cloth puller H is stopped by a proximity switch. The length cutter G then cuts the cloth extending over the table to a predetermined length.
While the cloth is on the folding table, folding dies I are lowered down on top of the cloth. Die lifters J are used for lowering the dies I down onto the cloth and retracting. Later they cycle to raise them up off of the cloth. Once the dies I are put in position on top of the cloth, the cloth puller H is moved back towards the cut edge to fold the leading edge of the cloth over the first folding die. It releases the cloth and retracts back to the end of the machine.
A trailing end folder K is then used for folding the trailing end of the cloth over the other die and other edge of the cloth. Once the cloth is folded, and in this particular instance for making a valance, a cloth hold down bar L is lowered on top of the free edges of the cloth pressing them in contact with a cloth shifter M. The cloth shifter M includes a plurality of drive belts which are supported on the folding table 8 directly beneath the bottom surface of the folded cloth and are in engagement therewith. In particular, the two dies and the cloth hold down bar L press the cloth down into engagement with the cloth shifting belts M.
The folded pattern is then shifted laterally off of the folding table.
As the folded pattern is shifted laterally off of the folding table, the leading edge comes in contact with an edge separating device N (see FIG. 26) which separates the upper edge from the lower edge and feeds it into a hem edge curler O which curls the upper edge inward to form a hem. The curled upper edge then is shifted by the cloth shifter M into engagement with the sewing head of a first sewing machine P. The first sewing machine sews the hem into the folded pattern to produce a pocket in the folded fabric. A second sewing head Q follows the first sewing head P and puts a continuous stitch in the fabric which is laterally spaced from the stitch placed by the first sewing head P so as to sew an elongated socket in the valance which is capable of receiving a curtain rod.
A photocell R is carried by the first sewing head P to sense the leading edge of the folded pattern as it is shifted by the cloth shifter M. At this point in the operation, both of the sewing heads P and Q are operating at the same speed so as to place the same number of stitches per inch in the fabric. However, upon the photosensor R sensing the leading edge of the folded pattern, it causes a signal to be generated that in turn slows down the rate that the cloth shifter is moving the cloth over the table and also slows down the stitching speed of the second sewing machine Q. As a result, the first sewing machine P goes into a tack mode to place more stitches per inch at the leading edge of the folded fabric. The tack mode continues for approximately one inch and then a controller associated with the operation of the sewing station returns the cloth edge shifter M to its original traveling speed and returns the speed of the second sewing head Q to its original speed. At this point in time, the folded fabric continues to be moved under both of the sewing heads P and Q to place a less dense stitch in the main body of the valance. Upon reaching the trailing edge of the folded pattern, the tack mode is again entered into to place more stitches per inch adjacent the trailing edge of the valance. All of this is under control of a controller that is activated by the photocell R. Any suitable controller can be used for synchronizing the operation of the feed of the fabric with the speed of the cloth shifter M and the sewing machine Q.
Before describing in detail the operation of the cloth cutting and sewing apparatus, one's attention is directed to a valance such as shown in FIGS. 27 and 28 that can be produced automatically on the apparatus. As can be seen, the valance 50 is produced from a predetermined length of fabric that is folded over and has a hem 52 sewed along its length. Another seam 54 is sewn longitudinally the length of the valance. As a result, a socket 56 is produced in the valance for receiving the conventional curtain rod holder and a pocket 58 is provided in the valance which can be stuffed with any suitable material to bulk up the valance if desired.
As shown in FIG. 27, when the valance is mounted over a window it has a header portion 60 located directly above the socket 56 through which the curtain rod extends. The valance can be gathered together to any degree to make the final position and design of the valance aesthetically pleasing.
Referring now to FIG. 1, the let off A may be any suitable conventional let off that allows the cloth to be unrolled from a large roll of cloth such as 10 and supplied under a uniform tension to a working table.
One particular cutter B that can be used for cutting an edge 70 off of the cloth is shown in FIG. 2. It includes a motor 74 which can be energized by any suitable source of power that is in direct engagement with a shaft 76 which carries a rotating cutting disc 78. As the cloth 24 moves under the disc 78, it severs the cloth. In order to make the cut produced by the rotating disc cleaner, a carbide block can be placed closely adjacent the lower edge of the blade so that the cloth is severed by the outer edge of the blade pressing against the carbide block. An edge sharpener 80 can be carried adjacent to the cutting edge of the blade for being brought into engagement when desired to sharpen the blade 78. The blade assembly and motor 74 is mounted on a carriage 80 which can be shifted laterally on a cross-support bar 82 that is in turn supported on the frame 84 of the table. As a result, the width of the cloth can be adjusted by moving the cutting head B laterally onto the cross bar 82.
As the edge of the cloth 24 is severed by the cutting blade 78, it then passes between a channel shaped member 86 which maintains the edge of the cloth straight during the severing operation by the blade.
After the cloth passes through the channel shaped member 86, it is fed to the edge folding and positioning station C. The edge folding and positioning station C is shown in greater detail in FIGS. 3 and 4. The purpose of the edge folding and positioning station C is to properly and uniformly fold both edges of the fabric so that a straight and uniform width hem can be subsequently sewed into the edges of the cloth. The location of the inner edge 90 of the cloth is sensed by a pair of photoelectric sensors 92 and 94. As long as the edge of the folded cloth is positioned in between the sensors 92 and 94, no signal is generated to rotate an adjusting wheel 96. As a result, a uniform width fold is produced in the edge of the cloth for subsequently hemming.
If the width of the fold is too great, then both of the photosensors 92 and 94 will be activated. When such occurs, a signal is generated and fed to an electric motor or any other suitable type motor 98 through conventional control circuitry. When the motor 98 is in turn activated, it rotates the wheel 96 clockwise. This clockwise motion of the wheel 96 causes the edge 90 of the cloth 24 to move outwardly. After a short delay, photosensors 92 and 94 are again activated for sensing the edge 90 of the cloth 24. If the cloth is not properly aligned at this point, the wheel 96 is rotated further. If inner edge 90 is properly aligned between sensors 92 and 94, no further adjustments are needed, and wheel 96 assumes a straight path.
If on the other hand the folded edge 90 is not wide enough and does not come between under each of the photosensors 92 and 94, then the wheel 96 is rotated in the counterclockwise direction similar to as described above to guide the edge 90 of the fabric back between the photosensor cells.
The photosensor cells 92 and 94 include a light source positioned under the fabric and a sensor positioned on a space member. The fabric moves between the light source and the two sensor heads and operates in the conventional manner.
The position of the wheel 96 can be physically adjusted by loosening a screw 100 that is carried within an elongated slot 102 provided in a bracket 104. The screw extends into a horizontal supporting plate 106 which is in turn carried on top of support block 108. As can be seen in FIG. 4, the support block 108 is in turn hinged adjacent its lower end through a hinge 110 to a fold forming plate 112.
The fold forming plate 112 has a vertically extending flange 114 that is in turn fixed to a vertical shaft 116 as shown in FIG. 3 that is in turn carried on a slidable tubular member 118. The slidable tubular member 118 is carried on a square horizontally extending tubular member 120. As a result, the horizontal or lateral position of the entire edge folding and positioning station C can be adjusted.
A spring loaded screw 122 extends between the support block 108 and the vertical flange member 114 for applying a predetermined pressure through the wheel to the cloth during its guiding operation. As can be seen in FIG. 4, the entire wheel assembly including the wheel 96 and the motor 98 can be pivoted slightly about the hinge 110 for controlling the pressure asserted on the cloth during the guiding operation.
After the cloth passes under the edge folding and positioning station C, it then moves through a conventional hem edge curler D such as shown in cross-section in FIG. 6. The hem edge curler D includes a spherically twisted piece of sheet metal 130 that curls the cloth 24 into a double fold adjacent its leading edge 90 such as best shown in FIG. 6. Such is a conventional hem forming mechanism. Once the fold is placed in the edge of the cloth 24, it then passes under a hem sewing head and cloth advancer E as shown in FIGS. 5, 7, 8, and 9. At this point on the table, the cloth has been advanced or moved forward by the cloth advancer E.
The hem sewing head 142 is a conventional sewing head that sews the hem into the edge of the cloth once it is folded by the folder D.
Coupled to the shaft 140 of the sewing head 142 is an eccentrically mounted linkage 144. This linkage in turn is connected off center to a shorter linkage 146 that is in turn carried on a shaft 148.
During the sewing operation, the upper shaft 140 of the sewing machine runs continuously. As a result of the linkage 144 being eccentrically attached to the shaft, a reciprocating motion is imparted to the linkage member 144. Such is shown by the arrow 150 in FIG. 8. This reciprocating motion is in turn imparted to the shaft 148 which has a sprague clutch mounted therein which permits rotation to take place in one direction. The output of the sprague clutch is connected to an advancing roll 152 that engages the surface of the cloth 24 for pulling the cloth through the sewing head and across the table described previously.
The purpose of intermittently pulling the cloth through the sewing head is for not pulling the cloth when the needle is in the cloth. In other words, the material is only pulled when the needle comes out of the cloth. Thus, the feed roll 152 advances the cloth a predetermined distance in synchronicity with the sewing machine. A second roller 154 is positioned in tandem with the drive roller 152 and is in pressure engagement therewith so that when the drive roll 152 is rotated it causes the cloth 24 to be advanced therebetween.
As shown in FIG. 8, the sewing head E is carried on laterally extending guide rails 156 and 158 so that its position can be adjusted for accommodating and sewing cloth of various widths.
As a result of using a sprague clutch to the output of shaft 148 instead of a ratchet, the clutch will give infinitesimal adjustable intermittent forward movement through the cloth as compared to a ratchet which would be controlled by the spacing between the individual teeth. The principle of moving in one direction is analogous to a ratchet operation but by operating through a sprague clutch one can adjust the forward stroke.
In FIGS. 8 and 9, two embodiments of a sewing head and cloth advancer E are shown. In particular, in FIG. 8 the drive roller 152 is located above second roller 154. In FIG. 9, on the other hand, drive roller 152 is located below the second roller 154. Either embodiment can be used in the apparatus of the present invention. However, for most conventional sewing heads such as 142, preferably the drive roller is located below the static roller for smoother operations. Of course, depending upon the equipment used or the particular circumstances, drive roller 152 can be placed in either position.
After the cloth 24 passes under the hem sewing head and cloth advancer E it is then fed into the accumulator F as shown in FIG. 1. The weight of the roll 30 pulls the cloth down into the accumulator to accumulate a reserve of cloth.
The cloth extends around the bottom surface of the roll 30 and up on top of the length cutting table where a length cutter G has previously severed the cloth. At the cutting table, the cloth is being held in place by means of a brush like member 170. The brush like member 170 extends entirely all the way across the frame. The angles of its bristles 172 point in the forward direction, in the direction of the cloth, so that the cloth can pass easily thereunder. However, brush member 170 prevents the cloth from being pulled backwards into the accumulator once the edge of the cloth has been severed by the length cutter G.
The length cutter G is shown in greater detail in FIGS. 10 and 11. It includes a cutting head 174 that is propelled back and forth across the cutting table by a gear tooth belt 176 that is driven by a driven pulley 178. The pulley 178 is driven by a conventional electric motor 180 through a gear box 182 which is shown in broken lines in FIG. 10 so as not to obscure the remaining parts of the drawing. The cutting head is carried on a channel shaped bracket 184 that is in turn attached to the gear tooth belt 176 by means of bolts 186 which extend through a plate 188. The channel member 184 is in turn attached to a supporting block 190 that has a pair of spaced guide channels 192 and 194 attached thereto. The pair of spaced guide channels are in turn supported on a rail 196. The guide channels 192 and 194 are made of a self-lubricating material such as high molecular weight polyethylene so that the cutting head can be readily reciprocated back and forth across the machine during the cutting operation.
The timing belt 176 extends around a roller 198 which guides the belt around a geared roller 200 for driving the gear roller 200. The belt then extends up around another idle roller 202. As a result, as the belt is driven by the drive roller 178, the cutting head moves back and forth across the cutting table. As it moves back and forth across the cutting table, the gear roller 200 is rotated. The gear roller 200 is fixed to a shaft 204. The other end of the shaft 204 has a circular cutting blade 206 secured thereto.
A leaf spring 208 is carried adjacent to the lower end of the cutting head and the blade 206 so that it passes under the cloth during the cutting operation and guides the cloth into engagement with the rotating edge of the blade 206. A carbide cutting block 210 is positioned adjacent to the bottom edge of the cutting blade 206 so as to make a clean severance of the cloth as the cutting head traverses back and forth across the machine.
The cutting head has a sharpening device 212 mounted thereon so that when a sharpening head 214 is brought into engagement with the rotating blade, it sharpens the edge of the blade at a proper angle.
The guide rail 196 upon which the length cutter G is carried extends entirely across the cutting table and is supported by its ends by any suitable standards.
As shown in FIG. 1, the cloth puller and leading edge folder device H is provided for pulling a predetermined length of cloth from the accumulator across a folding table 8 so that the length of the cloth can be cut by the length cutter G. The cloth puller has a gripping jaw that can be closed over the edge of the cloth that was cut by the length cutter. Once the cloth puller H engages the edge of the cloth, it can be retracted for pulling a predetermined length of cloth from the accumulator F.
The cloth puller H as shown in FIGS. 12 and 21 includes a pivoting gripping jaw 220 that has an upper movable flange member 222 that is hinged at hinge joint 224 that can be pivoted downwardly to a closed position to grip the leading edge of the cloth 24 with a cooperating jaw 226 located therebelow. The gripping jaw has a vertically extending flange 228 connected thereto so that when the flange is pushed forward by a plunger 230 to a vertical position, the gripping jaw 220 will be pushed down to grip the cloth. The plunger 230 is carried on the output of a pneumatically operated cylinder 232 that has a piston 234 extending therefrom. The hinge member 224 is supported on a base plate 236 that is in turn secured to a tubular member 238. The tubular member 238 is in turn supported on spaced slide blocks 240 constructed of lubricated high molecular weight polyethylene material. Angle members 242 secure the tubular member 238 to the side block 240. Side blocks 240 are carried on opposite sides of the frame as only one side of the cloth puller H is shown in FIG. 21. The slide blocks 240 are in turn carried on a tubular rail 244 that is suitably supported on side frame members 246. The guide blocks 240 have a metal support plate 248 attached to the bottom thereof which are in turn attached to a timing belt 250. The timing belt 250 extends around spaced driven pulleys 252. One of the pulleys 252 is supported on a rotatable shaft 254. The upper end of rotatable shaft 254 has a gear 256 provided thereon. The gear 256 is in turn coupled by a chain 258 to a grip driven gear 260. The driven gear 260 is coupled to the output of a gear box 262 which has its input connected to a motor 264. By turning the motor 264 on and off, the gripping jaw 220 can be moved along the guide rail 244 to a position closely adjacent the previously cut end of the cloth for gripping the cloth. Once the gripping jaw 220 is engaged to grip the cloth, it can be retracted to pull a predetermined length of cloth from the accumulator.
A spring 266 extends from a vertically extending portion 228 of the jaw and the slide block 240 to hold the jaws in a normally open position. In order to close the jaw 220, air is supplied to the pneumatic cylinder 232 to move the piston to the right, as shown in FIG. 12. When the piston 234 is moved to the right, the plunger 230 engages the vertically extending portion of the upper jaw to pivot it about the hinge 224 to cause the horizontal gripping jaw 222 to move to the closed position where it would engage the cloth.
Before describing the sequence of operation of the pulling head and the folding of the cloth on the folding table, the dies for facilitating the folding of the cloth will be described. The dies include two elongated metal plates 270 and 272 such as best shown in FIGS. 22 and 24. The dies are placed on top of the cloth 24 after the cloth 24 has been pulled onto the folding table 8. The dies are raised and lowered by lifting devices J. The lifting devices J as shown in FIG. 13 include an electrical magnet 274 carried on the end of a piston rod 276 extending out the lower end of a pneumatically operated cylinder 278. The die plates are raised and lowered from the lifting table by manipulating the pneumatically operated cylinders 278. In order to lower the die onto the cloth carried on the table, air is supplied to an upper port of the pneumatic cylinder 278 forcing the piston rod 276 out the lower end of the cylinder. The electromagnet 274 is energized at this time and has the metal die 272 secured thereto. When the die is positioned on top of the cloth, the electromagnet is deenergized releasing the die 272, and the pneumatic cylinder 278 has air supplied to its lower port for raising the piston with the electromagnet upwardly so as not to interfere with the folding operation.
There are three electromagnets positioned above each of the dies for engaging metal plates 280 carried on the dies.
In order to ensure that the dies are properly positioned on the folding table, a T-shaped attachment 282 is carried on one of the ends of each of the dies. The T-shaped attachment is positioned between three abutments 284, 286, and 288, which properly align the end of the die on the folding table 8. Aligning members 290 are provided adjacent to the other end of the dies and include a triangular shaped end portion 292 that is rotated into engagement with a V-shaped recess 294 provided on the end of the dies opposite the end where the T-shaped member 282 is carried. The positioning member 290 is carried on the end of an output shaft of a motor 291 that when energized rotates the engaged member 290 from a retracted position such as shown in FIG. 22 to a positioning position wherein the triangular shaped end portion 292 engages the V-shaped slot 294 to properly align the dies. The T-shaped attachments 282 and aligning members 290 maintain the dies 270 and 272 in their proper position during the folding operation as will be described hereinafter.
The entire pulling and folding operation of the fabric will be described below, but it is felt that it is best to describe some of the elements that are to be used in the operation before going through the sequences. Another functional device is the cloth hold down device L. The cloth hold down device L as shown in FIGS. 13 and 25 includes an elongated wooden block 300 that extends across the entire folding table 8. Positioned adjacent the bottom of the elongated wooden block 300 is a foam pad 302 that has secured to the bottom surface thereof a strip of high molecular weight polyethylene 304. The elongated block 300 is secured to the lower end of a plurality of pistons 306 that are in turn manipulated by pneumatically operated cylinders 308. The purpose of the cloth hold down bar L is to hold the cloth flush against the folding table when it is desired to transport the folded cloth pattern laterally to a subsequent sewing station. As a result of the foam pad 302, the low friction surface 304 is allowed to ride over seams and hems while imparting a substantially uniform pressure all the way across the cloth. The low friction surface 304 permits the cloth to slide under the hold down device when it is being shifted laterally to a subsequent sewing operation.
This sequence of the pulling and cutting of the predetermined lengths of fabric will now be described. First, reference is directed to FIG. 13 which shows on the right, the edge of the cloth 24 located directly under the cutter blade 206. At this point in time, the cloth puller H is retracted to the end of the machine such as shown in FIG. 13, and the gripping jaw 220 is in an open position. The controller for the machine energizes the drive motor 264 which causes the timing belt 250 to be driven to move the gripping head 220 to the right, to the position shown in FIG. 14. As the gripping head 220 approaches the position shown in FIG. 14, a metal member 320 which is carried by the timing belt 250 and which projects laterally beyond the frame of the machine first passes proximity switch 322 as shown in FIG. 25. At this point in time a signal is generated to slow the motor 264 down. The gripping head 220 continues, however, moving forward until the member 320 is positioned adjacent the proximity switch 324 which generates a signal that is fed back to stop the motor 264 in the position shown in FIG. 14. Note in FIG. 14 that the dies I are engaged with the electromagnets and are in a raised position so as to permit the gripping head to pass thereunder.
FIG. 15 shows the gripping head 220 lowered to a closed position gripping the leading edge of the fabric 24.
In FIG. 16, the controller associated with the machine again energizes the motor 264 to retract the puller H with the gripping head in the closed position pulling the cloth 24 out of the accumulator F. As the activating member 320 carried by the gripping head comes adjacent a proximity switch 326 as shown in FIG. 25, the motor slows down and keeps going backwards until it comes adjacent the proximity switch 328 which stops the motor 264. In this position, the cloth 24 is extended its full length such as shown in FIG. 16. The proximity switches are adjustable for extending the cloth 24 a predetermined distance.
The next step in the sequence is activating the pneumatic cylinders forming part of die lifters J to lower the dies I down on top of the folding table 8 as shown in FIG. 17. At this point in time, the electromagnets carried on the end of the pistons associated with the lifting device are deenergized and leave the dies 270 and 272 on top of the extended cloth 24 such as shown in FIG. 22. The cloth puller and leading edge folder H is again moved back to the right as shown in FIG. 18, and while it is moving to the right, it has the leading edge of the cloth engagement between the gripping jaws. When it reaches the position such as shown in FIG. 18, the jaws of the gripping device 220 are open to release the cloth. As can be seen in FIG. 18, a single fold has been made in the cloth at this time.
A trailing end folder K has an L-shaped angled member 340 carried on the upper end thereof which in turn has the trailing end of the fabric 24 resting on top. By pivoting the trailing end folder in the forward direction, the angle member 340 pushes the trailing edge of the fabric over the die 272 to produce the folded pattern such as shown in FIG. 19. This folded pattern is now in position for being transported to a sewing station which will sew a hem in the edge of the upper fold and produce two elongated stitch lines along across the width of the entire valance to define a pocket and a socket in the valance.
The next step in the sequence is to lower the cloth hold down bar L onto the folded cloth pattern directly above the ends of the cloth as shown in FIG. 20. The cloth shifter M, which is in the form of three driven belts 350, 352, and 354, is used for shifting the folded pattern of cloth laterally from the folding table to an adjacent sewing station. The T-shaped attachments 282 carried on the end of the dies 270 and 272 prevent the dies from being moved laterally as the cloth is pulled by the moving belts 350, 352, and 354, off of the folding table into the next sewing station.
As can be seen in FIG. 26, the folded pattern of cloth 24 is carried on the movable belts 350, 352, and 354. The pattern 24 is held down flush against the belts 352 and 354 by spring loaded plates not shown. The upper edge of the cloth 24 engages a first driven belt 360. Prior to engaging the belt 360, the folded pattern 24 moves into engagement with an edge separating device N which includes a thin upwardly projecting finger that protrudes between the adjacent folds in the pattern of cloth 24 and feeds the edge of the upper fold into a conventional hem edge curler O which curls the edge under to form a hem.
The hem is then fed towards a first sewing machine P which has a single needle.
The purpose of the first sewing head P is to put a length of stitch across the entire folded pattern and to tack stitches adjacent to the leading edge of the valance and the trailing edge of the valance. A second sewing machine Q follows the first sewing machine, and its purpose is to place a stitch continuously across the entire valance. The second sewing head is offset from the first sewing head so that you have offset stitch lines to define a socket for receiving a curtain rod and a pocket for receiving filler material.
A controller is used for controlling the drive of the sewing machines P and Q as well as the drive for the moving belts 350, 352 and 354 and the upper belts 360 and 362.
A photocell R is carried by the first sewing machine P, and it generates a signal indicating that the leading edge of the folded pattern 24 has reached the sewing head. This causes a signal to be sent to the controller which slows down the conveying belts 350, 352 and 354 and the trailing sewing machine Q. The first sewing machine P continues to sew at its normal rate but since the movement of the fabric under the head has been slowed, more stitches per inch are placed in the leading edge of the folded fabric. This occurs for approximately one inch, depending on the preference of the customer.
The same tacking operation takes place at the trailing edge of the folded fabric. The controller can be set for activating the tacking operation according to the lengths of valances being produced.
After the two elongated stitches have been placed across the valances by the sewing heads P and Q, the thread extending between adjacent valances is cut by a thread cutter 364, and the valances are moved off the end of the sewing station onto a rotating folder which folds the valances into a rectangular package.
Proper spacing is maintained between the valances being transferred from the folding table 8 to the final sewing station by means of a photocell 370 that is positioned adjacent to the side of the folding table as shown in FIG. 25. This photocell senses the trailing and leading edges of the folded valances, and activates the controller which starts and stops the conveying and sequencing operation of the machine. Any suitable conventional controller can be used for synchronizing the various conveying and sewing operations taking place.
The apparatus of the present invention can also be adapted to feed two rolls of material simultaneously through the system as can be shown in FIG. 25. The second or top roll of material is placed on the apparatus when it is desirable to have a liner included with the finished product. As shown in FIG. 25, a roll of fabric 400 is carried on a second let off A'. The let off A' includes a power driven roll 402 which has a friction covering thereon. Similar to as described above, power driven roll 402 is driven by an electric motor. The motor is a variable speed driven motor. The speed of the motor can be placed under the control of a dancer roll 404. The dancer roll 404 is permitted to move up and down responsive to variations in tension in the cloth extending therearound. As the dancer roll 404 moves up and down, the voltage applied to the motor drive board is varied for varying the let off speed of the cloth.
However, unlike roll let off A, roll let off A' further includes a second power driven roll 406. Preferably, roll 406 is driven by a slip clutch for varying the torque. Power driven roll 406 is added to let off A' in order to have differential tension on the face fabric in comparison to the liner.
In one embodiment, dancer roll 22 can be set at a particular weight and thus at a constant tension. Dancer roll 404 is then also set at a particular weight. However, by including the second powered roll 406 the tension exerted on the liner 410 can be varied by adjusting the slip clutch engaged with the motor. This adjustment can be made in response to the tension being exerted on the cloth by the sewing heads and cloth advancers E. Once a proper adjustment in the tension of liner 410 is made, the liner 410 and cloth 24 should feed simultaneously and uniformly.
In this arrangement, power roller 406 always applies a continuous torque to liner 410 for placing in equilibrium the rate at which the liner and the cloth are fed to the sewing heads. One type of clutch that can be used in conjunction with the motor used to drive roll 406 is a hysteresis clutch which is well-known in the art. Using a hysteresis clutch, by increasing the voltage, a magnetic field is increased which can be used to vary the torque placed upon roller 406. Of course, other similar types of clutches can be used in the present invention.
These and other modifications and variations to the present invention may be practiced by those of ordinary skill in the art, without departing from the spirit and scope of the present invention, which is more particularly set forth in the appended claims. In addition, it should be understood that aspects of the various embodiments may be interchanged both in whole or in part. Furthermore, those of ordinary skill in the art will appreciate that the foregoing description is by way of example only and is not intended to be limitative of the invention so further described in such appended claims. | An apparatus and method are provided for converting a roll of material into various products such as curtains, draperies, valances, or the like. Specifically, the apparatus includes a roll let off for supporting and feeding a roll of material or cloth. After the let off, the edges of the cloth are cut if desired and are engaged by a pair of edge folding and positioning stations for forming vertically folded edges. The folded edges are then converted into hems and sewn into the material by a pair of corresponding hem sewing heads and cloth advancers. Once vertical hems are formed in the cloth, the cloth is cut to predetermined lengths and if desired, folded in a predetermined pattern. The folded pattern can then be transported to a sewing station for further sewing the material into a desired product. | 3 |
The present invention provides lead-free glass frits for use in ceramic enamels.
BACKGROUND OF THE INVENTION
Glass frits used in ceramic enamels are typically low melting glasses. The compositions of the frits for ceramic enamels commonly contain a high percentage of lead oxide, and are lead borosilicate glasses. The lead oxide in the composition is primarily responsible for the low melting point of the frit. Cadmium oxide is also present in a number of ceramic enamels, and is present to provide color stability to enamels containing cadmium pigments. Due to concerns about the toxicity of lead and cadmium oxides, it is desirable to develop frits that do not contain either ingredient.
In addition to having a low melting range (required to avoid deformation of the substrate that the enamels is applied to), frits used in ceramic enamels need to meet other requirements. One of the additional criteria that has to be met is that the thermal expansion of the frit closely matches that of the substrate it is applied to. This is necessary to avoid crazing of the enamel and strength reduction of the substrate.
Another condition that has to be met is that the frit has some degree of chemical durability. This requirement can vary depending on the use of the frit, and includes durability to both acidic and alkaline media. With frit development there is usually a compromise involved with the final properties of the frit. In general frits that have low melting ranges have average chemical durability and relatively high thermal expansions, while frits with high melting ranges have above average/excellent durability and relatively low thermal expansions.
A number of lead free frit compositions have been disclosed.
By way of illustration, U.S. Pat. No. 4,554,258 discloses frits which require the presence of Bi 2 O 3 , B 2 O 3 , SiO 2 and alkali metal oxides where the bismuth oxide is necessarily present in large concentrations; U.S. Pat. No. 4,376,169 discloses frits which require the presence of alkali oxide, B 2 O 3 , Al 2 O 3 , SiO 2 , F, P 2 O 5 , ZnO and TiO 2 and which have critical compositional limits; U.S. Pat. No. 4,446,241 discloses frits which require the presence of Li 2 O, B 2 O 3 and SiO 2 among other oxides; U.S. Pat. No. 4,537,862 discloses frits which require the presence of B 2 O 3 , SiO 2 , ZrO 2 and rare earth oxides with the weight ratio of ZrO 2 to rare earth oxides being critical; and U.S. Pat. No. 4,590,171 discloses frits which require the presence of Li 2 O, Na 2 O, BaO, Ba 2 O 3 , Al 2 O 3 , SiO 2 , ZrO 2 and F. Reference is also made to U.S. Pat. Nos. 4,084,976, 4,224,074, 4,312,951, 4,340,645 and 4,361,654 as additional patents in this general area.
U.S. Pat. No. 5,342,810 discusses zinc-containing lead- and cadmium-free glass frits and their use in forming lead-free enamels that can be stored at below 630° C. Obligatory components in mole percent are 31-50 ZnO, 10-44 SiO 2 , 11-35 B 2 O 3 and 11-25 Na 2 O.
U.S. Pat. No. 5,306,674 discusses glass frits that can be fired at temperatures of from about 1100° F. to about 1300° F. The frits have the following composition range in weight percent: 20-40 ZnO, 20-32 B 2 O 3 , 10-30 SiO 2 and 4-12 Na 2 O.
Lead free glass frits characterized by low silica content are described in U.S. Pat. No. 5,252,521. The composition range in weight percent includes 35-77 Bi 2 O 3 , 10-30 B 2 O 3 and 10-32 ZnO.
U.S. Pat. No. 4,892,847 discloses bismuth based borosilicicates with the following composition range in weight percent: 25-35 SiO 2 , 25-45 Bi 2 O 3 , 10-25 B 2 O 3 , 4-19 R 2 O and 0.3-8 ZrO 2 /TiO 2 .
U.S. Pat. No. 5,308,803 discloses glass frits with the following composition range in mole percent: 35-75 SiO 2 , 0.1-15 Bi 2 O 3 , 0.1-10 Al 2 O 3 , 1-30 B 2 O 3 and 5-30 R 2 O.
Additionally, U.S. Pat. No. 4,970,178 discloses lead-free glass frits with good chemical acid resistance having the following composition range in mole percent: 5-14 Na 2 O, 8-25 ZnO, 6-13 B 2 O 3 , 45-60 SiO 2 and 0-10 Bi 2 O 3 .
It is seen, therefore, that the formulations for the glass frits have varied the nature and concentrations of the oxide components in an attempt to provide acceptable frit formulations. While such frits are alleged to exhibit a variety of desirable properties, they still exhibit deficiencies in one or more performance areas.
DESCRIPTION OF THE INVENTION
Accordingly, it is the primary object of the invention to provide lead free glass compositions which exhibit a broad range of improved performance characteristics.
It has been surprisingly determined that the aforementioned objectives are met by lead free glass compositions that contain ZnO, SiO 2 , Na 2 O, B 2 O 3 and F -1 in the appropriate amounts. The frits described in the invention have acceptable chemical durability and thermal expansion. Of particular significance is that the frits have exceptionally low melting ranges. As a result, the frits can be used in a wide range of firing conditions and yield mature enamels. They can also be applied by a wide variety of printing methods.
The glass frits of the present invention consist essentially of the following composition:
______________________________________Component Weight Percent Range______________________________________ZnO 25-35SiO.sub.2 10-17ZrO.sub.2 0-2Al.sub.2 O.sub.3 0-4Na.sub.2 O 8-12B.sub.2 O.sub.3 20-30Bi.sub.2 O.sub.3 6-25F.sup.-1 1-5______________________________________
The frits are produced by mixing together the oxide producing materials which are well known in the art. Thus, a batch of oxide, nitrate and fluoride powders can be thoroughly blended and charged into a glass melting furnace at a temperature of about 2100° F. (1150° C.) to form a molten liquid. The molten liquid is then rapidly cooled (quenched) by pouring it into water. Upon quenching small chunks of glass a few millimeters in diameter are formed. The glass is then ground to a fine powder by conventional milling techniques.
The frits of the invention may be used to form improved glass enamel compositions. These glass enamel compositions contain, as essential components, the glass frit and vehicle with the optional presence of a pigment such as a metal oxide pigment.
The vehicle to be employed is selected on the basis of the end use application. It is essential that the vehicle adequately suspend the particulates and burn off completely upon firing of the composition. Vehicles are typically organic and include compositions based on pine oils, vegetable oils, mineral oils, low molecular weight petroleum fractions, tridecyl alcohol and the like. The vehicles may be modified by viscous resins such as vinyl resins, solvents, film formers such as cellulosic materials, and the like.
The optional metal oxide pigments are well known to those skilled in the art. Applicable oxides include, for example, chrome, cobalt, iron, nickel, copper, manganese, and the like. Although the latter metal oxides form preferred black spinel pigments, other metal oxides to produce different pigments and other colors are likewise contemplated. The pigment component will generally comprise from 10 to 40% by weight, of the indicated glass frit.
Methods for applying the enamel coatings are well known to those skilled in the art. The dispersed compositions may be applied by techniques such as screen printing, decal application, spraying, brushing, roller coating, and the like. Screen printing is preferred for purposes of applying the composition to glass substrates.
Glass enamel paint compositions are also formulated with silver metal in order to provide conductive coatings for use, for example, as defrost circuits for automotive backlites and windshield. In such areas of utility, color maintenance, bond strength, solderability, absence of silver migration and abrasion resistance are required performance characteristics. It is to be noted that the compositions containing the inventive frits are applicable for use in conjunction with such conductive coatings for the above noted areas of utility. When the conductive coatings are applied in overlapping relationship with the enamels containing the inventive frits, performance improvements as observed after heat treatment include good resistance to silver migration into the enamel, substantial reduction of undesirable blue haze of the buss bar (bar connecting ends of individual horizontal conductive elements of defrost circuit) and permanence of solder connections.
The following further illustrates various embodiments of the invention. In these embodiments, known techniques are utilized to mix the appropriate raw batch glass compositions, to melt them at generally about 1150° C. for about 45 minutes and then to frit the compositions.
Testing is conducted by adding 4.0 grams of the glass frit to 1.5 cc of a pine oil-based medium and screen printing the resulting dispersion onto glass slides at a wet thickness of 2 mils. The slides are fired at several temperatures to determine the "firing temperature". The firing temperature is the temperature where the glass has sufficient time to flow within a 15 minute fire and yield a glossy, smooth surface.
The acid resistance was evaluated by utilizing ASTM C724-91 using a ten weight percent solution of citric acid. Fired trials are exposed to the 10% citric acid solution for 15 minutes at room temperature and they are graded according to the following scale:
Grade 1--No attack apparent
Grade 2--Appearance of iridescence or visible stain on the exposed surface when viewed at a 45° angle but not apparent at angles less than 30°
Grade 3--A definite stain which does not blur reflected images and is visible at angles less than 30°
Grade 4--Definite stain with a gross color change or strongly iridescent surface visible at angles less than 30° and which may blur reflected images
Grade 5--Surface dull or matte with chalking possible
Grade 6--Significant removal of enamel with pinholing evident
Grade 7--Complete removal of enamel in exposed area
The thermal expansion of the frits was measured from 25° C. to 325° C. and has units of 10 -7 ° C -1 .
Typical frit formulations of this invention and their attendant performance characteristics are noted in the following table:
______________________________________FORMULATION (WEIGHT %)Component 1 2 3______________________________________ZnO 33.9 31.6 29.6SiO.sub.2 14.9 13.9 13.0ZrO.sub.2 0.9 0.9 0.8Al.sub.2 O.sub.3 3.3 3.0 2.8Na.sub.2 O 11.1 10.3 9.7B.sub.2 O.sub.3 26.0 24.2 22.7Bi.sub.2 O.sub.3 7.3 13.6 19.1F.sup.-1 2.6 2.5 2.3Firing 576 565 559Temperature (°C.)Acid Resistance 5 5 5ASTM C-724-91Thermal expansion 86 83 87(25-325° C.)______________________________________
These results demonstrate the excellent performance characteristics of the glass frits of the present invention, and particularly the low temperature firing characteristics and adequate acid resistance and thermal expansion characteristics. | Lead-free glass frits having the following composition in weight percent:
______________________________________
ZnO 25-35 SiO 2 10-17 ZrO 2 0-2 Al 2 O 3 0-4 Na 2 O 8-12 B 2 O 3 20-30 Bi 2 O 3 6-25 F -1 1-5______________________________________
are useful in the formulation of ceramic enamel compositions. | 2 |
BACKGROUND OF THE INVENTION
[0001] The subject matter disclosed herein relates to an impingement sleeve for a gas turbine engine. Such impingement sleeves are typically fixedly attached about a transition piece. The geometry of some transition pieces necessitates that the impingement sleeve be made of two or more portions that are assembled around the transition piece and fixedly attached to one another. In such applications, it is common practice to weld the two or more portions of the impingement sleeves together. Such welding operations can be difficult to perform and can make replacing defective impingement sleeves in the field time consuming and difficult. As such, impingement sleeves that are easily assembled and disassembled may be well received in the art.
BRIEF DESCRIPTION OF THE INVENTION
[0002] Disclosed herein is an impingement sleeve for a gas turbine combustion transition piece. The impingement sleeve includes, a housing positionable proximate a first portion of a transition piece body having at least two flanges integrally formed thereon, and a cover positionable proximate a second portion of the transition piece body having at least two lips integrally formed thereon, the at least two lips are weldlessly attachable to the at least two flanges to position the impingement sleeve radially outwardly of the transition piece body.
[0003] Further disclosed herein is a method of assembling an impingement sleeve at a transition piece body. The method includes, positioning a housing of the impingement sleeve over a first portion of the transition piece body, positioning a cover of the impingement sleeve over a second portion of the transition piece body, and weldlessly attaching at least one flange of the impingement sleeve housing to at least one lip of the impingement sleeve cover.
BRIEF DESCRIPTION OF THE DRAWINGS
[0004] The following descriptions should not be considered limiting in any way. With reference to the accompanying drawings, like elements are numbered alike:
[0005] FIG. 1 depicts a perspective view of an impingement sleeve disclosed herein assembled to a gas turbine combustion transition piece;
[0006] FIG. 2 depicts an exploded view of the impingement sleeve and the transition piece of FIG. 1 ;
[0007] FIG. 3 depicts a cross sectional perspective view of the impingement sleeve and the transition piece of FIG. 1 ; and
[0008] FIG. 4 depicts a cross sectional view of the impingement sleeve and the transition piece of FIG. 1 .
DETAILED DESCRIPTION OF THE INVENTION
[0009] A detailed description of one or more embodiments of the disclosed apparatus and method are presented herein by way of exemplification and not limitation with reference to the Figures.
[0010] Referring to FIGS. 1 and 2 , an embodiment of an impingement sleeve 10 disclosed herein is illustrated. The impingement sleeve 10 includes, an impingement sleeve housing 14 having mounting flanges 18 , an impingement sleeve cover 22 having mounting lips 26 , and a plurality of fasteners 30 , depicted herein as screws. In the assembled configuration, as illustrated in FIG. 1 , the impingement sleeve 10 is positioned radially outwardly of a gas turbine combustion transition piece 34 , which has an outer surface 42 . Both the housing 14 and the cover 22 have a plurality of holes 38 therethrough that allow cooling fluid, such as air, to pass therethrough.
[0011] Referring to FIGS. 3 and 4 , the housing 14 is formed to closely mimic a shape of a portion 46 of the transition piece 34 to which the housing 14 is positioned in close proximity. As such, a controlled gap 50 is created between the housing 14 and the portion 46 . Similarly, the cover 22 is formed to closely mimic a shape of a portion 54 of the transition piece 34 to which the cover 22 is positioned in close proximity. As such, a controlled gap 58 is created between the cover 22 and the portion 54 . During operation cooling fluid flows through the holes 38 in the housing 14 and cover 22 , across the gaps 50 and 58 , and impinges on the outer surface 42 of the portions 46 and 54 , respectively, thereby cooling the transition piece 34 .
[0012] The housing 14 and the cover 22 are configured such that the flanges 18 and the lips 26 are substantially parallel with one another when the housing 14 and the cover 22 are positioned in an encasing configuration about the transition piece 34 . When in this position, a plurality of holes 62 in the flanges 18 aligns with a plurality of holes 66 in the lips 26 , through which a plurality of fasteners 30 is fastened. The fasteners 30 , in this embodiment, are screws that screw into threaded holes in plates 69 ; however, alternate embodiments could use rivets, pins or other fasteners to attach the flanges 18 to the lips 26 . In still other embodiments the flanges 18 could be attached to the lips 26 by other techniques that do not involve welding, such as by crimping of one of the flanges 18 and the lips 26 to the other of the flanges 18 and the lips 26 , or by attaching the flanges 18 to the lips 26 with an adhesive, for example.
[0013] A first end 68 of each of a pair of support brackets 70 are attached by a pair of the fasteners 30 to one of the flanges 18 and one of the lips 26 on either side of the housing 14 or cover 22 . A second end 74 of each of the support brackets 70 is attached to one of a pair of protrusions 78 from a first end 82 of the transition piece 34 . The brackets 70 positionally support the housing 14 and the cover 22 relative to the first end 82 of the transition piece 34 . Additional support between the housing 14 and the first end 82 of the transition piece 34 is provided by an edge 86 of the housing 14 that extends into a slot 90 in the first end 82 . Similarly, additional support between the cover 22 and the first end 82 of the transition piece 34 is provided by an edge 94 of the cover 22 that extends into the slot 90 in the first end 82 . In addition to supporting the housing 14 and the cover 22 , engagement of the edges 86 , 94 with the slot 90 provides a fluidic seal that blocks cooling fluid from flowing into the gaps 50 , 58 through this interface.
[0014] The housing 14 and the cover 22 are supported and sealed to a conduit 98 located near a second end 102 of the transition piece 34 . An edge 106 of the housing 14 forms a lap joint 110 with the conduit 98 , and an edge 114 of the cover 22 forms a lap joint 118 with the conduit 98 . Hoop strength generated by assembly of the housing 14 with the cover 22 maintains the edges 106 and 114 in contact with the conduit 98 to assure support thereto and sealing therebetween.
[0015] While the invention has been described with reference to an exemplary embodiment or embodiments, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the invention. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from the essential scope thereof. Therefore, it is intended that the invention not be limited to the particular embodiment disclosed as the best mode contemplated for carrying out this invention, but that the invention will include all embodiments falling within the scope of the claims. Also, in the drawings and the description, there have been disclosed exemplary embodiments of the invention and, although specific terms may have been employed, they are unless otherwise stated used, in a generic and descriptive sense only and not for purposes of limitation, the scope of the invention therefore not being so limited. Moreover, the use of the terms first, second, etc. do not denote any order or importance, but rather the terms first, second, etc. are used to distinguish one element from another. Furthermore, the use of the terms a, an, etc. do not denote a limitation of quantity, but rather denote the presence of at least one of the referenced item. | Disclosed herein is an impingement sleeve for a gas turbine combustion transition piece. The impingement sleeve includes, a housing positionable proximate a first portion of a transition piece body having at least two flanges integrally formed thereon, and a cover positionable proximate a second portion of the transition piece body having at least two lips integrally formed thereon, the at least two lips are weldlessly attachable to the at least two flanges to position the impingement sleeve radially outwardly of the transition piece body. | 8 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This is a continuation-in-part of our copending application Ser. No. 559,616, filed Mar. 18, 1975, now abandoned.
BACKGROUND OF THE INVENTION
The invention pertains to the field of salicylanilide derivatives which demonstrate parasiticidal activity.
The subject salicylanilides differ from those of the prior art by, among other differences, the presence of an α -cyano-arylmethyl group, in the 4-position of the anilino moiety.
The prior art may be represented by the following references: British Pat. No. 1.183.461; and Belgium Pat. No. 796.406.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The novel salicylanilide derivatives of this invention may be structurally represented by the formula: ##STR1## wherein: R is a member selected from the group consisting of hydrogen, halo, lower alkyl and nitro;
R 1 is a member selected from the group consisting of hydrogen and halo;
R 2 is a member selected from the group consisting of hydrogen, halo, lower alkyl and nitro;
R 3 is a member selected from the group consisting of hydrogen, hydroxy and lower alkyl, provided that when said R 3 is hydroxy or lower alkyl then said R 1 is hydrogen;
R 4 is a member selected from the group consisting of hydrogen, halo and lower alkyl;
R 5 is a member selected from the group consisting of hydrogen, halo, lower alkyl, cyano and trifluoromethyl; and
Ar is a member selected from the group consisting of phenyl, substituted phenyl, thienyl, halothienyl and naphthalenyl, wherein said "substituted phenyl" represents phenyl having from 1 to 3 substituents independently selected from the group consisting of halo, lower alkyl, lower alkyloxy and trifluoromethyl.
As used herein, "lower alkyl" may be straight or branch chained and have from 1 to about 5 carbon atoms, such as, for example, methyl, propyl, isopropyl, butyl, tert-butyl, pentyl and the like and; the term "halo" is generic to bromo, fluoro, chloro and iodo. Among the preferred substituted phenyls represented by the symbol "Ar" are halophenyl, dihalophenyl, trihalophenyl, lower alkylphenyl, lower alkyloxyphenyl, trifluoromethylphenyl and halotrifluoromethylphenyl. The preferred "thienyl" is 2-thienyl and the preferred "halothienyl" is 5-chloro-2-thienyl.
Also within the scope of the present invention are the pharmaceutically acceptable replacement or amine addition salts of the compounds of formula (I).
Examples of such salts include metal salts such as, for example, sodium, potassium, calcium, copper and iron salts, and amine salts such as, for example, piperidine, piperazine, triethylamine, N-methylglucamine, methylamine, α-methylbenzylamine and ethanolamine salts.
The compounds of formula (I) may conveniently be prepared by the application of methodologies known in the art, more particularly, by procedures described in the literature for the preparation of salicylanilides.
Such procedures generally comprise the reaction of an appropriately substituted salicylic acid or a reactive functional derivative thereof with an appropriately substituted aniline or reactive derivative thereof under appropriate reaction conditions, for example as described in British Pat. No. 1.183.461.
A convenient method of preparing the compounds (I) consists in the condensation of an appropriately substituted salicylic acid halide of formula (II), preferably the chloride, wherein R, R 1 , R 2 and R 3 are as previously indicated ##STR2## with an appropriately substituted amine of formula (III), wherein R 4 , R 5 and Ar are as previously indicated, said amine being either in base form or in the form of an appropriate acid addition salt. ##STR3##
Said condensation reaction is carried out in a reaction-inert organic solvent from which the desired products of formula (I) are recovered by conventional procedures, for example, by evaporation of the solvent and recrystallization of the residue. Elevated temperatures and, preferably, reflux conditions may be employed to enhance the rate of the reaction. In order to pick up the acid which is liberated during the course of the reaction, there may be added an appropriate base such as, for example, N,N-diethylethanamine, pyridine and the like.
As used herein, the term "reaction-inert organic solvent" is meant to include any organic liquid which will not interfere with the interaction of the reactants (II) and (III) such as, for example, ethers, such as dioxane, tetrahydorfuran, diethylether and the like; aromatic hydrocarbons such as benzene, toluene, xylene and the like; and chlorinated hydrocarbons such as chloroform, methylene chloride and the like.
Alternatively the compounds (I) may be prepared by the reaction of (III) with an appropriate salicylic acid ester, preferably a phenyl ester of formula (IV) wherein R, R 1 , R 2 and R 3 have the same meaning as assigned to them previously. ##STR4##
The reaction of (III) with (IV) is preferably carried out at elevated temperatures in an appropriate reaction-inert organic solvent such as, for example, 1,2,4-trichlorobenzene, 1,2-dichlorobenzene, nitrobenzene, diphenylether, diphenylmethane, tetrahydronaphthalene, decahydronaphthalene and the like.
Another convenient method of preparing the compounds (I) is by the reaction of an appropriate salicylic acid (V) wherein the substituents have the abovedefined meaning with a phosphoramide of formula (VI) wherein R 4 , R 5 and Ar are as defined hereinbefore. ##STR5##
The phosphoramide (VI) which may be prepared in situ by the reaction of (III) with phosphoryl chloride, POCl 3 , is reacted with the salicylic acid (V) by stirring the reactants together, preferably at elevated temperatures, in a suitable organic solvent such as, for example, an aliphatic hydrocarbon, e.g., hexane; cyclohexane and the like or a mixture of such hydrocarbons, e.g., petroleumether; an aromatic hydrocarbon, e.g., benzene, toluene, xylene and the like; a halogenated hydrocarbon, e.g., chloroform, methylene chloride, tetrachloroethane and the like or; a halogenated aromatic hydrocarbon, e.g., chlorobenzene, 1,2-dichlorobenzene, 1,2,4-trichlorobenzene and the like.
Still another method of preparing the compounds (I) is by the reaction of (V) with a compound of the formula (VII) ##STR6## wherein R 4 , R 5 and Ar are as previously defined in a similar manner as herebefore for the reaction of (V) with (VI).
The compounds of formula (VII) may conveniently be prepared, preferably in situ, by the reaction of (III) with phosphorous trichloride.
The compounds of formula (I) wherein R 1 and R 3 are each hydrogen and R and R 2 are each iodo, (I-a), may still be prepared by iodinating a compound of formula (I) wherein R, R 1 , R 2 and R 3 are hydrogen, (I-b). Said iodination reaction is preferably carried out with iodine monochloride, previously prepared by the reaction of iodine with chlorine, in an acidic medium such as, for example in a mixture of acetic acid and water. ##STR7##
The salicylic acids of formula (V) as well as their halides (II) and esters, including the phenyl esters of formula (IV) are generally known and are obtained from procedures described in the literature.
The anilines of formula (III), a number of which are also known compounds, may be prepared from several synthetic routes. For example, they may conveniently be prepared by:
i. reacting an appropriate arylacetonitrile of formula (VIII) with an appropriately substituted 4-halonitrobenzene of formula (IX) in the presence of an appropriate strong base, in a suitable reaction-inert organic solvent as more specifically described hereafter, and
ii. subsequently reducing the nitro function in the thus obtained (X) to an amine function using standard nitro-to-amine reduction procedures, for example, with zinc metal and acetic acid, with iron metal and ammonium chloride, with sodium dithionite or by catalytic hydrogenation, using, for example, palladium-on-charcoal catalyst.
Suitable bases to aid the reaction of (VIII) with (IX) include, for example, alkali metal amides and hydrides, such as, sodium amide and sodium hydride, respectively, and the like; alkali metal alkoxides such as, sodium ethanolate and the like; and alkali metal hydroxides such as, sodium hydroxide, potassium hydroxide and the like. Suitable solvents for this reaction include reaction-inert organic solvents such as, for example, aromatic hydrocarbons such as, benzene, toluene, xylene and the like, and ethers such as, dioxane, tetrahydrofuran, diethylether and the like. Good results have been obtained by using potassium hydroxide in pyridine.
A convenient and most preferred method of conducting the reaction of (VII) with (IX) is in a two-phase system as described, for example, by Makosza et al. in Tetrahedron, 30, 3723-3735 (1974). Typically in such type of reaction there is used concentrated aqueous alkali, e.g. 40-60% sodium hydroxide, and an appropriate water-immiscible reactioninert organic solvent such as, for example, benzene, toluene, xylene, tetrahydrofuran, methylene chloride and the like, in the presence of an appropriate quaternary ammonium catalyst, preferably N,N,N-triethylbenzenemethanaminium chloride, (BTEAC).
The foregoing reactions may be illustrated by the following schematic representation: ##STR8##
The amines of formula (III) may alternatively be prepared by the condensation of an arylacetonitrile of formula (VIII) with a nitrobenzene of formula (XI) to obtain a phenylcyanomethylene quinone oxime of formula (XII). The reduction of (XII) to obtain (III) may be carried out with an appropriate reducing agent such as, for example, zinc powder and acetic acid, iron powder and ammonium chloride, or by catalytic hydrogenation using, for example, palladium-on-charcoal catalyst.
The foregoing reactions are illustrated in the following schematic representation: ##STR9##
The starting materials of the formulas (VIII), (IX) and (XI) are generally known and may be prepared according to known procedures as described in the literature.
The compounds of formula (I) may, if desired, be converted into a pharmaceutically acceptable salt by the reaction with an appropriate base and from such salts the free salicylanilides may in turn be liberated by acid treatment.
The subject compounds of formula (I) have useful parasiticidal properties.
They are very potent anthelminthics, being very active against, for example, liver fluke, e.g. Fasciola hepatica, and against nematodes such as, for example, Haemonchus contortus in sheep and cattle.
Moreover they possess strong activity against a number of arthropod parasites such as, for example, Oestrus ovis, Hypoderma bovis, Dermatobia hominis, Lucillia etc.
In view of their broad spectrum of antiparasitic activity the compounds of this invention are valuable tools for the treatment of warm-blooded hosts, suffering from such parasites.
Accordingly, this invention embraces methods of killing parasites which comprise treating infected subjects with an effective antiparasitic amount of the novel compounds described herein. For this purpose about 1 to 200 milligrams per kilogram of body weight may be advantageously employed. Also within the scope of this invention are antiparasitical compositions comprising an effective anti-parasitical amount of the subject compounds in combination with suitable carriers.
The subject compounds can be used, for example, in the form of pharmaceutical and veterinarian preparations containing an anti-parasitical amount of a suitable organic or inorganic, solid or liquid pharmaceutical carrier, such as, for example, water, gelatine, lactose, starch, magnesium stearate, talc, vegetable oils, gums, polyalkylene glycols, etc..
The compositions are formulated by conventional methods and may be in any one of the conventional pharmaceutical forms, for example, for systemic application by way of oral or parenteral administration or for external application by direct contact onto the skin. Typical formulations include solutions, suspensions, emulsions, injectables, powders, slugs, granules, capsules, tablets, pellets and the like, including unit dosage forms thereof, as well as other convenient forms which might be suitable for veterinarian or human use. They may be sterilized, for example, for parenteral administration, and/or may contain assistants such as conventional excipients, preserving, stabilizing, wetting, dispersing, desintegrating or emulsifying agents, fillers, buffers, bacteriostats, bactericidal agents, sporicidal agents, thickening agents, preservatives, coloring agents, etc..
They may also contain further veterinary or therapeutically useful substances, including, for example, other known anthelminthics such as tetramisole, levamisole, mebendazole, thiabendazole, pyrvinium pamoate, piperazine citrate, 2-β-methoxy-ethylpyridine and the like. The subject compounds may also be used as additives and pre-mixes to animal feeds, drinking water, etc..
In such compositions and formulations, the concentration of the subject compound should be at least about 0.01%, and preferably at least about 0.05%, by weight. The concentration of compound may vary widely above these figures, depending on the form of composition taken, and indeed, in some cases the concentration of the compound may go as high as about 95%.
For example, compositions suitable for oral administration may be liquid or solid compositions. Suitable liquid compositions include, for example, aqueous concentrated solutions of the active ingredients, which solutions may optionally contain one or more buffers and/or stabilizing agents, for example sodium bisulfite, hydroxylamine or an acid addition salt thereof, for example the hydrochloride. The liquid compositions also include, for example solutions in a vegetable oil, for example arachis oil, dimethylacetamide, poly-alkylene glycols. The solid compositions include tablets, slugs, pellets or capsules, which may be formulated using conventional excipients. Alternatively, the solid compositions may be in the form of dispersible compositions containing at least one adsorbent solid, for example, fuller's earth or kieselguhr. The solid compositions may be in the form of pre-mix compositions suitable for addition to animal foodstuffs, or in the form of medicated animal foodstuff compositions, for example compositions comprising the active ingredients and animal foodstuffs. Compositions suitable for parenteral administration include, for example, sterile injectable aqueous and non-aqueous solutions or suspensions.
The invention may be illustrated by, although not limited to, the following examples. As used therein, unless otherwise stated, all parts are by weight.
EXAMPLE I
To a solution of 39 parts of potassium hydroxide in 39 parts of pyridine is added a solution of 17 parts of 1-chloro-4-nitrobenzene in 46 parts of pyridine. The whole is cooled to -5° C and there is added dropwise a solution of 22 parts of 2,4-dichlorobenzeneacetonitrile in pyridine, while still cooling at -5° C. Upon completion, stirring is continued for 10 hours at 0° C. After the addition of 90 parts of benzene, the product is precipitated. It is filtered off, washed on the filter with benzene and taken up in water. The aqueous mixture is treated with acetic acid, whereupon the product is separated as an oil. The latter is extracted with methylbenzene. The extract is dried, filtered and evaporated. The residue is crystallized from a mixture of methanol, 2,2' -oxybispropane, petroleumether and trichloromethane, yielding 2,4-dichloro-α-(4-nitrophenyl)benzeneacetonitrile; mp. 81°- 82.5° C.
EXAMPLE II
EXAMPLE II
To a stirred and warmed (30° C) mixture of 105 parts of 1-chloro-4-nitro-2-(trifluoromethyl)benzene, 10 parts of N,N,N-triethylbenzenemethanaminium chloride, 900 parts of sodium hydroxide solution 50% and 135 parts of tetrahydrofuran is added dropwise a mixture of 67.5 parts of 4-fluorobenzeneacetonitrile and 450 parts of tetrahydrofuran (exothermic reaction: temperature rises to 50° C). Upon completion, stirring is continued for 5 hours at 60° C. After cooling, the reaction mixture is poured onto crushed ice and the whole is acidified with a concentrated hydrochloric acid solution, while cooling. The product is extracted with methylbenzene. The extract is washed with water, dried filtered and evaporated. The residue is suspended in a mixture of 2,2'-oxybispropane and petroleumether. The product is filtered off, yielding α-(4-fluorophenyl)-4-nitro-2-(trifluoromethyl)-benzeneacetonitrile; mp. 68° C.
EXAMPLE III
Following the procedure of Example II and using equivalent amounts of the appropriate starting materials, the following nitrile compounds are prepared:
3,4-dichloro-α-(2-chloro-4-nitrophenyl)benzeneacetonitrile; mp. 105.8° C;
α-(4-bromophenyl)-4-nitro-2-(trifluoromethyl)benzeneacetonitrile; mp. 63.9° C;
α-(4-chlorophenyl)-2-cyano-4-nitrobenzeneacetonitrile as an oily residue;
4-chloro-α-[4-nitro-2-(trifluoromethyl)phenyl]-3-(trifluoromethyl)-benzeneacetonitrile; mp. 126.2° C;
4-nitro-2-(trifluoromethyl)-α-[3-(trifluoromethyl)phenyl]benzeneacetonitrile; mp. 88.4° C; and
2-chloro-α-[4-chloro-3-(trifluoromethyl)phenyl]-4-nitrobenzeneacetonitrile; mp. 110.2° C.
EXAMPLE IV
To a stirred mixture of 21 parts of 1-chloro-4-nitro-2-(trifluoromethyl)benzene, 180 parts of sodium hydroxide solution 60%, 2parts of N,N,N-triethylbenzenemethanaminium chloride and 90 parts of tetrahydrofuran is added dropwise a mixture of 11.7 parts of benzeneacetonitrile and 27 parts of tetrahydrofuran at 30° C. Upon completion, stirring is continued for 4 hours at 50° C. After cooling, the reaction mixture is poured onto crushed ice. The whole is acidified with a hydrochloric acid solution (pH 1) while the temperature is kept below 20° C. The product is extracted with benzene. The extract is washed with water, dried, filtered and evaporated. The oily residue is crystallized from 70 parts of 2,2'-oxybispropane at 0° C, yielding 4-nitro-α-phenyl-2-(trifluoromethyl) benzeneacetonitrile; mp. 70.4° C.
EXAMPLE V
Following the procedure of Example IV and using equivalent amounts of the appropriate starting materials, the following nitrile compounds are prepared:
α-(4-chlorophenyl)-4-nitro-2-(trifluoromethyl)benzeneacetonitrile; mp. 60.2° C;
2,6-dichloro-α-[4-nitro-2-(trifluoromethyl)phenyl]benzeneacetonitrile; m.p. 122.1° C;
2,4-dichloro-α-[4-nitro-2-(trifluoromethyl)phenyl]benzeneacetonitrile; mp. 107° C;
α-(4-methoxyphenyl)-4-nitro-2-(trifluoromethyl)benzeneacetonnitrile;
α-(4-methylphenyl)-4-nitro-2-(trifluoromethyl)benzeneacetonitrile; mp. 87.4° C;
3,4-dichloro-α -[4-nitro-2-(trifluoromethyl)phenyl]benzeneacetonitrile; mp. 124° C;
2,6-dichloro-α-(2-chloro-4-nitrophenyl)benzeneacetonitrile; mp. 139.6° C;
2-chloro-α-(3-chlorophenyl)-4-nitrobenzeneacetonitrile; mp. 70° C; and
2-chloro-4-nitro-α-[3-(trifluoromethyl)phenyl]benzeneacetonitrile; mp. 123° C.
EXAMPLE VI
20 parts of iron-powder are added to 190 parts of ammonium chloride solution 0.78N at reflux temperature. Then there is added dropwise a solution of 20 parts of 2,4-dichloro-α-(4-nitrophenyl)benzeneacetonitrile in 180 parts of methylbenzene. Upon completion, stirring is continued overnight at reflux. The reaction mixture is cooled at 60° C and filtered over hyflo. The filter-cake is washed with tetrahydrofuran. The filtrate is dried, filtered and evaporated. The residue is converted into the hydrochloride salt in 2,2'-oxybispropane, methanol and 2-propanol. The salt is filtered off and dried, yielding α-(4-aminophenyl)-2,4-dichlorobenzeneacetonitrile hydrochloride; mp. 207.2° C.
EXAMPLE VII
Following the procedure of Example VI and using an equivalent amount of an appropriate α-aryl-4-nitro-benzeneacetonitrile in place of the 2,4-dichloro-α-(4-nitrophenyl)benzeneacetonitrile used therein, the following 4-amino-α-arylbenzeneacetonitriles or hydrochloride salts are prepared:
______________________________________ ##STR10## mp.R.sup.4R.sup.5 Ar Salt ° C______________________________________H Cl 2,4-Cl.sub.2C.sub.6 H.sub.3 HCl 220-227H Cl 3-ClC.sub.6 H.sub.4 -- 103.5H Cl 3-CF.sub.34-ClC.sub.6 H.sub.3 -- 68.1H Cl 3-CF.sub.3C.sub.6 H.sub.4 -- 87.5H CF.sub.3 3-CF.sub.34-ClC.sub.6 H.sub.3 -- 114H CF.sub.3 3-CF.sub.3C.sub.6 H.sub.4 -- 78.3H CN 4-ClC.sub.6 H.sub.4 -- 101.9H CF.sub.3 4-BrC.sub.6 H.sub.4 -- 93.5H Cl 2,6-Cl.sub.2C.sub.6 H.sub.3 -- 123.7H Cl 3,4-Cl.sub.2C.sub.6 H.sub.3 -- 125.2H CF.sub.3 4-FC.sub.6 H.sub.4 --H CF.sub.3 4-ClC.sub.6 H.sub.4 -- 78H CF.sub.3 2,6-Cl.sub.2C.sub.6 H.sub.3 -- 162H CF.sub.3 C.sub.6 H.sub.5 -- 124H CF.sub.3 4-OCH.sub.3C.sub.6 H.sub.4 --H CF.sub.3 2,4-Cl.sub.2C.sub.6 H.sub.3 --H CF.sub.3 3,4-Cl.sub.2C.sub.6 H.sub.3 -- 114.3H CF.sub.3 4-CH.sub.3C.sub.6 H.sub.3 -- 100.4Cl Cl 4-ClC.sub.6 H.sub.4 -- 130.4Cl Cl 2,4-Cl.sub.2C.sub.6 H.sub.3 -- 150.3______________________________________
EXAMPLE VIII
To a stirred solution of 75 parts of potassium hydroxide in 240 parts of methanol, are added 27 parts of 2,4-dichlorobenzeneacetonitrile. Then there is added a solution of 25.5 parts of 1-chloro-4-methyl-3-nitrobenzene in 40 parts of methanol (exothermic reaction: temperature rises to 40° C). Stirring is continued for 2 hours while meantime the mixture is allowed to cool to 20° -25° C. 1000 parts of water are added. Upon the addition of a mixture of acetic acid and water (1:1 by volume), an oil is precipitated. The supernatant aqueous phase is decanted and the oil is taken up in methylbenzene. The solution is evaporated. The oily residue is triturated in a mixture of 2,2'-oxybispropane and petroleumether, yielding 2,4-dichloro-α-[2-chloro-4-(hydroxyimino)-5-methyl-2,5-cyclohexadien-1-ylidene]benzeneacetonitrile.
370 parts of ammonium chloride solution 0.78N are stirred and heated to reflux. Then there are added 37 parts of iron-powder, followed by the dropwise addition of a solution of 37 parts of 2,4-dichloro-α-[2-chloro-4-(hydroxyimino)-5-methyl-2,5-cyclohexandien-1-ylidene]benzeneacetonitrile in 333 parts of methylbenzene. Upon completion, stirring at reflux is continued overnight. The reaction mixture is cooled to 60° C, filtered and the filter-cake is washed with tetrahydrofuran. The filtrate is dried, filtered and evaporated. The residue is converted into the hydrochloride salt in 2,2'-oxybispropane and 2-propanol, yielding 4-amino-2-chloro-α-(2,4-dichlorophenyl)-5-methylbenzeneacetonitrile hydrochloride.
EXAMPLE IX
A mixture of 40 parts of 4-chloro-α-[2-chloro-4-(hydroxyimino)-5-methyl-2,5-cyclohexadien-1-ylidene]benzeneacetonitrile, 50 parts of iron-powder, 1500 parts of ammonium chloride solution 0.78N and 270 parts of methylbenzene is stirred and refluxed overnight. The reaction mixture is filtered over hyflo and the filter-cake is washed with 4-methyl-2-pentanone. The filtrate is dried, filtered and evaporated. The solid residue is crystallized from methylbenzene. The product is filtered off and recrystallized from methylbenzene, yielding 4-amino-2-chloro-α-(4-chlorophenyl)-5-methylbenzeneacetonitrile; mp. 152.6° C.
EXAMPLE X
A mixture of 4 parts of 2-hydroxy-3,5-diiodobenzoyl chloride, 2.9 parts of 4-amino-2-chloro-α-(4-chlorophenyl)-5-methylbenzeneacetonitrile and 75 parts of 1,4-dioxane is stirred and refluxed for 10 minutes. The reaction mixture is evaporated and the oily residue is crystallized from methanol. The product is filtered off and dried, yielding 5.3 parts of N-{5-chloro-4-[α-(4-chlorophenyl)-α-cyanomethyl]-2-methylphenyl}-2-hydroxy-3,5-diiodobenzamide; mp. 217.8° C.
EXAMPLE XI
Following the procedure of Example X and using equivalent amounts respectively of an appropriately substituted salicyloyl chloride and of an appropriately substituted 4-amino-α-aryl-benzeneacetonitrile or hydrochloride salt thereof, the following compounds of formula (I) were prepared:
______________________________________ ##STR11## mpR.sup.1R.sup.2 R R.sup.4 R.sup.5 Ar ° C______________________________________H I I H H 3-CH.sub.3C.sub.6 H.sub.4 223-225H I I H H 4-ClC.sub.6 H.sub.4 238.2H I I H H 4-CH.sub.3C.sub.6 H.sub.4 244.9H I I H H 4-OCH.sub.3C.sub.6 H.sub.4 205.4H I I H Cl 3,4-Cl.sub.2C.sub.6 H.sub.3 240.6H I I H Cl 2,6-Cl.sub.2C.sub.6 H.sub.3 245.3H I I H Cl 3-ClC.sub.6 H.sub.4 205-206H I I H Cl 2,4-Cl.sub.2C.sub.6 H.sub.3 238.7H I I H H 2,4-Cl.sub.2C.sub.6 H.sub.3 238H I I H Cl C.sub.6 H.sub.5 199.1H I I CH.sub.3 Cl 2,4-Cl.sub.2C.sub.6 H.sub.3 249Cl Cl Cl H H 4-FC.sub.6 H.sub.4 247.8Cl Cl Cl H H C.sub.6 H.sub.5 259.1Cl Cl Cl H H 4-OCH.sub.3C.sub.6 H.sub.4 231.6Cl Cl Cl H H 4-ClC.sub.6 H.sub.4 244-245Cl Cl Cl H H 3-CH.sub.3C.sub.6 H.sub.4 249-250Cl Cl Cl H H 4-CH.sub.3C.sub.6 H.sub.4 254.2Cl Cl Cl H Cl 4-ClC.sub.6 H.sub.4 227.6Cl Cl Cl H Cl 3,4-Cl.sub.2C.sub.6 H.sub.3 216Cl Cl Cl H Cl 2,6-Cl.sub.2C.sub.6 H.sub.3 297Cl Cl Cl H Cl 3-ClC.sub.6 H.sub.4 248.2Cl Cl Cl H Cl C.sub.6 H.sub.5 244Cl Cl Cl CH.sub.3 Cl 4-ClC.sub.6 H.sub.4 207.2Cl Cl Cl CH.sub.3 Cl 2,4-Cl.sub.2C.sub.6 H.sub.3 244.1Cl Cl Cl Cl Cl 4-ClC.sub.6 H.sub.4 232H I I Cl Cl 4-ClC.sub.6 H.sub.4 242-247Cl Cl Cl Cl Cl 2,4-Cl.sub.2C.sub.6 H.sub.3 244.1H I I Cl Cl 2,4-Cl.sub.2C.sub.6 H.sub.3 219.6- 221.2______________________________________
EXAMPLE XII
A mixture of 8 parts of 3,5-diiodosalicyloyl chloride, 5.3 parts of 2-(4-aminophenyl)-2-(p-fluorophenyl)acetonitrile hydrochloride and 150 parts of dioxane is stirred and refluxed for 15 minutes. The reaction mixture is concentrated to a volume of about 50 parts. Upon the addition of 80 parts of methanol and 20 parts of water, the product is crystallized. It is filtered off and dried, yielding α-cyano-α-(p-fluorophenyl)-3,5-diiodosalicylo-p-toluidide; mp. 232° C (dec.).
EXAMPLE XIII
A mixture of 12 parts of 3,5-diiodosalicyloyl chloride, 8.3 parts of 2-(4-amino-2-chloro)-2-(p-chlorophenyl)acetonitrile and 150 parts of dioxane is stirred and refluxed for 15 minutes. The solvent is concentrated to about 50 parts of its volume. 160 parts of methanol and 5 parts of water are added and upon complete crystallization, the solid product is filtered off. It is washed with methanol and dried in vacuo at 100° C, yielding 3'-chloro-α-(p-chlorophenyl)-α-cyano-3,5-diiodo-p-salicylotoluidide; mp. 229° C.
EXAMPLE XIV
A solution of 4.9 parts of 2-hydroxy-3,5-diiodobenzoyl chloride and 3.7 parts of 4-amino-2-(trifluoromethyl)-α-[3-trifluoromethyl)phenyl]benzeneacetonitrile in 60 parts of 1,4-dioxane is stirred and refluxed for 10 minutes. The reaction mixture is evaporated. The residue is boiled in methylbenzene for 10 minutes. After cooling to room temperature, the precipitated product is filtered off, yielding N-[4-{α-cyano-α-[3-trifluoromethyl)phenyl]methyl-}3-(trifluoromethyl)phenyl]-2-hydroxy-3,5-diiodobenzamide; mp. 206.3° C.
EXAMPLE XV
Following the procedure of Example XIV and using equivalent amounts of the appropriate starting materials the following compounds of formula (I) are prepared:
______________________________________ ##STR12## mp.R.sup.1R.sup.2 R R.sup.4 R.sup.5 Ar ° C______________________________________H I I H CF.sub.3 C.sub.6 H.sub.5 194.8H I I H CF.sub.3 4-FC.sub.6 H.sub.4 207.1H I I H CF.sub.3 4-BrC.sub.6 H.sub.4 213.3H I I H Cl 3-CF.sub.34-ClC.sub.6 H.sub.3 210H I I H Cl 3-CF.sub.3C.sub.6 H.sub.4 184.4Cl Cl Cl H CF.sub.3 3-CF.sub.34-ClC.sub.6 H.sub.3 219-221Cl Cl Cl H CF.sub.3 3-CF.sub.3C.sub.6 H.sub.4 208.2Cl Cl Cl H CF.sub.3 4-BrC.sub.6 H.sub.4 199.5Cl Cl Cl H CF.sub.3 4-FC.sub.6 H.sub.4 226-228Cl Cl Cl H CF.sub.3 C.sub.6 H.sub.5 232.3Cl Cl Cl H Cl 3-CF.sub.34-ClC.sub.6 H.sub.3 229______________________________________
EXAMPLE XVI
A mixture of 9.8 parts of 2-hydroxy-3,5-diiodobenzoyl chloride, 7.6 parts of 4-amino-α-[4-chloro-3-(trifluoromethyl)phenyl]2-(trifluoromethyl)benzeneacetonitrile and 100 parts of 1,4-dioxane is stirred and refluxed for 10 minutes. The reaction mixture is evaporated. The residue solidifies on triturating in a mixture of methylbenzene, petroleumether and trichloromethane. The product is filtered off and crystallized from acetonitrile, yielding N-[4-{α-[4-chloro-3-(trifluoromethyl)phenyl]-α-cyanomethyl-}3-(trifluoromethyl)phenyl]-2-hydroxy-3,5-diiodobenzamide; mp. 203.3° C.
EXAMPLE XVII
A mixture of 3.5 parts of 3,5-dibromo-2-hydroxybenzoyl chloride, 3.47 parts of 4-amino-α-(2,4-dichlorophenyl)-2-(trifluoromethyl)benzeneacetonitrile and 50 parts of 1,4-dioxane is stirred and refluxed for 10 minutes. The reaction mixture is evaporated. The solid residue is boiled in a mixture of trichloromethane and 2,2'-oxybispropane. The product crystallizes after cooling, while stirring. It is sucked off, dried in vacuo at 110° C and recrystallized from acetonitrile, yielding 3,5-dibromo-N-{4-[α-cyano-α-(2,4-dichlorophenyl)methyl]-3-(trifluoromethyl) -2-hydroxybenzamide; mp. 241.2° C.
EXAMPLE XVIII
Following the procedure of Example XVII and using equivalent amounts of the appropriate starting materials, the following compounds of formula (I) are prepared:
N-{4-[α-cyano-α-(3,4-dichlorophenyl)methyl]-3-(trifluoromethyl)phenyl}-2-hydroxy-3,5-diiodobenzamide; mp. 252.1° C (dec.);
N-{4-[α-cyano-α-(4methylphenyl)methyl]-3-(trifluoromethyl)phenyl}-2-hydroxy-3,5-diiodobenzamide; mp. 208.5° C;
3,4,5-trichloro-N-{4-[α-cyano-α-(2,4-dichlorophenyl)methyl]-3-(trifluoromethyl)phenyl}-2-hydroxybenzamide; mp. 109.9° C; and
3,4,5-trichloro-N-{4-[α -cyano-α-(4-methoxyphenyl)methyl]-3-(trifluoromethyl)phenyl}-2-hydroxybenzamide; mp. 219°-220° C.
EXAMPLE XIX
A mixture of 5 parts of 2-hydroxy-3,5-diiodobenzoyl chloride, 4 parts of 4-amino-α-(2,6-dichlorophenyl)-2-(trifluoromethyl)benzeneacetonitrile and 60 parts of 1,4-dioxane is stirred and refluxed for 10 minutes. The reaction mixture is evaporated and 1,1'-oxybisethane is added to the residue, whereupon the product is precipitated. It is crystallized from acetonitrile. The product is filtered off and dried in vacuo at 140° C, yielding N-{4-[α-cyano-α-(2,6-dichlorophenyl)methyl]-3-(trifluoromethyl)phenyl}-2-hydroxy-3,5-diiodobenzamide; mp. 247.8° C.
EXAMPLE XX
A mixture of 3.7 parts of 3,4,5-trichloro-2-hydroxybenzoyl chloride, 4.5 parts of 4-amino-α-(3,4-dichlorophenyl)-2-(trifluoromethyl)benzeneacetonitrile and 50 parts of 1,4-dioxane is stirred and refluxed for 10 minutes. The reaction mixture is evaporated and the residue is crystallized from 2,2'-oxybispropane. The product is filtered off, dried and recrystallized from acetonitrile. It is filtered off again and dried, yielding 3,4,5-trichloro-N-{4-[α-cyano-α-(3,4-dichlorophenyl)methyl] -3-(trifluoromethyl)phenyl}-2-hydroxybenzamide; mp. 146.5° C.
EXAMPLE XXI
A mixture of 3.1 parts of 3,4,5-trichloro-2-hydroxybenzoyl chloride, 3.5 parts of α-(4-aminophenyl)-2,4-dichlorobenzeneacetonitrile hydrochloride and 100 parts of 1,4-dioxane is stirred and refluxed for 25 minutes. The reaction mixture is evaporated. The residue solidifies on triturating in acetonitrile. The product is filtered off and dried, yielding 3,4,5-trichloro-N-{4-[α-cyano-α-(2,4-dichlorophenyl)methyl]phenyl}-2-hydroxybenzamide; mp. 142.8° C.
EXAMPLE XXII
A mixture of 4.9 parts of 2-hydroxy-3,5-diiodobenzoyl chloride, 2.7 parts of 4-amino-2-cyano-α-(4-chlorophenyl)benzeneacetonitrile and 60 parts of 1,4-dioxane is stirred and refluxed for 10 minutes. The reaction mixture is evaporated and the residue is crystallized from acetonitrile. The product is filtered off and dried, yielding N-{4-[α-(4-chlorophenyl)-α-cyanomethyl]-3-cyanophenyl}-2-hydroxy-3,5-diiodobenzamide; mp. 250° -252° C.
EXAMPLE XXIII
A mixture of 3.6 parts of 3,4,5-trichlorosalicyloyl chloride 3.9 parts of 4-amino-2-chloro-α-[3-(trifluoromethyl)phenyl]benzeneacetonitrile and 100 parts of 1,4-dioxane is stirred and refluxed for 10 minutes. The reaction mixture is evaporated and the residue is triturated in 2,2'-oxybispropane. The product is filtered off and dried, yielding 3,4,5-trichloro-N-[3-chloro-4-{α-cyano-α-[3-(trifluoromethyl)phenyl]methyl{phenyl]-2-hydroxybenzamide; mp. 233.1° C.
EXAMPLE XXIV
A mixture of 2.8 parts of 3,4,5-trichlorosalicyloyl chloride, 2.7 parts of 4-amino-2-cyano-α-(4-chlorophenyl)benzeneacetonitrile and 60 parts of 1,4-dioxane is stirred and refluxed for 10 minutes. The reaction mixture is evaporated and the residue solidifies on triturating in acetonitrile. The product is filtered off and dried, yielding 3,4,5-trichloro-N-{4-[α-(4-chlorophenyl)-α-cyanomethyl]-3-cyanophenyl}-2-hydroxybenzamide; mp. 247° C.
EXAMPLE XXV
A mixture of 8 parts of 2-hydroxy-3,5-diiodobenzoyl chloride, 5 parts of 4-amino-α-phenylbenzeneacetonitrile hydrochloride and 150 parts of 1,4-dioxane is stirred and refluxed for 15 minutes. The reaction mixture is filtered and the filtrate is evaporated. The oily residue is crystallized from ethanol, yielding N-[4-(α-cyano-α-phenylmethyl)phenyl]-2-hydroxy-3,5 -diiodobenzamide; mp. 243.3° C.
EXAMPLE XXVI
A mixture of 7.28 parts of 3,4,5-trichloro-2-hydroxybenzoyl chloride, 10 parts of 4-amino-2-chloro-α-(2,4-dichlorophenyl)benzeneacetonitrile hydrochloride and 135 parts of 1,4-dioxane is stirred and refluxed for 2h.30. After cooling, the reaction mixture is evaporated. The residue solidifies on triturating in 68 parts of warm 2-propanol. The product is filtered off, yielding 3,4,5-trichloro-N-{3-chloro-4-[α-cyano-α-(2,4-dichlorophenyl)methyl]phenyl}2hydrobenzamide; mp. 240° -242° C.
EXAMPLE XXVII
A mixture of 3.6 parts of 3,4,5-trichlorosalicyloyl chloride, 3 parts of 4-amino-α-(4-chlorophenyl)-2-(trifluoromethyl)benzeneacetonitrile and 50 parts of 1,4-dioxane is stirred and refluxed for 10 minutes. The reaction mixture is evaporated. The residue is taken up in 2,2'-oxybispropane and the resulting oil is dissolved in methanol. The solution is evaporated and the residue is crystallized from a mixture of petroleumether, 2-propanol and trichloromethane. The product is filtered off and recrystallized from a mixture of methylbenzene and petroleumether, yielding 3,4,5-trichloro-N-{4-[α-(4-chlorphenyl)-α-cyanomethyl]-3-(trifluoromethyl)phenyl}-2-hydroxybenzamide; mp. 195° -197° C.
EXAMPLE XXVIII
A mixture of 5.3 parts of 3,4,5-trichlorosalicyloyl chloride, 5.8 parts of 4-amino-α-(4-methylphenyl)-2-(trifluoromethyl)benzeneacetonitrile and 50 parts of 1,4-dioxane is stirred and refluxed for 10 minutes. The reaction mixture is evaporated and the residue is crystallized from 2,2'-oxybispropane. The product is filtered off and dried at 170° C for 5 hours, yielding 3,4,5-trichloro-N-{4-[α-cyano-α-(4-methylphenyl)methyl]-3-(trifluoromethyl)phenyl}-2-hydroxybenzamide; mp. 202° -203° C.
EXAMPLE XXIX
A mixture of 5 parts of 2-hydroxy-3,5-diiodobenzoyl chloride, 4 parts of 4-amino-α-(2,4-dichlorophenyl)-2-(trifluoromethyl)benzeneacetonitrile and 60 parts of 1,4-dioxane is stirred and refluxed for 10 minutes. The reaction mixture is evaporated. The residue is crystallized from a mixture of 2-propanol and methylbenzene. The product is filtered off and dried, yielding N-{4-[α-cyano-α-(2,4-dichlorophenyl)methyl]-3-(trifluoromethyl)phenyl}-2-hydroxy-3,5-diiodobenzamide; mp. 220° -222° C.
EXAMPLE XXX
A mixture of 4.9 parts of 2-hydroxy-3,5-diiodobenzoyl chloride, 3 parts of 4-amino-α-(4-chlorophenyl)-2-(trifluoromethyl)benzeneacetonitrile and 60 parts of 1,4-dioxane is stirred and refluxed for 15 minutes. The reaction mixture is evaporated. The residue solidifies on triturating in 2,2'-oxybispropane. The product is dissolved in methylbenzene and the solution is boiled for 5 minutes. Upon cooling, the product is crystallized. It is filtered off and dried in vacuo at 140° C, yielding N-{4-[α-(4-chlorphenyl)-α-cyanomethyl] -3-(trifluoromethyl)phenyl}-2-hydroxy-3,5-diiodobenzamide; mp. 202.5° -203.5° C.
EXAMPLE XXXI
Following the procedure of Example X and using equivalent amounts of the appropriate starting materials, the following compounds of formula (I) may still be prepared:
3,5-dibromo-N-{5-chloro-4-[α-(4-chlorophenyl)-α-cyanomethyl]2-methylphenyl}-2-hydroxybenzamide;
3,5-dibromo-N-{5-chloro-4-[α-(4-chlorphenyl)-α-cyanomethyl]phenyl}-2-hydroxybenzamide;
N-{2-chloro-4-[α-(4-chlorophenyl)-α -cyanomethyl]phenyl-2-hydroxy-3,5-diiodobenzamide;
3,4,5-trichloro-N-{2-chloro-4-[α-(4-chlorophenyl)-α-cyanomethyl]phenyl}-2-hydroxybenzamide;
4-chloro-N-{5-chloro-4-[α-(4-chlorophenyl)-α-cyanomethyl]-2-methylphenyl}-2-hydroxy-3,5-diiodobenzamide;
4-chloro-N-{5-chloro-4-[α-(4-chlorphenyl)-α-cyanomethyl]phenyl}-2-hydroxy-3,5-diiodobenzamide;
3-bromo-4,5-dichloro-N-{5-chloro-4-[-α-(4-chlorphenyl)-α-cyanomethyl]2-methylphenyl}-2-hydroxybenzamide; and
3-bromo-4,5-dichloro-N-{5-chloro-4-[α-(4-chlorophenyl)-α-cyanomethyl] phenyl}-2hydroxybenzamide.
EXAMPLE XXXII
A warm solution of 1 part of N-{5-chloro-4-[α-(4-chlorophenyl)-α-cyanomethyl]-2-methylphenyl}-2-hydroxy-3,5-diiodobenzamide, 0.3 parts of sodium hydroxide solution 10N, 8 parts of methanol and 10 parts of water is allowed to crystallize. The product is filtered off, washed with water and dried, yielding 0.7 parts (67.5%)of N-{5-chloro-4-[α-(4-chlorophenyl)-α-cyanomethyl]-2-methylphenyl}-2-hydroxy-3,5-diiodobenzamide, sodium salt hydrate; mp. 270° -300° C.
EXAMPLE XXXIII
0.65 Parts of N-{5-chloro-4-[α-(4-chlorophenyl)-α-cyanomethyl]-2-methylphenyl}-2-hydroxy-3,5-diiodobenzamide and 0.1 parts of piperidine are dissolved in 4 parts of methanol and 5 parts of 1,4-dioxane. The solvent is removed by evaporation in vacuo. The residue solidifies on triturating in 2,2'-oxybispropane. The product is filtered off and washed with 2,2'-oxybispropane, yielding, after drying, N-{5-chloro-4-[α-(4-chlorophenyl)-α-cyanomethyl]-2-methylphenyl}-2-hydroxy-3,5-diiodobenzamide compound with piperidine; mp. 140.3° C. (dec.).
EXAMPLE XXXIV
0.494 Parts of N-{5-chloro-4-[α-(4-chlorophenyl)-α-cyanomethyl]-2-methylphenyl}-2-hydroxy-3,5-diiodobenzamide and 0.1 parts of α-methylbenzenemethanamine are dissolved in 4 parts of methanol and 5 parts of 1,4-dioxane. The solvent is removed by evaporation in vacuo. The residue solidifies on triturating in 2,2'-oxybispropane. The product is filtered off, washed with 2,2'-oxybispropane and dried, yielding N-{5-chloro-4-[α-(4-chlorophenyl)-α-cyanomethyl]-2-methylphenyl}-2-hydroxy-3,5-diiodobenzamide compound with α-methylbenzenemethanamine; mp. 116.7° C. (dec.).
EXAMPLE XXXV
To a stirred and cooled (-5° C) mixture of 325 parts of nitric acid and 975 parts of a concentrated sulfuric acid solution are added dropwise 220 parts of 1,2-dichloro-4-(1,1-dimethylethyl)benzene. Upon completion, stirring is continued for 30 minutes at 5° C. The reaction mixture is poured onto water: the product precipitates as an oil. The supernatant aqueous water: is decanted and the residual oil is extracted with trichloromethane. The extract is washed with water, dried, filtered and evaporated. The residue is crystallized from 2-propanol. The product is filtered off and recrystallized from 2-propanol, yielding 34.5 parts of 1,2-dichloro-4-(1,1-dimethylethyl)-5-nitrobenzene; mp. 80° C.
EXAMPLE XXXVI
Following the procedure of Example XXXV and using an equivalent amount of 1,2-dichloro-4-(1-methylethyl)benzene in place of the 1,2-dichloro-4-(1,1-dimethylethyl)benzene used therein, there is obtained:
1,2-dichloro-4-(1-methylethyl)-5-nitrobenzene; mp. <50° C.
EXAMPLE XXXVII
Following the procedure of Example IV and using equivalent amounts of the appropriate starting materials, the following nitrile compounds are prepared:
3,4-dimethoxy-α-[4-nitro-2-(trifluoromethyl)phenyl]benzeneacetonitrile; mp. 96° -103° C;
α-(2-chloro-4-nitrophenyl)-2-naphtaleneacetonitrile; mp. 171.7° C;
α-[4-nitro-2-(trifluoromethyl)phenyl]-2-naphthaleneacetonitrile; mp. 120° C;
α-(2-chloro-4-nitrophenyl)-2-thiopheneacetonitrile as an oily residue;
5-chloro-α-(2-chloro-5-methyl-4-nitrophenyl)-2-thiopheneacetonitrile as an oily residue;
5-chloro-α-(2-chloro-4-nitrophenyl)-2-thiopheneacetonitrile as an oily residue;
2-chloro-α-(4-chlorophenyl)-5-(1,1-dimethylethyl)-4-nitrobenzeneacetonitrile as a residue; and
2-chloro-α-(4-chlorophenyl)-5-(1-methylethyl)-4-nitrobenzeneacetonitrile; mp. 111° C.
EXAMPLE XXXVIII
Following the procedure of Example VI and using an equivalent amount of an appropriate α-aryl-4-nitrobenzeneacetonitrile in place of the 2,4-dichloro-α-(4-nitrophenyl)benzeneacetonitrile used therein, the following 4-amino-α-aryl-benzeneacetonitriles or hydrochloride salts are prepared:
4-amino-α-(3,4-dimethoxyphenyl)-2-(trifluoromethyl)benzeneacetonitrile; mp. 168° C;
α-[4-amino-2-(trifluoromethyl)phenyl]-2-naphthaleneacetonitrile hydrochloride;
α-(4-amino-2-chlorophenyl)-2-naphthaleneacetonitrile;
α-(4-amino-2-chlorophenyl)-2-thiopheneacetonitrile; mp. 87° C;
α-(4-amino-2-chloro-5-methylphenyl)-5-chloro-2-thiopheneacetonitrile; mp. 147° C;
α-(4-amino-2-chlorophenyl)-5-chloro-2-thiopheneacetonitrile hydrochloride; mp. 130° C;
4-amino-2-chloro-α-(4-chlorophenyl)-5-(1,1-dimethylethyl)benzeneacetonitrile as a residue; and
4-amino-2-chloro-α-(4-chlorophenyl)-5-(1-methylethyl)benzeneacetonitrile hydrochloride.
EXAMPLE XXXIX
A mixture of 4.5 parts of 2-hydroxy-3,5-diiodobenzoyl chloride, 3 parts of 4-amino-α-(4-methoxyphenyl)-2-(trifluoromethyl)benzeneacetonitrile and 50 parts of 1,4-dioxane is stirred and refluxed for 5 minutes. The reaction mixture is evaporated and the residue is crystallized from a mixture of 75 parts of trichloromethane and 35 parts of 2,2'-oxybispropane, yielding 6.5 parts of N-{4-[α-cyano-α-(4-methoxyphenyl)methyl]-3-(trifluoromethyl)phenyl}-2-hydroxy-3,5-diiodobenzamide; mp. 198° -200° C.
EXAMPLE XL
Following the procedure of Example X and using equivalent amounts of the appropriate starting materials, the following compounds are prepared:
N-{3-chloro-4-[α-cyano-α-(2-thienyl)methyl]phenyl}-2-hydroxy-3,5-diiodobenzamide; mp. 233.6° C;
3,4,5-trichloro-N-{3-chloro-4-[α-cyano-α-(2-thienyl)methyl]phenyl}-2-hydroxybenzamide; mp. 229.9° C;
3,4,5-trichloro-N-{5-chloro-4-[α-(5-chloro-2-thienyl)-α-cyanomethyl]-2-methylphenyl}-2-hydroxybenzamide; mp. 209° -211° C; and
N-{5-chloro-4-[α-(5-chloro-2-thienyl)-α-cyanomethyl]-2-methylphenyl}-2-hydroxy-3,5-diiodobenzamide; mp. 180.3° C.
EXAMPLE XLI
Following the procedure of Example XIV and using equivalent amounts of the appropriate starting materials, the following compounds are prepared:
N-{3-chloro-4-[α-(4-chlorophenyl)-α-cyanomethyl]phenyl}-2-hydroxybenzamide; mp. 173.5° C; and
3,4,5-trichloro-N-{4-[α-cyano-α-(2-naphthalenyl)methyl]-3-(trifluoromethyl)phenyl]-2-hydroxybenzamide hemihydrate; mp. 221.7° C.
EXAMPLE XLII
Following the procedure of Example X and using equivalent amounts of the appropriate starting materials, the following compounds are obtained after crystallization in a mixture of methanol and 1,1'-oxybisethane:
3,4,5-trichloro-N-{3-chloro-4-[α-(5-chloro-2-thienyl)-α-cyanomethyl]phenyl}-2-hydroxybenzamide; mp. 205.4° C; and
N-{3-chloro-4-[α-(5-chloro-2-thienyl)-α-cyanomethyl]phenyl}-2-hydroxy-3,5-diiodobenzamide; mp. 180°-183° C.
EXAMPLE XLIII
A mixture of 4.4 parts of 2-hydroxy-3,5-diiodobenzoyl chloride, 2.9 parts of α-(4-amino-2-chlorophenyl)-2-naphthaleneacetonitrile and 50 parts of 1,4-dioxane is stirred and refluxed for 10 minutes. The reaction mixture is evaporated. The residue is triturated in methanol. The product is filtered off, boiled in ethyl acetate and filtered off again, yielding 4.5 parts (68%) of N-{3-chloro-4-[α-cyano-α-(2-naphthalenyl)methyl]phenyl}-2-hydroxy-3,5-diiodobenzamide; mp. 263.8° C.
EXAMPLE XLIV
A mixture of 2.8 parts of 3,4,5-trichlorosalicyloyl chloride, 2.9 parts of α-(4-amino-2-chlorophenyl)-2-naphtaleneacetonitrile and 50 parts of 1,4-dioxane is stirred and refluxed for 10 minutes. The reaction mixture is evaporated. The residue solidifies in boiling methanol. The product is filtered off and boiled in ethyl acetate. It is filtered off again and dried, yielding 3.5 parts (67%) of 3,4,5-trichloro-N-}3-chloro-4-[α-cyano-α-(2-naphthalenyl)methyl]phenyl}-2-hydroxybenzamide; mp. 249.2° C.
EXAMPLE XLV
A mixture of 4.4 parts of 2-hydroxy-3,5-diiodobenzoyl chloride, 3.6 parts of α-[4-amino-2-(trifluoromethyl)phenyl]-2-naphthaleneacetonitrile hydrochloride and 50 parts of 1,4-dioxane is stirred and refluxed for 10 minutes. The reaction mixture is evaporated. The residue solidifies in boiling methylbenzene. After cooling, the product is filtered off and boiled in acetonitrile. It is filtered off again and dried at 120° C/10.sup. -3 , yielding 4.5 parts (64%) of N-{4-[α-cyano-α-(2-naphthalenyl)methyl]-3-(trifluoromethyl)phenyl}-2-hydroxy-3,5-diiodobenzamide; mp. 249.3° C.
EXAMPLE XLVI
A mixture of 2.3 parts of 2-hydroxybenzoyl chloride, 4.1 parts of 4-amino-α-(4-methylphenyl)-2-(trifluoromethyl)-benzeneacetonitrile and 50 parts of 1,4-dioxane is stirred and refluxed for 10 minutes. The reaction mixture is evaporated and the residue is boiled in methylbenzene. The product is filtered off and dissolved in a mixture of acetonitrile and methanol. The solution is filtered and the filtrate is evaporated. The solid residue is stirred with acetonitrile. The product is filtered off and dried, yielding 2.6 parts of N-{4-[α-cyano-α-(4-methylphenyl)methyl]-3-(trifluoromethyl)phenyl}-2-hydroxybenzamide; mp. 165.5° C.
EXAMPLE XLVII
A mixture of 3.1 parts of 2-hydroxybenzoyl chloride, 4.2 parts of 4-amino-α-phenylbenzeneacetonitrile and 100 parts of 1,4-dioxane is stirred and refluxed for 2 hours. Then there are added 0.7 parts of N,N-diethylethanamine and the whole is evaporated. The oily residue is triturated in methylbenzene. The product is filtered off and crystallized from methylbenzene, yielding 2.3 parts of N-[4-(α-cyano-α-phenylmethyl)phenyl]-2-hydroxybenzamide; mp. 176.8° C.
EXAMPLE XLVIII
A mixture of 3.1 parts of 2-hydroxybenzoyl chloride, 6.7 parts of 4-amino-α-(3,4-dimethoxyphenyl)-2-(trifluoromethyl)-benzeneacetonitrile and 100 parts of 1,4-dioxane is stirred and refluxed till HCl-gas evolution is ceased (duration: ±2 hours). The reaction mixture is evaporated. The oily residue is taken up in acetonitrile. After cooling, the precipitated product is filtered off and dissolved in a boiling mixture of 2-propanone and methanol. The whole is filtered while hot and the filtrate is evaporated. The residue is crystallized from methanol. The product is filtered off and dried in vacuo at 140° C, yielding 1.1 parts of N-{4-[α-cyano-α-(3,4-dimethoxyphenyl)methyl]-3-(trifluoromethyl)-phenyl}-2-hydroxybenzamide; mp. 194.6° C.
EXAMPLE IL
A mixture of 3.1 parts of 2-hydroxybenzoyl chloride, 4.4 parts of 4-amino-α-(4-methylphenyl)benzeneacetonitrile and 100 parts of 1,4-dioxane is stirred and refluxed for one hour: during this reflux-time 0.7 parts of N,N-diethylethanamine are added. The reaction mixture is evaporated. The residue is stirred in ethanol. The product is filtered off and crystallized from ethyl acetate. It is filtered off again and dissolved in 2-propanone. The solution is filtered and the filtrate is evaporated, yielding 0.9 parts of N-{4-[α-cyano-α-(4-methylphenyl)methyl]phenyl}-2-hydroxybenzamide; mp. 157.4° C.
EXAMPLE L
A mixture of 6.5 parts of 3,5-diiodo-2-hydroxybenzoyl chloride, 5.3 parts of 4-amino-2-chloro-α-(4-chlorophenyl)-5-(1,1-dimethylethyl)benzeneacetonitrile and 60 parts of 1,4-dioxane is stirred and refluxed for 30 minutes. The reaction mixture is evaporated. The residue is purified by column-chromatography over silica gel using trichloromethane as eluent. The pure fractions are collected and the eluent is evaporated. The residue is crystallized from methylbenzene. The product is filtered off and dried, yielding 2.2 parts of N-{5-chloro-4-[α-(4-chlorophenyl)-α-cyanomethyl]-2-(1,1-dimethylethyl)phenyl}-2-hydroxy-3,5-diiodobenzamide; mp. 149.1° C.
EXAMPLE LI
A mixture of 2.9 parts of 3,4,5-trichloro-2-hydroxybenzoyl chloride, 3.3 parts of 4-amino-2-chloro-α-(4-chlorophenyl)-5-(1,1-dimethylethyl)benzeneacetonitrile and 60 parts of 1,4-dioxane is stirred and refluxed for 20 minutes. The reaction mixture is evaporated and the residue is purified by column-chromatography over silica gel using trichloromethane as eluent. The pure fractions are collected and the eluent is evaporated. The residue is crystallized from 2,2'-oxybispropane. The product is filtered off and dried in vacuo at 100° C/10.sup. -3 mm., yielding 3.5 parts of 3,4,5-trichloro-N-{5-chloro-4-[α-(4-chlorophenyl)-α-cyanomethyl]-2-(1,1-dimethylethyl)phenyl}-2-hydroxybenzamide; mp. 231.9° C.
EXAMPLE LII
A mixture of 4.4 parts of 3,4,5-trichloro-2-hydroxybenzoyl chloride, 5.4 parts of 4-amino-2-chloro-α-(4-chlorophenyl)-5-(1-methylethyl)benzeneacetonitrile hydrochloride and 70 parts of 1,4-dioxane is stirred and refluxed for 40 minutes. The reaction mixture is evaporated and the residue is crystallized from 2,2'-oxibispropane. The product is filtered off and dried, yielding 6.3 parts of 3,4,5-trichloro-N-{5-chloro-4-[α-(4-chlorophenyl)-α-cyanomethyl]-2-(1-methylethyl)phenyl}-2-hydroxybenzamide; mp. 207.1° C.
EXAMPLE LIII
A mixture of 4.8 parts of 2-hydroxy-3,5-diiodobenzoyl chloride, 6.5 parts of 4-amino-2-chloro-α-(4-chlorophenyl)-5-(1-methylethyl)benzeneacetonitrile hydrochloride and 60 parts of 1,4-dioxane is stirred and refluxed for 30 minutes. The reaction mixture is evaporated and the residue is purified by column-chromatography over silica gel using a mixture of trichloromethane, hexane and methanol (50:50:5) as eluent. The pure fractions are collected and the eluent is evaporated. The residue is crystallized from acetonitrile, yielding 4.2 parts of N-{5-chloro-4-[α-(4-chlorophenyl)-α-cyanomethyl]-2-(1-methylethyl)phenyl}-2-hydroxy-3,5-diiodobenzamide; mp. 200.6° C.
EXAMPLE LIV
A mixture of 9.2 parts of phenyl 2,6-dihydroxybenzoate, 9 parts of 4-amino-α-(4-fluorophenyl)benzeneacetonitrile and 30 parts of 1,2,4-trichlorobenzene is stirred for 10 minutes at 200° C. The reaction mixture is cooled and upon the addition of 150 parts of trichloromethane, the product is crystallized. It is filtered off, washed with trichloromethane and dried, yielding 11.4 parts of N-{4-[α-cyano-α-(4-fluorophenyl)-methyl]phenyl}-2,6-dihydroxybenzamide; mp. 239° C.
EXAMPLE LV
Following the procedure of Example LIV and using equivalent amounts of the appropriate starting materials, the following compounds are prepared:
N-{4-[α-cyano-α-(4-methylphenyl)methyl]phenyl}-2,6-dihydroxybenzamide; mp. 211.4° C;
N-[3-chloro-4-(α-cyano-α-phenylmethyl)phenyl]-2,6-dihydroxybenzamide; mp. 229.5° C;
N-[4-(α-cyano-α-phenylmethyl)phenyl]-2,6-dihydroxybenzamide; mp. 229.3° C; and N-{4-[α-cyano-α-(4-methoxyphenyl)methyl]phenyl}-2,6-dihydroxybenzamide; mp. 199.6° C.
EXAMPLE LVI
A mixture of 4.14 parts of phenyl 2,6-dihydroxy-3-nitrobenzoate, 5.25 parts of 4-amino-α-(2,4 -dichlorophenyl)-2-(trifluoromethyl)benzeneacetonitrile and 30 parts of 1,2,4-trichlorobenzene is stirred for 10 minutes at 195° C. The reaction mixture is poured onto 105 parts of 2,2'-oxybispropane while stirring. The precipitated product is filtered off, washed with 2,2'-oxybispropane and crystallized from a mixture of acetonitrile and 2,2'-oxybispropane. The product is filtered off and dried in vacuo at 110° C, yielding 6.07 parts of N-{4-[α-cyano-α-(2,4-dichlorophenyl)methyl]-3-(trifluoromethyl)phenyl}-2,6-dihydroxy-3-nitrobenzamide; mp. 220.9° C.
EXAMPLE LVII
Following the procedure of Example LVI and using equivalent amounts of the appropriate starting materials, the following compounds are prepared:
N-{4-[α-cyano-α-(4-methoxyphenyl)methyl]-3-(trifluoromethyl)-phenyl}-2,6-dihydroxy-3-nitrobenzamide; mp. 200° C; and
N-[3-chloro-4-{α-cyano-α-[3-(trifluoromethyl)phenyl]methyl}-phenyl]-2,6-dihydroxybenzamide; mp. 240.5° C.
EXAMPLE LVIII
A mixture of 3.5 parts of phenyl 3-bromo-2,6-dihydroxy-5-nitrobenzoate, 3.5 parts of 4-amino-α-(2,4-dichlorophenyl)-2-(trifluoromethyl)benzeneacetonitrile and 22.5 parts of 1,2,4-trichlorobenzene is stirred for 10 minutes at 190° C. The reaction mixture is allowed to cool to room temperature and poured onto 140 parts of petroleumether. The supernatant phase is decanted and the residual solid product is crystallized from acetonitrile. It is sucked off and dried in vacuo at 110° C, yielding 3.9 parts of 3-bromo-N-{4-[α-cyano-α-(2,4-dichlorophenyl)methyl]-3-(trifluoromethyl)phenyl}-2,6-dihydroxy-5-nitrobenzamide; mp. 246.6° C.
EXAMPLE LIX
Following the procedure of Example LVIII there is prepared 3-bromo-N-{4-[α-cyano-α-(4-methoxyphenyl)methyl]-3-(trifluoromethyl)phenyl}-2,6-dihydroxy-5-nitrobenzamide; mp. 197° C by the reaction of phenyl 3-bromo-2,6-dihydroxy-5-nitrobenzoate with 4-amino-α-(4-methoxyphenyl)-2-(trifluoromethyl)benzeneacetonitrile.
EXAMPLE LX
A mixture of 2.3 parts of phenyl 2,6-dihydroxybenzoate, 3 parts of 4-amino-α-(4-methoxyphenyl)-2-(trifluoromethyl)benzeneacetonitrile and 22.5 parts of 1,2,4-trichlorobenzene is stirred for 10 minutes at 190° C. The reaction mixture is poured onto petroleumether. The supernatant phase is decanted and the residual crude product is boiled in methylbenzene. The solution is stirred in activated charcoal. The latter is filtered off and 2,2'-oxybispropane is added to the filtrate till turbid. The product is allowed to crystallize while stirring, filtered off and recrystallized from acetonitrile, yielding 1.5 parts of N-{4-[α-cyano-α-(4-methoxyphenyl)methyl]-3-(trifluoromethyl)phenyl}-2,6-dihydroxybenzamide; mp. 181.5° C.
EXAMPLE LXI
Following the procedure of Example LX there is prepared N-{4-[α-cyano-α-(2,4-dichlorophenyl)methyl]-3-(trifluoromethyl)-phenyl}-2,6-dihydroxybenzamide; mp. 199.5° C, by the reaction of phenyl 2,6-dihydroxybenzoate with 4-amino-α-(2,4-dichlorophenyl)-2-(trifluoromethyl)benzeneacetonitrile.
EXAMPLE LXII
A mixture of 4.5 parts of phenyl 3-chloro-2,6-dihydroxy-5-nitrobenzoate, 4.5 parts of 4-amino-α-(4-chlorophenyl)-2-(trifluoromethyl)benzeneacetonitrile and 37.5 parts of 1,2,4-trichlorobenzene is stirred for 10 minutes at 180° C. After cooling, the reaction mixture is poured onto petroleumether, whereupon the product is separated as an oil. The supernatant phase is decanted and discarded. The oily product solidifies after stirring for 30 minutes in a mixture of 150 parts of trichloromethane and 70 parts of petroleumether. The solid product is filtered off and crystallized from 75 parts of trichloromethane (activated charcoal), yielding 2.7 parts of 3-chloro-N-{4-[α-(4-chlorophenyl)-α-cyanomethyl]-3-(trifluoromethyl)phenyl}-2,6-dihydroxy-5-nitrobenzamide; mp. 186.1° C.
EXAMPLE LXIII
Following the procedure of Example LXII there is prepared N-{4-[α-cyano-α-(4-fluorophenyl)methyl]-3-(trifluoromethyl)phenyl}-2,6-dihydroxybenzamide; mp. 206.4° C, by the reaction of phenyl 2,6-dihydroxybenzoate with 4-amino-α-(4-fluorophenyl)-2-(trifluoromethyl)benzeneacetonitrile.
EXAMPLE LXIV
A mixture of 3 parts of phenyl 3-chloro-2,6-dihydroxy-5-nitrobenzoate, 3.5 parts of 4-amino-α-(2,4-dichlorophenyl)-2-(trifluoromethyl)benzeneacetonitrile and 30 parts of 1,2,4-trichlorobenzene is stirred for 10 minutes at 190° C. The reaction mixture is poured onto 140 parts of petroleumether. The supernatant organic phase is decanted. The residue is boiled in methylbenzene and stirred with activated charcoal. The latter is filtered off over hyflo and petroleumether is added to the filtrate till turbid. The product is allowed to crystallize on standing. It is filtered off and dried in vacuo at 100° C, yielding 3 parts of 3-chloro-N-{4-[α-cyano-α-(2,4-dichlorophenyl)methyl]-3-(trifluoromethyl)phenyl}-2,6-dihydroxy-5-nitrobenzamide; mp. 224.7° C.
EXAMPLE LXV
A mixture of 3.5 parts of phenyl 2,6-dihydroxybenzoate, 4.5 parts of 4-amino-α-(4-chlorophenyl)-2-(trifluoromethyl)benzeneacetonitrile and 22.5 parts of 1,2,4-trichlorobenzene is stirred at 200° C for 20 minutes. The reaction mixture is cooled and poured onto 140 parts of petroleumether. The supernatant phase is decanted and the residual oil is dissolved in 75 parts of trichloromethane. 175 Parts of petroleumether are added and the whole is boiled for 30 minutes while stirring. The product is filtered off and crystallized from 235 parts of benzene, yielding 2.5 parts of N-{4-[α-(4-chlorophenyl)-α-cyanomethyl]-3-(trifluoromethyl)phenyl}-2,6-dihydroxybenzamide; mp. 187.7° C.
EXAMPLE LXVI
A mixture of 4.7 parts of phenyl 2,6-dihydroxybenzoate, 7.24 parts of 4-amino-α-(3,4-dichlorophenyl)-2-(trifluoromethyl)benzeneacetonitrile and 15 parts of 1,2,4-trichlorobenzene is stirred for 10 minutes at 180°-200° C. After cooling, the reaction mixture is poured onto petroleumether. The resulting oil is separated and boiled in a mixture of petroleumether and trichloromethane, while stirring. The solid product is filtered off and crystallized from methylbenzene, yielding 3 parts of N-{4-[α-cyano-α-(3,4-dichlorophenyl)methyl]-3-(trifluoromethyl)phenyl}-2,6-dihydroxybenzamide; mp. 189.7° C.
EXAMPLE LXVII
A mixture of 5.16 parts of phenyl 2,6-dihydroxybenzoate, 6.6 parts of 4-amino-α-(4-methylphenyl)-2-trifluoromethyl)benzeneacetonitrile and 75 parts of 1,2,4-trichlorobenzene is stirred for 10 minutes at 180°-200° C. The reaction mixture is cooled and poured onto petroleumether. The supernatant oily product is separated and boiled in a mixture of petroleumether and trichloromethane. The resulting solution is cooled and the product is filtered off. It is purified by column-chromatography over silica gel, using a mixture of trichloromethane and 5% of methanol as eluent. The pure fractions are collected and the eluent is evaporated, yielding 1 part of N-{4-[α-cyano-α-(4-methylphenyl)methyl]-3-(trifluoromethyl)phenyl}-2,6-dihydroxybenzamide; mp. 212.5° C
EXAMPLE LXVIII
A mixture of 4.6 parts of phenyl 2,6-dihydroxybenzoate, 5.6 parts of 4-amino-α-phenyl-2-(trifluoromethyl)benzeneacetonitrile and 26 parts of 1,2,4-trichlorobenzene is stirred for 15 minutes at 200° C. After cooling, the reaction mixture is poured onto 140 parts of petroleumether, whereupon an oil is precipitated. The supernatant phase is decanted and the residual oil is dissolved in trichloromethane. The solution is boiled in 140 parts of petroleumether for 30 minutes, while stirring. The precipitated product is filtered off and purified by column-chromatography over silica gel using a mixture of trichloromethane and 5% of methanol as eluent. The pure fractions are collected and the eluent is evaporated. The residue is crystallized from 180 parts of methylbenzene, yielding 3.8 parts of N-[4-(α-cyano-α-phenylmethyl)-3-(trifluoromethyl)-phenyl]-2,6-dihydroxybenzamide; mp. 201° C.
EXAMPLE LXIX
A mixture of 6 parts of phenyl 3-bromo-2,6-dihydroxy-5-nitrobenzoate, 4.5 parts of 4-amino-α-(4-chlorophenyl)-2-(trifluoromethyl)benzeneacetonitrile and 22.5 parts of 1,2,4-trichlorobenzene is stirred and boiled at 190°-200° C for 10 minutes. After cooling, the reaction mixture is poured onto 140 parts of petroleumether, whereupon an oil is precipitated. The supernatant phase is decanted and the residual oil is dissolved in 75 parts of trichloromethane and 45 parts of methylbenzene, 140 Parts of petroleumether are added and the whole is boiled for 30 minutes while stirring. The precipitated product is filtered off and crystallized from 30 parts of trichloromethane. The product is filtered off and washed with trichloromethane, yielding 3 parts of 3-bromo-N-{4-[α-(4-chlorophenyl)-α-cyanomethyl]-3-(trifluoromethyl)phenyl}-2,6-dihydroxy-5-nitrobenzamide; mp. 200.7° C.
EXAMPLE LXX
A mixture of 3 parts of phenyl 3-chloro-2,6-dihydroxy-5-nitrobenzoate, 3 parts of 4-amino-α-(4-methoxyphenyl)-2-(trifluoromethyl)benzeneacetonitrile and 30 parts of 1,2,4-trichlorobenzene is stirred for 10 minutes at 190° C. The reaction mixture is cooled and poured onto 140 parts of petroleumether while stirring. The supernatant phase is decanted and the residue is boiled in methylbenzene and stirred with activated charcoal. The latter is filtered off over hyflo. Petroleumether is added to the filtrate till turbid and the product is allowed to crystallize while stirring. It is filtered off, dried and crystallized from acetonitrile, yielding 4.5 parts of 3-chloro-N-{4-[α-cyano-α-(4-methoxyphenyl)methyl]-3-trifluoromethyl)phenyl}-2,6-dihydroxy-5-nitrobenzamide; mp. 206.4° C.
EXAMPLE LXXI
A mixture of 2.3 parts of phenyl 2,6-dihydroxybenzoate, 2.7 parts of 4-amino-2-cyano-α-(4-chlorophenyl)benzeneacetonitrile and 22.5 parts of 1,2,4-trichlorobenzene is stirred and refluxed for 10 minutes. The reaction mixture is cooled and poured onto petroleumether: whereupon an oil is precipitated. The supernatant phase is decanted and the residual oil solidifies on triturating in a mixture of petroleumether and trichloromethane. The product is filtered off and boiled in 40 parts of acetonitrile, yielding 1.5 parts of N-{4-[α-(4-chlorophenyl)-α-cyanomethyl]-3-cyanopheny}-2,6-dihydroxybenzamide; mp. + 300° C (dec.).
EXAMPLE LXXII
A mixture of 4.5 parts of phenyl 2,6-dihydroxybenzoate, 4.2 parts of 4-amino-2-chloro-α-(4-chlorophenyl)benzeneacetonitrile and 22.5 parts of 1,2,4-trichlorobenzene is stirred for 10 minutes at 180°-200° C. The reaction mixture is poured onto petroleumether, whereupon the product is precipitated as an oil. The supernatant phase is decanted and the residual oil is crystallized from 150 parts of trichloromethane, yielding 4.5 parts of N-{3-chloro-4-[α-(4-chlorophenyl)-α-cyanomethyl]phenyl}-2,6-dihydroxybenzamide; mp. 162.8° C.
EXAMPLE LXXIII
A mixture of 6.9 parts of phenyl 2,6-dihydroxybenzoate, 10.6 parts of 4-amino-α-(4-bromophenyl 2-(trifluoromethyl)benzeneacetonitrile and 30 parts of 1,2,4-trichlorobenzene is stirred for 20 minutes at 180° C. The reaction mixture is cooled and poured onto petroleumether. The supernatant phase is decanted and the residual oil is taken up in 2,2'-oxybispropane and petroleumether. The whole is filtered and the filtrate is evaporated. The oily residue is taken up in trichloromethane and petroleumether. The product is filtered off and crystallized from methylbenzene, yielding 5 parts of N-{4-[α-(4-bromophenyl)-α-cyanomethyl]-3-(trifluoromethyl)phenyl}-2,6-dihydroxybenzamide; mp. 190.6° C.
EXAMPLE LXXIV
To a stirred and hot (60° C) mixture of 4 parts of 3-(1,1-dimethylethyl)-2-hydroxy-6-methyl-5-nitrobenzoic acid, 7.5 parts of 4-amino-2-chloro-α-[3-(trifluoromethyl)phenyl]benzeneacetonitrile and 66 parts of chlorobenzene is added dropwise a solution of 1.5 parts of phosphoryl chloride in 11 parts of chlorobenzene. Upon completion, stirring is continued for 2 hours at reflux temperature. The reaction mixture is poured onto trichloromethane and the whole is filtered over hyflo. The filtrate is evaporated. The residue is purified by column-chromatography over silica gel using a mixture of hexane, trichloromethane and methanol (50:50:5) as eluent. The pure fractions are collected and the eluent is evaporated. The residue is crystallized from a mixture of trichloromethane and petroleumether, yielding 4 parts of N-[3-chloro-4-{α-cyano-α-[3-(trifluoromethyl)phenyl]methyl}phenyl]-3-(1,1-dimethylethyl)-2-hydroxy-6-methyl-5-nitrobenzamide; mp. 118.6° C.
EXAMPLE LXXV
Following the procedure of Example LXXIV there is prepared N-{4-[α-cyano-α-(2,4-dichlorophenyl)methyl]phenyl}-3-(1,1-dimethylethyl)-2-hydroxy-6-methyl-5-nitrobenzamide; mp. 175.9° C by the reaction of 3-(1,1-dimethylethyl)-2-hydroxy-6-methyl-5-nitrobenzoic acid with α-(4-aminophenyl)-2,4-dichlorobenzeneacetonitrile.
EXAMPLE LXXVI
To a stirred and hot mixture of 4 parts of 3-(1,1-dimethylethyl)-2-hydroxy-6-methyl-5-nitrobenzoic acid, 4 parts of 4-amino-2-chloro-α-(4-chlorophenyl)benzeneacetonitrile and 55 parts of chlorobenzene is added dropwise a solution of 1 part of phosphoryl chloride in 11 parts of chlorobenzene at 60° C. Upon completion, stirring is continued for 6 hours at reflux. The reaction mixture is filtered while hot. The filtrate is allowed to cool and poured onto 750 parts of petroleumether: the product separates as an oil. The supernatant phase is decanted and the residual oil is dissolved in 1,1'-oxybisethane. The solution is saturated with gaseous hydrogen chloride and filtered over hyflo. The filtrate is washed with water, dried, filtered and evaporated. The residue is purified by column-chromatography over silica gel using trichloromethane as eluent. The pure fractions are collected and the eluent is evaporated. The residue is crystallized from a mixture of trichloromethane and petroleumether. The product is filtered off and dried at 100° C/10.sup. -3 mm., yielding 3.3 parts of N-{3-chloro-4-[α-(4-chlorophenyl)-α-cyanomethyl]phenyl}-3-(1,1-dimethylethyl)-2-hydroxy-6-methyl-5-nitrobenzamide; mp. 185.4° C.
EXAMPLE LXXVII
To a stirred mixture of 4 parts of 3-(1,1-dimethylethyl)-2-hydroxy-6-methyl-5-nitrobenzoic acid, 6.9 parts of 4-amino-2-chloro-α-(4-chlorophenyl)-5-methylbenzeneacetonitrile and 55 parts of chlorobenzene is added dropwise a solution of 1.5 parts of phosphoryl chloride in 11 parts of chlorobenzene at 60° C. Upon completion, stirring is continued for 3 hours. The reaction mixture is cooled and poured onto 450 parts of petroleumether. The latter is decanted and the residual precipitate is boiled in 350 parts of 1,1'-oxybisethane. The solution is saturated with gaseous hydrogen chloride and filtered over hyflo. The filtrate is washed twice with water, dried, filtered and evaporated. The residue is crystallized from methylbenzene, yielding 4 parts (47%) of N-{5-chloro-4-[α-(4-chlorophenyl)-α-cyanomethyl]-2-methylphenyl}-3-(1,1-dimethylethyl)-2-hydroxy-6-methyl-5-nitrobenzamide; mp. 133.4° C.
EXAMPLE LXXVIII
To a stirred and hot (60° C) mixture of 4 parts of 3-(1,1-dimethylethyl)-2-hydroxy-6-methyl-5-nitrobenzoic acid, 17.5 parts of 4-amino-2,5-dichloro-α-(4-chlorophenyl)benzeneacetonitrile and 55 parts of chlorobenzene is added dropwise a solution of 1.5 parts of phosphoryl chloride in 11 parts of chlorobenzene. Upon completion, stirring is continued for 3 hours at reflux temperature. The reaction mixture is cooled and poured onto 350 parts of petroleumether. The precipitate is filtered off and the product is allowed to crystallize from the filtrate. It is filtered off and dried, yielding 3 parts of N-{2,5-dichloro-4-[α-(4-chlorophenyl)-α-cyanomethyl]phenyl}-3-(1,1-dimethylethyl)-2-hydroxy-6-methyl-5-nitrobenzamide; mp. 161.2° C.
EXAMPLE LXXIX
To a stirred and hot (60° C) mixture of 3 parts of 3-(1,1-dimethylethyl)-2-hydroxy-6-methyl-5-nitrobenzoic acid, 6.2 parts of 4-amino-2-(trifluoromethyl)-α-[3-(trifluoromethyl)phenyl]benzeneacetonitrile and 55 parts of chlorobenzene is added dropwise a solution of 1.3 parts of phosphoryl chloride in 11 parts of chlorobenzene. Upon completion, stirring is continued for 3 hours at reflux temperature. The reaction mixture is cooled and poured onto 350 parts of petroleumether. The product is filtered off and dissolved in 1,1'-oxybisethane. The solution is saturated with gaseous hydrogen chloride and filtered over hyflo. The filtrate is evaporated. The residue is purified by column-chromatography over silica gel using a mixture of hexane, trichloromethane and methanol (10:10:1 by volume) as eluent. The pure fractions are collected and the eluent is evaporated. The residue is crystallized from a mixture of trichloromethane and petroleumether, yielding 1.2 parts of N-[4-{α-cyano-α-[3-(trifluoromethyl)phenyl]methyl}-3-(trifluoromethyl)phenyl]-3-(1,1-dimethylethyl)-2-hydroxy-6-methyl- 5-nitrobenzamide; mp. 146.7° C.
EXAMPLE LXXX
To a stirred and hot (60° C) mixture of 4 parts of 3-(1,1-dimethylethyl)-2-hydoxy-6-methyl-5-nitrobenzoic acid, 7.5 parts of 4-amino-α-(4-chlorophenyl)-2-(trifluoromethyl)benzeneacetonitrile and 55 parts of chlorobenzene is added dropwise a solution of 1.5 parts of phosphoryl chloride in 11 parts of chlorobenzene. Upon completion, stirring is continued for 3 hours at reflux temperature. The reaction mixture is cooled and poured onto petroleumether: the product precipitates as an oil. The supernatant phase is decanted and the residual oil is taken up in 1,1'-oxybisethane. The solution is saturated with gaseous hydrogen chloride and filtered over hyflo. The filtrate is washed with water, dried, filtered and evaporated. The residue is crystallized from a mixture of trichloromethane and petroleumether. The product is filtered off and recrystallized from acetonitrile, yielding 3.8 parts of N-{4-[α-(4-chlorophenyl)-α-cyanomethyl]-3-(trifluoromethyl)phenyl}-3-(1,1-dimethylethyl)-2-hydroxy-6-methyl-5-nitrobenzamide; mp. 211.8° C.
EXAMPLE LXXXI
To a stirred and hot (60° C) mixture of 4 parts of 3-(1,1-dimethylethyl)-2-hydroxy-6-methyl-5-nitrobenzoic acid, 8.5 parts of 4-amino-α-(4-bromophenyl)-2-(trifluoromethyl)benzeneacetonitrile and 55 parts of chlorobenzene is added dropwise a solution of 1.5 parts of phosphoryl chloride in 22 parts of chlorobenzene. Upon completion, stirring is continued for 3 hours at reflux temperature. The reaction mixture is cooled and filtered over hyflo. The filtrate is poured onto 350 parts of petroleumether: the product precipitates as an oil. The supernatant phase is decanted and the residual oil is taken up in 350 parts of 1,1'-oxybisethane. The solution is saturated with gaseous hydrogen chloride and filtered over hyflo. The filtrate is washed with water, dried, filtered and distilled azeotropically with methylbenzene. The solvent is evaporated and the residue is crystallized from a mixture of trichloromethane and petroleumether. The product is filtered off and recrystallized from methylbenzene, yielding 3.4 parts of N-{4-[α-(4-bromophenyl)-α-cyanomethyl]-3-(trifluoromethyl)phenyl}-3-(1,1-dimethylethyl)-2-hydroxy-6-methyl-5-nitrobenzamide; mp. 211.5° C.
EXAMPLE LXXXII
To a stirred solution of 5 parts of 3-(1,1-dimethylethyl)-2-hydroxy-5-iodo-6-methylbenzoic acid and 5 parts of 4-amino-α-(4-chlorophenyl)-2-(trifluoromethyl)benzeneacetonitrile in 55 parts of chlorobenzene is added dropwise a solution of 1.25 parts of phosphoryl chloride in 11 parts of chlorobenzene while heating at 60° C. Upon completion, stirring is continued for 2 hours at 120° C. After cooling to 60° C, another portion of 2.5 parts of 4-amino-α-(4-chlorophenyl)-2-(trifluoromethyl)benzeneacetonitrile are added and the whole is stirred for 2 hours at 120° C. The reaction mixture is cooled and 300 parts of trichloromethane are added. The solution is filtered over hyflo and the filtrate is washed with a sodium carbonate solution 5%, dried, filtered and evaporated. The residue is purified by column-chromatography over silica gel using a mixture of trichloromethane, 50% of hexane and 5% of methanol as eluent. The pure fractions are collected and the eluent is evaporated. The residue is crystallized from cyclohexane, yielding 2.5 parts of N-{4-[α-(4-chlorophenyl)-α-cyanomethyl]-3-(trifluoromethyl)phenyl}-3-(1,1-dimethylethyl)-2-hydroxy-5-iodo-6-methylbenzamide; mp. 154.3° C.
EXAMPLE LXXXIII
To a stirred and hot (60° C) mixture of 4 parts of 3-(1,1-dimethylethyl)-2-hydroxy-6-methyl-5-nitrobenzoic acid and 6.2 parts of 4-amino-2-chloro-α-(2,4-dichlorophenyl)-5-methylbenzeneacetonitrile in 55 parts of chlorobenzene is added dropwise a solution of 1.5 parts of phosphoryl chloride in 17 parts of chlorobenzene. Upon completion, stirring is continued for 3 hours at 140° C. The reaction mixture is cooled and poured onto 375 parts of trichloromethane. The whole is filtered over hyflo. The filtrate is washed with water, dried, filtered and evaporated. The residue is crystallized from a mixture of trichloromethane and petroleumether. The product is filtered off and recrystallized from methylbenzene, yielding, after drying at 100° C/10.sup. -3 mm., 6 parts of N-{5-chloro-4-[α-cyano-α-(2,4-dichlorophenyl)methyl]-2-methylphenyl}-3-(1,1-dimethylethyl)-2-hydroxy-6-methyl-5-nitrobenzamide; mp. 141.9° C.
EXAMPLE LXXXIV
To a stirred and hot (60° C) mixture of 4 parts of 3-(1,1-dimethylethyl)-2-hydroxy-6-methyl-5-nitrobenzoic acid, 6.6 parts of 4-amino-α-phenyl-2-(trifluoromethyl)benzeneacetonitrile and 55 parts of chlorobenzene is added dropwise a solution of 1.5 parts of phosphoryl chloride in 17 parts of chlorobenzene. Upon completion, stirring is continued for 2.50 hours at reflux temperature. The reaction mixture is cooled and poured onto 300 parts of trichloromethane. The whole is filtered and the filtrate is evaporated. The residue is crystallized from a mixture of 150 parts of trichloromethane and and 140 parts of petroleumether. The product is filtered off and dried, yielding 4 parts of N-{4-(α-cyano-α-phenylmethyl)-3-(trifluoromethyl)phenyl]-3-(1,1-dimethylethyl)-2-hydroxy-6 -methyl-5-nitrobenzamide; mp. 188.8° C.
EXAMPLE LXXXV
To a stirred and hot (60° C) mixture of 4 parts of 3-(1,1-dimethylethyl)-2-hydroxy-6-methyl-5-nitrobenzoic acid, 6.5 parts of 4-amino-2-cyano-α-(4-chlorophenyl)benzeneacetonitrile and 66 parts of chlorobenzene are added 1.5 parts of phosphoryl chloride and the whole is stirred and refluxed for 2 hours. The reaction mixture is cooled and poured onto trichloromethane. The whole is filtered and the filtrate is evaporated. The residue is crystallized from a mixture of trichloromethane and petroleumether, yielding 7 parts (88%) of N-{4-[α-(4-chlorophenyl)-α-cyanomethyl]-3-cyanophenyl}-3-(1,1-dimethylethyl)-2-hydroxy-6-methyl-5-nitrobenzamide; mp. 233.5° C.
EXAMPLE LXXXVI
To a stirred mixture of 4 parts of 3-(1,1-dimethylethyl)-2-hydroxy-6-methyl-5-nitrobenzoic acid, 8.3 parts of 4-amino-α-(2,4-dichlorophenyl)-2-(trifluoromethyl)benzeneacetonitrile and 66 parts of chlorobenzene are added 1.5 parts of phosphoryl chloride at 60° C. Stirring is continued for 2 hours at reflux temperature. The reaction mixture is cooled and poured onto trichloromethane. The whole is washed with water, dried, filtered and evaporated. The residue is dissolved in 150 parts of trichloromethane and petroleumether is added till turbid. The product is allowed to crystallize on standing. It is filtered off and recrystallized from a mixture of trichloromethane and petroleumether, yielding 4 parts of N-{4-[α-cyano-α-(2,4-dichlorophenyl)methyl]-3-(trifluoromethyl)phenyl}-3-(1,1-dimethylethyl)-2-hydroxy-6-methyl-5-nitrobenzamide; mp. 213.4° C.
EXAMPLE LXXXVII
To a stirred and hot (60° C) mixture of 4 parts of 3-(1,1-dimethlethyl)-2-hydroxy-6-methyl-5-nitrobenzoic acid, 6 parts of 4-amino-2-chloro-α-(4-chlorphenyl)-5-(1,1-dimethylethyl) benzeneacetronitrile and 66 parts of chlorobenzene is added 1 part of phosphoryl chloride, The whole is stirred and refluxed for 1 hour. After cooling, 300 parts of trichloromethane are added. The mixture is washed with a 5% sodium hydrogen carbonate solution and with water, dried, filtered and evaporated. The residue is purified by column-chromatography over silica gel using a mixture of trichloromethane, hexane and methanol (50:50:5) as eluent. The pure fractions are collected and the eluent is evaporated. The residue is crystallized from a mixture of trichloromethane and petroleumether. The product is filtered off and recrystallized from acetonitrile, yielding 2.3 parts of N-{5-chloro-4-[α-(4-chlorophenyl)-α-cyanomethyl]-2-(1,1-dimethylethyl)phenyl}-3-(1,1-dimethyl-ethyl)-2-hydroxy-6-methyl-5-nitrobenzamide; mp. 206.2° C.
EXAMPLE LXXXXVIII
To a stirred and hot (60° C) mixture of 4 parts of 3-(1,1-dimethylethyl)-2-hydroxy-56-methyl-5-nitrobenzoic acid, 7.7 parts of 4-amino-2-chloro-α-(4-chlorophenyl)-5-(1-methylethyl)-benzeneacetonitrile and 66 parts of chlorobenzene are added 1.5 parts of phosphoryl chloride. The whole is stirred and refluxed for 2 hours. The reaction mixture is cooled and poured onto 300 parts of trichloromethane. The whole is saturated with gaseous hydrogen chloride and filtered over hyflo. The filtrate is washed with a sodium hydrogen carbonate solution and with water, dried, filtered and evaporated. The residue is crystallized from a mixture of trichloromethane and petroleumether. The product is is filtered off and dried, yielding 6.3 parts (72%) of N-{5-chloro-4-[α-(4-chlorophenyl)α-cyanomethyl]-2-(1-methylethyl)phenyl}-3-(1,1-dimethyl)-2-hydroxy-6-methyl-5-nitrobenzamide; mp. 205.3° C.
EXAMPLE LXXXIX
This example illustrates the fasciolicidal activity of the compounds of formula (I). The compounds described below are highly potent agents against Fasciola hepatica in sheep as is apparent from the results obtained in the following test procedure.
Adult sheep with body weight between 21 and 51 kg were infected with 300 metacercaria and 13 weeks thereafter the same animals were treated with a single oral dose of 5 mg/kg of the compound under investigation. Eight days after treatment the animals were slaughtered, the liver and the gall-bladder removed, and the number of adult flukes present in both organs were counted. In a series of 22 control animals, receiving only solvent, the mean number of adult flukes found in both the liver and the gall-bladder was 116.
The following table gives the structures of a number of the claimed compounds and their efficacy at a single oral dose of 5 mg/kg. Efficacy is expressed in percent reduction of flukes found as compared to the controls (n = 22, number of flukes = 116).
All compounds were dissolved in polyethylene glycol 200, the control animals therefore received the polyethylene glycol alone.
The compounds listed in the following table are not given for the purpose of limiting the invention thereto, but only to exemplify the useful fasciolicidal properties of all the compounds within the scope of formula (I).
______________________________________ ##STR13## %R.sup.1R.sup.2 R R.sup.4 R.sup.5 Ar efficacy______________________________________H I I H H C.sub.6 H.sub.5 100H I I H H 4-FC.sub.6 H.sub.4 100H I I H H 4-ClC.sub.6 H.sub.4 98H I I H H 2,4-Cl.sub.2C.sub.6 H.sub.3 70H I I H H 3-CH.sub.3C.sub.6 H.sub.4 89H I I H H 4-CH.sub.3C.sub.6 H.sub.4 85H I I H CN 4-ClC.sub.6 H.sub.4 44H I I H Cl C.sub.6 H.sub.5 70H I I H Cl 3-ClC.sub.6 H.sub.4 100H I I H Cl 4-ClC.sub.6 H.sub.4 98H I I H Cl 2,4-Cl.sub.2C.sub.6 H.sub.3 95H I I H Cl 3,4-Cl.sub.2C.sub.6 H.sub.3 99H I I H Cl 3-CF.sub.3C.sub.6 H.sub.4 96H I I H Cl 3-CF.sub.34-ClC.sub.6 H.sub.3 100H I I H CF.sub.3 C.sub.6 H.sub.5 90H I I H CF.sub.3 4-FC.sub.6 H.sub.4 100H I I H CF.sub.3 4-ClC.sub.6 H.sub.4 100H I I H CF.sub.3 4-BrC.sub.6 H.sub.4 100H I I H CF.sub.3 2,4-Cl.sub.2C.sub.6 H.sub.3 94H I I H CF.sub.3 2,6-Cl.sub.2C.sub.6 H.sub.3 86H I I H CF.sub.3 4-CH.sub.3C.sub.6 H.sub.4 70H I I H CF.sub.3 4-OCH.sub.3C.sub.6 H.sub.4 75H I I H CF.sub.3 3-CF.sub.3C.sub.6 H.sub.4 100H I I H CF.sub.3 3-CF.sub.34-ClC.sub.6 H.sub.3 100H I I CH.sub.3 Cl 4-ClC.sub.6 H.sub.4 100Cl Cl Cl H H C.sub.6 H.sub.5 89Cl Cl Cl H H 4-FC.sub.6 H.sub.4 81Cl Cl Cl H H 4-ClC.sub.6 H.sub.4 47Cl Cl Cl H H 2,4-Cl.sub.2C.sub.6 H.sub.3 100Cl Cl Cl H H 3-CH.sub.3C.sub.6 H.sub.4 81Cl Cl Cl H H 4-CH.sub.3C.sub.6 H.sub.4 84Cl Cl Cl H Cl C.sub.6 H.sub.5 60Cl Cl Cl H Cl 3-ClC.sub.6 H.sub.4 100Cl Cl Cl H Cl 4-ClC.sub.6 H.sub.4 100Cl Cl Cl H Cl 2,4-Cl.sub.2C.sub.6 H.sub.3 94Cl Cl Cl H Cl 3,4-Cl.sub.2C.sub.6 H.sub.3 93Cl Cl Cl H Cl 3-CF.sub.3C.sub.6 H.sub.4 100Cl Cl Cl H Cl 3-CF.sub.34-ClC.sub.6 H.sub.3 100Cl Cl Cl H CF.sub.3 C.sub.6 H.sub.5 88Cl Cl Cl H CF.sub.3 4-FC.sub.6 H.sub.4 93Cl Cl Cl H CF.sub.3 4-ClC.sub.6 H.sub.4 98Cl Cl Cl H CF.sub.3 4-BrC.sub.6 H.sub.4 100Cl Cl Cl H CF.sub.3 2,4-Cl.sub.2C.sub.6 H.sub.3 86Cl Cl Cl H CF.sub.3 4-CH.sub.3C.sub.6 H.sub.4 95Cl Cl Cl H CF.sub.3 4-OCH.sub.3C.sub.6 H.sub.4 94Cl Cl Cl H CF.sub.3 3-CF.sub.3C.sub.6 H.sub.4 98Cl Cl Cl H CF.sub.3 3-CF.sub.34-ClC.sub.6 H.sub.3 89Cl Cl Cl CH.sub.3 Cl 4-ClC.sub.6 H.sub.4 93Cl Cl Cl CH.sub.3 Cl 2,4-Cl.sub.2C.sub.6 H.sub.3 86______________________________________
EXAMPLE XC
This example is intended to demonstrate the useful activity of the compounds of formula (I) against Oestrus ovis and Haemonchus contortus in sheep. The experimental procedure was as follows:
24 Sheep were selected on clinical signs of Oestrus ovis infestation. Before commencement of the trial, 15 sheep of this group were treated orally with mebendazole at a dose of 15 mg/kg, in preparation for artificial infestations with Haemonchus contortus. 9 Sheep were not treated as above. The group of 15 sheep were then artificially infested with a daily dose of about 300 L 4 Haemonchus contortus larvae for 9 consecutive days (day --11 to day --3). On day 0 all 24 sheep were weighed and randomly allocated to 3 groups. Group I was left untreated as controls. Group II and III were treated respectively with:
compound A: N-{5-chloro-4-[α-(4-chlorophenyl)-α-cyanomethyl]-2-methylphenyl}-2-hydroxy-3,5-diiodobenzamide; and
3'-chloro-α-(p-chlorophenyl)-α-cyano-3,5-diiodo-p-salicylotoluidide.
The compounds tested were administered by intramuscular injection of a 5% injectable solution at a dose of 2.5 mg/kg live mass. The injectable solution used in the test had the following composition:
______________________________________Active ingredient 5 gN-methylglucamine 5 gPolyethylene glycol 400 15 mlEthylenediamine tetraacetate 0.1 g disodium saltWater ad. 100.0 ml______________________________________
The 8 control animals were slaughtered on day +10 and the 16 treated animals on +11. At the day of slaughter Haemonchus contortus worms were recovered from the abomasum and small intestines. The heads of all sheep were split longitudinally and all sinuses and turbinates were macroscopically inspected for all stages of Oestrus ovis. The number of Haemonchus contortus worms and Oestrus ovis larvae found in each sheet are tabulated in the following table:
______________________________________Recovery of worms and larvae. Larvae of O. ovis Sheep recovered (instars) L.sub.4 H. contortusTreatment number 1st 2nd + 3rd total recovered______________________________________ 447 0 3 3 -- 448 0 7 7 -- 449 0 19 19 --Controls 733 0 3 3 290 428 0 0 0 400 432 1 1 2 197 429 7 4 11 410 427 0 0 0 230______________________________________ 445 0 0 0 -- 444 0 0 0 -- 442 0 0 0 --Compound A 405 0 0 0 02.5 mpk i.m. 435 0 0 0 2 430 0 0 0 4 436 0 0 0 0 437 0 0 0 7______________________________________ 446 0 0 0 -- 443 0 0 0 -- 450 0 0 0 --Compound B 412 0 0 0 32.5 mpk i.m. 718 0 0 0 3 410 0 0 0 3 420 0 0 0 2 431 0 0 0 2______________________________________
EXAMPLE XCI
The fasciolicidal activity of a number of the compounds of formula (I) in sheep was investigated following the same test procedure as described in Example LXXXIX except that the drugs were injected intramuscularly at a dose of 2.5 mg/kg live mass. Injectable solutions of the tested compounds had the same composition as described in Example XC.
The following table gives the structures of a number of the claimed compounds and their efficacy at a single intramuscular dose of 2.5 mg/kg live mass. Efficacy is expressed in percent reduction of flukes found as compared to the controls.
It is to be understood that the compounds listed in the following table are not given for the purpose of limiting the invention thereto but in order to exemplify the useful flukicidal properties of all the compounds within the scope of formula I.
__________________________________________________________________________ ##STR14##R R.sup.1 R.sup.2 R.sup.3 R.sup.4 R.sup.5 Ar %efficacy__________________________________________________________________________Cl -- NO.sub.2 OH -- CF.sub.3 2,4-(Cl).sub.2C.sub.6 H.sub.3 42-- -- -- OH -- CF.sub.3 4-ClC.sub.6 H.sub.4 72-- -- -- OH -- CF.sub.3 4-(CH.sub.3)C.sub.6 H.sub.4 71-- -- -- OH -- CF.sub.3 4-(OCH.sub.3)C.sub.6 H.sub.4 83-- -- -- OH -- CF.sub.3 4-FC.sub.6 H.sub.4 75-- -- -- OH -- CF.sub.3 2,4-(Cl).sub.2C.sub.6 H.sub.3 71-- -- NO.sub.2 OH -- CF.sub.3 2,4-(Cl).sub.2C.sub.6 H.sub.3 45-- -- -- OH -- CN 4-ClC.sub.6 H.sub.4 79-- -- -- OH -- CF.sub.3 4-BrC.sub.6 H.sub.4 57-- -- -- OH -- -- 4-FC.sub.6 H.sub.4 96-- -- -- OH -- -- 4-(CH.sub.3)C.sub.6 H.sub.4 85-- -- -- -- -- -- C.sub.6 H.sub.5 60-- -- -- OH -- Cl C.sub.6 H.sub.5 75-- -- -- OH -- -- C.sub.6 H.sub.5 73-- -- -- OH -- -- 4-(OCH.sub.3)C.sub.6 H.sub.4 71-- -- -- OH -- Cl 3-(CF.sub.3)C.sub.6 H.sub.4 100-- -- -- -- -- -- 4-(CH.sub.3)C.sub.6 H.sub.4 69I -- I -- -- Cl 2-naphthalenyl 99Cl Cl Cl -- -- Cl 2-naphthalenyl 99Cl Cl Cl -- -- CF.sub.3 2-naphthalenyl 84Cl Cl Cl -- CH.sub.3 Cl 5-Cl2-thienyl 61I -- I -- CH.sub.3 Cl 5-Cl2-thienyl 92Cl Cl Cl -- -- Cl 5-Cl2-thienyl 62I -- I -- -- Cl 5-Cl2-thienyl 87t . C.sub.4 H.sub.9 -- NO.sub.2 CH.sub.3 -- Cl 4-ClC.sub.6 H.sub.4 91t . C.sub.4 H.sub.9 -- NO.sub.2 CH.sub.3 CH.sub.3 Cl 4-ClC.sub.6 H.sub.4 100t . C.sub.4 H.sub.9 -- NO.sub.2 CH.sub.3 Cl Cl 4-ClC.sub.6 H.sub.4 100t . C.sub.4 H.sub.9 -- NO.sub.2 CH.sub.3 -- CF.sub.3 3-(CF.sub.3)C.sub.6 H.sub.4 98t . C.sub.4 H.sub.9 -- NO.sub.2 CH.sub.3 -- CF.sub.3 4-ClC.sub.6 H.sub.4 85t . C.sub.4 H.sub.9 -- NO.sub.2 CH.sub.3 -- CF.sub.3 4-BrC.sub.6 H.sub.4 92t . C.sub.4 H.sub.9 -- NO.sub.2 CH.sub.3 CH.sub.3 Cl 2,4-(Cl).sub.2C.sub.6 H.sub.3 68t . C.sub.4 H.sub.9 -- NO.sub.2 CH.sub.3 -- CF.sub.3 2,4-(Cl).sub.2C.sub.6 H.sub.3 67I -- I -- t . C.sub.4 H.sub.9 Cl 4-ClC.sub.6 H.sub.4 100t . C.sub.4 H.sub.9 -- NO.sub.2 CH.sub.3 -- Cl 3-(CF.sub.3)C.sub.6 H.sub.4 70Cl Cl Cl -- t . C.sub.4 H.sub.9 Cl 4-ClC.sub.6 H.sub.4 100t . C.sub.4 H.sub.9 -- NO.sub.2 CH.sub.3 t . C.sub.4 H.sub.9 Cl 4-ClC.sub.6 H.sub.4 100t . C.sub.4 H.sub.9 -- NO.sub.2 CH.sub.3 -- -- 2,4-(Cl).sub.2C.sub.6 H.sub.3 61Cl Cl Cl -- i . C.sub.3 H.sub.7 Cl 4-ClC.sub.6 H.sub.4 63I -- I -- i . C.sub.3 H.sub.7 Cl 4-ClC.sub.6 H.sub.4 100t . C.sub.4 H.sub.9 -- NO.sub.2 CH.sub.3 i . C.sub.3 H.sub.7 Cl 4-ClC.sub.6 H.sub.4 51__________________________________________________________________________
EXAMPLE XCII
This example illustrates the effectiveness of the compounds of this invention against Hypoderma bovis in cattle.
The test is carried out with naturally infected cattle showing visible warbles caused by Hypoderma bovis. The animals are shaved on their back to make the marbles clearly visible for counting. Treatment is given by intramuscular injection of a 5% injectable solution of N-{5-chloro-4-[α-(4-chlorophenyl)-α-cyanomethyl]-2-methylphenyl}-2-hydroxy-3,5-diiodobenzamide having the composition described in Example XC.
Ten days after treatment, the grubs are pressed out of the warbles and examined for being alive or dead. This examination is done by direct observation of the larvae's further evolution, in an artificial environment, to the pupa stage and finally to the imago.
The results obtained in this experiment are given in the following table.
Activity of N-{5-chloro-4-[α-(4-chlorophenyl)-α-cyanomethyl]-2-methylphenyl}-2-hydroxy-3,5-diiodobenzamide by intramuscular injection on Hypoderma bovis in cattle
______________________________________ Activity control Weight Dose 10 days after treatmentCattle No. in kg mpk Grubs died/Grubs extracted______________________________________ 285 2.5 12/152 191 2.5 5/63 220 2.5 1/34 291 2.5 4/75 244 5 5/56 190 5 5/57 456 5 5/58 364 5 3/3______________________________________
EXAMPLE XCIII
A mixture of 8.75 parts of 4-amino-2-α-(4-chlorophenyl)-5-methylbenzeneacetonitrile, 2.10 parts of phosphorous trichloride and 176 parts of chlorobenzene is stirred and refluxed for 2 hours. After cooling to 60° C, there are added 11.7 parts of 2-hydroxy-3,5-diiodobenzoic acid and the whole is heated to 115° C. Stirring is continued for 2 hours at 115° C. The reaction mixture is filtered while hot. The product is allowed to crystallize from the filtrate at room temperature. It is filtered off and dried, yielding 10.5 parts (52.8%) of N-{5-chloro-4-[α-(4-chlorophenyl)-α-cyanomethyl]-2-methylphenyl}-2-hydroxy-3,5-diodobenzamide; mp. 217° C.
EXAMPLE XCIV
To a stirred mixture of 4.14 parts of 2-hydroxybenzoic acid, 8.75 parts of 4-amino-2-chloro-α-(4-chloropenyl)-5-methylbenzeneacetonitrile and 176 parts of chlorobenzene are added 2.8 parts of phosphorous trichloride. The whole is stirred and refluxed for 1.50 hours. The reaction mixture is cooled to room temperature and 132 parts of hexane are added while stirring vigorously. Upon standing overnight at room temperature, the product is crystallized. It is filtered off and dried in vacuo at 50° C, yielding 10 parts (81.3%) of N-{5-chloro-4-[α-(4-chlorophenyl)-α-cyanomethyl]-2-methylphenyl}-2-hydroxybenzamide; mp. 183-186.5° C.
To a stirred mixture of 8.22 parts of N-{5-chloro-4-[α-(4-chlorophenyl)-α-cyanomethyl]-2-methylphenyl}-2-hydroxybenzamide and 40 parts of acetic acid are added quickly 12.9 parts of an iodine monochloride solution in acetic acid. After the addition of 86 parts of water, the whole is stirred for 45 minutes at 80° C. The reaction mixture is cooled to about 17° C. The precipitated product is filtered off, washed successively with 20 parts of water, 20 parts of acetic acid and again with 20 parts of water, and stirred for 30 minutes with 80 parts of 2-propanone. Then there are added 150 parts of water and stirring is continued for 1 hour. The product is filtered off, washed with water and crystallized from chlorobenzene, yielding 7.5 parts (76.3%) of N-{5-chloro-4-[α-(4-chlorophenyl)-α-cyanomethyl]-2-methylphenyl}-2-hydroxy-3,5-diodobenzamide; mp. 214°-216° C. | Compounds of the class of salicylanilides substituted in the 4-position of the anilino moiety with a --CH(CN)-Ar group wherein Ar is phenyl, substituted phenyl, thienyl, halothienyl or naphthalenyl, said salicylanilides being useful as parasiticides. | 2 |
CROSS REFERENCE TO RELATED APPLICATIONS
This application is a continuation of U.S. patent application Ser. No. 09/791,114 filed Feb. 22, 2001, now U.S. Pat. No. 6,546,813; which is a continuation in part of U.S. patent application Ser. No. 09/169,759 filed Oct. 9, 1998, which issued May 1, 2001 as U.S. Pat. No. 6,223,606; which is a divisional of U.S. patent application Ser. No. 08/780,435 filed Jan. 8, 1997, which issued on Oct. 13, 1998 as U.S. Pat. No. 5,821,633.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
Not Applicable
BACKGROUND OF THE INVENTION
The present invention is related to the field of patient monitoring equipment.
Patient monitoring systems are used in many settings to assist medical personnel in providing care. In many settings, such as hospital wards and nursing homes, there can be problems associated with patients' getting out of bed without supervision or assistance. A patient may suffer a fall whose effects can range from minor to major. Older patients are at risk of breaking their hips in a fall, requiring extended bed rest and attendant problems. Systems have been known that monitor whether a patient is present in a bed or wheelchair. Essentially, these systems employ a flat sensor laid on the mattress or cushion, and electronic apparatus that responds to signals from the sensor. For example, the strength of a sensor output signal may be proportional to the weight applied to the sensor. The electronic apparatus therefore compares the sensor output signal with one or more predetermined values corresponding to significant thresholds of interest. For example, if the sensor output signal falls below a predetermined low value, the apparatus generates an indication that the patient has gotten out of bed.
Prior patient monitoring systems have used sensors having certain drawbacks that limit performance. One such drawback is size. Sensors to be used on a bed are as wide as the bed, but extend only about a foot in the longitudinal direction. These sensors are intended for placement in the middle of the bed, on the assumption that a patient's weight is concentrated there. However, a patient may move into a position away from the sensor, resulting in a false alarm. Existing sensors have also employed switches as sensing elements, which can provide only a binary indication. Due to the lack of resolution, only limited information can be obtained from the sensor.
BRIEF SUMMARY OF THE INVENTION
In accordance with the present invention, a sensor-based patient monitoring system is disclosed incorporating features that overcome limitations of the prior art. In addition to having superior performance for traditional uses, such as reducing the incidence of patient falls, the system can be used for a variety of other clinical purposes to assist medical personnel and enhance the quality of care.
The system includes a replaceable laminar sensor placed on a bed or similar surface, the sensor including distributed force sensing elements providing output signals to processing apparatus for processing the force distribution information. The processing apparatus includes a near-bed processor and a central processor coupled to the near-bed processor by a wireless communication link. The processing apparatus applies spatial weighting to the sensor output signals to derive the force distribution across the sensor, and processes the force distribution information over time to generate pertinent patient status information. The information can vary depending on the operational purpose for the monitoring. For example, the information can include patient presence, position, agitation, seizure activity, or respiration. The information can be used to generate a display at a central monitoring station, and to update medical databases coupled to the central processor. The information can also be provided to a paging system to alert attending medical personnel.
The disclosed laminar sensor is made of layers of olefin film having patterns of conductive ink deposited thereon to form capacitive sensing elements, ground planes, and signal traces. The layers are laminated with a foam core selected to provide desired sensitivity of the capacitive sensing elements for a range of expected patient weights. Both a low-cost process and a high-volume process for manufacturing the sensor are shown.
Other aspects, features, and advantages of the present invention are disclosed in the detailed description that follows.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING
The invention is more fully understood by reference to the following Detailed Description in conjunction with the Drawing, of which:
FIG. 1 is a block diagram of a patient monitoring system in accordance with the present invention;
FIG. 2 is a diagram showing the arrangement of a multi-layer sensing sheet used in the system of FIG. 1 ;
FIG. 3 is a layout diagram of a top layer of the sensing sheet of FIG. 2 ;
FIG. 4 is a layout diagram of a bottom layer of the sensing sheet of FIG. 2 ;
FIG. 5 is a first detailed layout view of a connection edge of the bottom layer of FIG. 4 ;
FIG. 6 is a second detailed layout view of the connection edge of the bottom layer of FIG. 4 ;
FIG. 7 is a detailed view of the connection between a cable lead and the top layer of FIG. 3 or the bottom layer of FIG. 4 ;
FIG. 8 is a detailed layout view of an area of the bottom layer of FIG. 4 in which a capacitor plate is formed;
FIG. 9 (consisting of FIGS. 9 a and 9 b ) is a flow diagram of a single-station process of manufacturing the sensing sheet of FIG. 2 ;
FIG. 10 is a diagram showing the manner in which heat pressing is used to laminate the layers of FIGS. 3 and 4 and additional layers to form the sensing sheet of FIG. 2 ; and
FIG. 11 (consisting of FIGS. 11 a and 11 b ) is a flow diagram of a multiple-station process of manufacturing the sensing sheet of FIG. 2 .
DETAILED DESCRIPTION OF THE INVENTION
The disclosure of U.S. patent application Ser. No. 09/169,759, filed Oct. 9, 1998 and entitled Center Of Weight Sensor, is hereby incorporated by reference herein.
In FIG. 1 , the motion of a patient 10 is transmitted to a sensing sheet 12 by direct physical contact, such as exists when the sensing sheet 12 is placed on a bed and the patient 10 lies on top of the sensing sheet 12 . The sensing sheet 12 includes a number of spaced-apart sensing elements or transducers (not shown in FIG. 1 ) capable of converting applied forces into an electrical signals representative of the forces. One example of such a sensing sheet 12 , described in detail below, employs sensing elements that function as variable capacitors whose capacitance changes in response to applied forces. Other types of sensing elements may also be employed, such as piezoelectric sensing elements, force-sensing resistors, etc.
The signals generated by the sensing sheet 12 are communicated to a nearby sensor signal processing unit (SSPU) 14 . The unit 14 contains analog-to-digital (A/D) converters 16 , a signal processor 18 , and a radio-frequency (RF) modem 20 . The A/D converters 16 continually translate the analog signals from the sensing sheet 12 into corresponding digital values. The signal processor 18 applies spatial weighting to the digital output streams from the A/D converters 16 to reflect the respective locations of the sensing elements on the sensing sheet 12 , and uses the spatially-weighted digital signal streams in performing one or more analysis processes. Spatial weighting is described further below.
In general, the processor 18 monitors the outputs of the sensing elements to detect the occurrence of certain predetermined “patient states” that pertain to a particular analysis being performed. Generally, the patient states are defined by one or more thresholds associated with certain analysis variables. For example, an analysis process for determining whether the patient 10 is present may simply integrate the force distribution over the sensing sheet 12 , as reported by the various sensing elements, and compare the integrated value with a predetermined threshold representing the minimum value that would be expected if a patient were present. Appropriate values to use for the threshold can be determined analytically or empirically. There may be a selectable threshold based on certain parameters, such as the patient's weight.
Much more sophisticated analysis processes can also be performed. Analyses may also include time as a parameter. For example, an analysis process may be used to help reduce the incidence of bedsores, which can develop if a patient remains in a given position too long. The movement of the center of the patient's mass over time can be monitored, and appropriate action taken when the extent of movement is less than a predetermined threshold for more than a predetermined time. Processes may be employed for detecting and providing information about patient agitation, respiration, reaction to drugs, sleep disorders, or seizures. The system can also be used to enhance patient safety and security. By monitoring weight changes on a patient's bed, the system can provide an indication that a patient has gotten up, or that an additional person is on the bed.
When significant patient states or state transitions are detected by the processor 18 , a corresponding information message is generated by the processor 18 and transmitted on a wireless communications link 22 via the RF modem 20 . In general, the information message contains information identifying the patient, such as the patient's name, room number, etc., and information about the detected patient state. In addition, the processor 18 may also update a local data collection log (not shown) maintained for administrative or diagnostic purposes.
In the illustrated system, it is desirable that the RF modem function as a “slave” with respect to a “master ” modem 24 residing in a central information-processing unit (CIPU) 26 . Because the CIPU 26 communicates with a number of SSPUs 14 , it would be inefficient to continually maintain individual communications links 22 between the CIPU 26 and each SSPU 14 . By employing a master-slave arrangement, a link 22 is in existence only when needed. When the slave modem 20 receives a message from the processor 18 , it requests a connection with the master modem 24 using a separate, low-rate signaling channel (not shown). The master modem 24 informs the slave modem 20 when the link 22 has been established, whereupon the slave modem 20 transmits the information message. Preferably, the master modem 24 transmits a positive acknowledgement message to the slave modem 20 if the information message is received correctly.
It may be desirable that the master modem 24 also be capable of initiating the establishment of the link 22 . This capability can be useful, for example, when configuration information, updates, or other information is to be transferred from the CIPU 26 to the SSPU 14 . When directed by the master modem 24 , the slave modem 20 monitors the link 22 for incoming messages containing such information and forwards these messages to the processor 18 . Software executing in the processor 18 responds in a desired predetermined fashion.
When a patient state information message is received at the CIPU 26 , the data is used to update a central database archive 30 and is also provided to a user interface platform 32 . The information in the database archive 30 can be used for a variety of generally offline activities, such as administrative record keeping, statistics gathering, etc. The user interface platform 32 provides the information to one or more real-time users, who in general are medical personnel responsible for the care of the patient 10 . For example, the platform 32 may include a graphical display at a nurses' desk to provide the information to a desk nurse 34 . The platform 32 may also include paging equipment programmed to send an alert message to a floor nurse 36 or other personnel. The alert message preferably includes patient identifying information, such as the identity and room number of the patient 10 , and a brief description of the detected patient state. For example, when a “patient not present” state is detected, an alert message such as “Jones, 302, Out Of Bed” may be generated.
As shown, the CIPU 26 may also communicate with other entities via a local- or wide-area network. There may be inter-departmental communications with other departments 38 of a medical facility, such communications typically occurring over a local-area network. Examples include communications with medical laboratories and administrative offices such as a patient billing department. There may also be wider-area communications with remote entities 40 , such as a patient's family, affiliated research facilities, physicians' offices, and insurance companies, for example.
As a scaled-back alternative to the system of FIG. 1 , the SSPU 14 may itself include a pager (not shown) in place of the slave RF modem 20 , and the CIPU 26 and its network connections dispensed with. In such a system, the SSPU 14 itself sends a paging signal to the desk nurse 34 , floor nurse 36 , or other personnel as appropriate. While such a system has overall less functionality than the system of FIG. 1 , it retains the important core functions of the sensing sheet 12 and SSPU 14 , and can provide greater cost effectiveness and flexibility in deployment. Of course, other system configurations are also possible.
As shown in FIG. 2 , the sensing sheet 12 includes a number of layers laminated together. The sheet 12 includes a multi-layer top sheet 42 , a multi-layer bottom sheet 44 , and a foam core 46 disposed therebetween. Both the top sheet 42 and bottom sheet 44 include a layer of olefin film 48 approximately 0.0065″ thick, such as sold by duPont, Inc. under the trademark TYVEK®. Both sides of each layer of film 48 are coated with conductive material. Each outer layer 50 is a ground plane covering substantially the entire surface of the respective film 48 to provide shielding from electrical noise. Each inner layer 52 has patterned conductive traces that define the sensing elements, as described in more detail below.
The conductive layers 50 and 52 are preferably made using conductive inks that are applied to the respective surfaces of the films 48 during manufacture of the sensing sheet 12 . These layers are approximately 0.001″ thick. The inner layers 52 are preferably made using a silver-based conductive ink for its excellent electrical properties. The outer layers 50 may be made using a copper-based conductive ink, which will have suitable electrical properties and lower cost than a silver-based ink.
The foam core 46 is approximately 0.5″ thick when uncompressed. The compression properties of the foam core 46 can vary depending on the application, more specifically on the range of weights of the patient 10 being monitored. The compression properties of the foam core 46 largely dictate the sensitivity of the sensors, which refers to the change in sensor capacitance due to changes in applied force. For adults in a normal weight range, it is desirable that the foam core 46 deflect about 25% when a pressure of 25 lbs. per square foot is applied. The useful upper limit of deflection is approximately 50% of uncompressed thickness. If the sensing sheet 12 is to be used with a different class of patients 10 , such as infants for example, it may be desirable to use a foam core 46 having different compression characteristics so as to achieve optimal sensitivity.
FIG. 3 shows the top sheet 42 , specifically the surface on which the conductive layer 52 ( FIG. 2 ) is formed. The top sheet 42 measures approximately 6.5 feet long by 3 feet wide. The conductive layer 52 comprises a number of conductive planar elements referred to as “plates” 54 interconnected by a conductive trace 56 . A segment 58 of the trace 56 is formed at the bottom of the sheet 42 for purposes of establishing an electrical interconnection between the trace 56 and a separate connector (not shown), as described in more detail below. The plates 54 measure approximately 5″ on a side.
FIG. 4 shows the bottom sheet 44 , specifically the surface on which the conductive layer 52 is formed. The bottom sheet 44 also measures 6.5 feet by 3 feet. Conductive plates 60 (shown as 60 - 1 through 60 - 8 ) are formed at respective positions corresponding to the positions of the plates 54 on the top sheet 42 (FIG. 3 ), so as to form eight plate capacitors when the sensing sheet 12 is assembled. The plates 60 are connected to respective traces in a set 62 that extends to the bottom edge of the bottom sheet 44 . The traces 62 are described in more detail below.
In operation, a suitable drive signal such as a 5 volt peak-to-peak sine wave of 50 KHz is applied to the plates 54 of the top sheet 42 via the trace 56 formed thereon. This signal is capacitively coupled to each of the plates 60 of the bottom sheet 44 . The capacitance of each plate capacitor formed by a given plate 54 and its opposite plate 60 changes in response to locally experienced forces that change the plate spacing by compressing the foam core 46 (FIG. 2 ). As a result, the respective strengths of the 50 KHz signals appearing on the plates 60 vary accordingly, and these signals are sampled and processed by the SSPU 14 ( FIG. 1 ) as described above. In particular, different two-dimensional weights are applied to the signals from the plates 60 to reflect their respective spatial characteristics, including location, size, and shape. These spatial weights are chosen from a suitable two-dimensional space, such as a rectangular grid with vertices at ( 0 , 0 ), ( 0 , 1 ), ( 1 , 0 ) and ( 1 , 1 ). For the sheet 12 as shown herein, the plates 60 are of uniform size and are distributed symmetrically on the surface of the bottom layer 44 . In this case, the spatial weights in the following table might be used, where each spatial weight corresponds to a different plate 60 as shown:
Plate
X
Y
60-1
0.2
0.3
60-2
0.2
0.7
60-3
0.4
0.5
60-4
0.5
0.1
60-5
0.5
0.9
60-6
0.6
0.5
60-7
0.8
0.3
60-8
0.8
0.7
FIG. 5 shows the bottom edge of the bottom sheet 44 in more detail. The traces 62 are arranged in two groups, one to the right of the bottom-most plate 60 and the other to the left. The right group includes seven individual traces, consisting of four ground traces interspersed with three signal traces, one for each of the three plates 60 on the right side of the sheet 44 (FIG. 4 ). Similarly, the left group includes nine individual traces, consisting of five ground traces interspersed with four signal traces, one for the top-most plate 60 and one for each of the three plates 60 on the left side of the sheet 44 (FIG. 4 ).
FIG. 6 shows the manner in which connections are formed between the traces 62 and a cable 66 at the connection edge of the bottom sheet 44 . The traces 62 are shown as signal traces 62 -S and ground traces 62 -G. Each conductor of the cable 66 is provided with a solderless terminal 68 which is secured to the sheet 44 in contact with a corresponding signal trace 62 -S. A conductive snap 70 is used to electrically couple each ground trace 62 -G to the ground plane on the opposite surface of the sheet. Specifically, a male component (not shown) of the snap 70 extends through a hole in the trace 62 -G and sheet 44 , and the male component is received by a female component (not shown) on the other side. Although it is not shown in the Figures, it is generally desirable to place several such snaps 70 along the length of each ground trace 62 -G, to minimize stray impedance in the ground path that can contribute to noise. Also, it may be desirable that the snaps 70 and/or terminals 68 be epoxied to the sheet 44 for an even more secure attachment.
FIG. 7 shows the attachment of a conductive lead of the cable 66 to either sheet 42 or 44 in greater detail. A plastic rivet 72 extends through a copper washer 74 , the sheet 42 or 44 , and the solderless terminal 68 as shown. A rivet head 76 is placed over the rivet 72 , and the rivet 72 and rivet head 76 are then squeezed together in a conventional fashion. By this action, the terminal 68 makes secure connection to the conductive layer 52 of the sheet 42 , 44 .
FIG. 8 shows the area around a typical plate 60 . The plate 60 is connected to a corresponding signal trace 62 -S, which is surrounded on both sides by ground traces 62 -G for shielding purposes. Each pair of ground traces 62 -G extends alongside the entire run of the corresponding signal trace 62 -S from plate 60 to the bottom edge of the sheet 44 .
FIG. 9 shows a single-station process for manufacturing the sensing sheet 12 . In step 80 , a silk screening machine is set up with a roll of olefin film. At step 82 , the outer conductive layer 50 ( FIG. 2 ) is silk screened onto a length of film sufficient for 60 top sheets 42 and 60 bottom sheets 44 . Because the outer layer 50 is a ground plane extending across the entire surface of each sheet, this layer can be deposited as one continuous film along 780 feet (120×6.5) of the olefin film. After the layer 50 has been deposited, the individual sheets are cut as each 6.5′ length of film exits the machine.
At step 84 , the sheets are placed into an oven to allow the conductive ink to dry. The sheets are then removed from the oven at step 86 . At step 88 , the patterned conductive layer 52 is silk screened onto the 60 top sheets 42 , and these are returned to the oven for curing at step 90 . At the same time, at step 92 a press, assembly machine and testing apparatus can be set up in preparation for the final assembly and testing of the sheets 12 .
At step 94 , the cured top sheets 42 are removed from the oven, and at step 96 ground leads are “snapped” to the ground plane of the cured top sheets 42 using snaps as described above with reference to FIG. 6 . At the same time, at step 98 the patterned layer 52 is silk screened onto the bottom sheets 44 . The bottom sheets 44 are then placed in the oven for curing at step 100 , while at step 102 the top sheets 42 are moved to an assembly area and the press is set up for the bottom sheets 44 . At step 104 , ground leads are snapped to the ground plane of the cured bottom sheets 44 , while at the same time at step 106 a cable assembly is riveted to each top sheet 42 . At step 108 , a cable assembly is riveted to each bottom sheet 44 .
At step 110 , each sheet 42 and 44 is tested for continuity of connections, such as between each plate 60 and its associated trace 62 for example. Each sheet is also tested for the absence of any short circuits between the outer and inner layers 50 and 52 , which could occur for example if the conductive ink were to bleed through the olefin film. This testing is preferably done prior to the attachment of the cables. Once the cables are attached, additional testing is performed to ensure proper connectivity between the conductors of the cable and the various conductive elements on the sheet.
At step 112 the top and bottom sheets 42 and 44 are assembled into the final sheet 12 . The core 46 is pre-treated with a heat-activated adhesive on both surfaces, and then pressed together with the sheets 42 and 44 in a heated press. This process is illustrated in FIG. 10 , where the elements 114 are heated press elements.
FIG. 11 illustrates a process for manufacturing the sensing sheet 12 which follows more of an assembly line model than the process of FIG. 9 . It is assumed that there are separate workers at each station. Also, some of the equipment, such as the silk screening machines and cable assembly stations, are duplicated for improved throughput. The overall process reflected in steps 120 - 142 of FIG. 11 is generally the same as that shown in FIG. 9 . However, much greater volumes of sheets 12 can be produced due to the assembly line structure. Several batches of material are in process simultaneously, with each batch being in a different stage of completion. The process of FIG. 11 is capable of yielding approximately 210 finished sensing sheets 12 per day, whereas the single-person process of FIG. 9 can yield approximately 60 sheets per day.
A patient monitoring system employing a laminar sensor sheet has been shown. It will be apparent to those skilled in the art that modifications to and variations of the disclosed methods and apparatus are possible without departing from the inventive concepts disclosed herein, and therefore the invention should not be viewed as limited except to the full scope and spirit of the appended claims. | A patient monitoring system includes a replaceable laminar sensor to be placed on a bed, the sensor including distributed force sensing elements providing output signals to processing apparatus including a near-bed processor and a central processor coupled to the near-bed processor by a wireless communication link. The processing apparatus applies spatial weighting to the sensor output signals to derive the force distribution across the sensor, and processes the force distribution over time to generate patient status information such as patient presence, position, agitation, seizure activity, respiration, and security. This information can be displayed at a central monitoring station, provided to a paging system to alert attending medical personnel, and used to update medical databases. The sensor may be manufactured from layers of olefin film and conductive ink to form capacitive sensing elements. | 1 |
BACKGROUND OF THE INVENTION
This invention relates to a clothes drying apparatus, and in particular to clothes drying apparatus which operates in whole or in part using electrolysis to remove water from clothing.
Although clothes drying apparatus have been known heretofore, it has been found that in most home environments that gas or electric dryers are most common. However it is not forgotten that the outdoor, or sometimes indoor, clothes line in combination with solar heat and wind has been used for centuries. Demands on gas supplies, generally natural gas or propane gas, and rising costs in the industry are making gas dryers less cost efficient. Likewise, electrical dryers suffer from the increased demand for electricity, and the fact that electric companies offer rebates for energy saving methods. It is, therefore important to develope alternative methods for reducing both natural gas and electricity consumption.
Prior electrical clothes dryers operate on either 120 v or 240 v. The basic clothes dryer is provided with a rotating drum and circulating hot air is produced by forcing air over an electrically heated coil element. The heated air mixes with the tumbling clothes in the rotating dryer to remove moisture. A clothes dryer is constructed like a clothes washer which uses a drum and an agitator where one or the other reciprocates to agitate the clothes in soapy water. It is possible to adapt the apparatus of a clothes washer for use as a clothes dryer which could reduce the number of apparatuses needed, and, in addition, the demand for space would be about half. The applicant is aware of various electrolysis apparatuses, however, to the applicant's knowledge there have not been any prior showings of the use of electrolysis to remove moisture from clothing.
SUMMARY OF THE INVENTION
The present invention provides an alternative source of energy for operating a clothes dryer. Briefly, the invention includes an apparatus for removing moisture from clothing. The apparatus is provided with a rotating drum mounted in a housing. A plurality of electrodes are mounted inside the drum with half of the electrodes connected to one end of the drum, the other half are connected to the other end. The electrodes are half cathode and the other half anodes with the cathodes alternating with anodes around the inside of the drums. The electrodes are connected to a source of direct current to separate water into hydrogen and oxygen gases.
If needed, heated air produced by heating air with natural gas or electricity may be used to supplement the drying process. There may be a point where the electrolysis becomes inadequate to remove moisture, at which point sensors in the apparatus would shut off the direct current and switch on the natural gas or electricity.
In case the dryer apparatus is incorporated in a washing apparatus, it will be a provision that the direct current, natural gas and alternating current electricity will be shut off when the washer is operational.
It is the primary object of the improved dryer apparatus to provide an efficient clothes dryer which employs electrolysis to remove moisture.
It is a further object of the improved dryer apparatus to provide a clothes dryer that is less expensive to operate.
It is another object of the improved dryer apparatus to provide a combination washer and dryer apparatus.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side plan view of a clothes dryer according to the present invention;
FIG. 2 is a cross sectional view taken along the line 2--2 of FIG. 1;
FIG. 3 is a schematic of a direct current electrode arrangement of the present invention;
FIG. 4 is a partial plan view of a rotary drum of the present invention;
FIG. 5 is a partial cross sectional view taken along the line 5--5 of FIG. 1.
FIG. 6 is another embodiment of the present invention.
DESCRIPTION OF THE INVENTION
Referring to FIG. 1, there is shown a clothes dryer 10 including a housing 12 and a rotating drum 14. An electric motor 16 is connected to the drum 14 by a pulley system 18 to rotate the drum. A conventional dryer door 20 seals opening 22 at one end of the drum 14, while the other end of the drum has an opening 24 that exhausts moist air and lint from the apparatus 10. There are a pair of rotary seals 26 and 28 to seal the edges of the drum 14.
The electric motor 16 is provided with a propeller 30. Air is drawn into an air duct 32 by the propeller 30 and pushed through the duct 32 to air inlets 34, FIG. 2, of rotary drum 14. The air circulates around the clothes in the drum 14 picking up moisture and carrying it out through opening 24 and vent 36. The vent 36 will usually have a filter to trap lint to prevent it from being exhausted into the atmosphere.
FIGS. 2 through 5 show electrodes 38, FIG. 3, divided into half cathodes 40 and half anodes 42. The cathodes 40 and anodes 42 are wrapped around the inside of the drum 14 with the free ends of the electrodes 38 extending across the drum, as in FIGS. 1 and 4. In FIG. 3, the cathode rods 40 and anode rods 42 are alternated to have cathode, anode, cathode, etc. The attached ends of the electrodes 38 connect to connecting electrodes 44 with leads 46 that connect to circular bus bars 48, FIGS. 1, 4 and 5. Each of the bus bars 48 is an electrically conductive metal, such as copper, that connects to one of the leads 46. FIG. 4 shows one of the connecting electrodes 44 and a lead 46 on the outside of the drum 14. The other bus bar 48 is mounted on the other end of drum 14. It is important that the bus bars 48 be insulated from the drum 14. Drum 14 has inwardly directed dividers 50 to separate the cathodes 40 from anodes 42 so as to separate the electrolysis action on the different electrodes 38.
The bus bar 48 in FIG. 5 is connected by an electrical contact 52 to a source of direct current. Contact 52 has a feeler 54 which rubs on the surface of the bus bar 48, transferring direct current to the electrodes.
In use, the drying apparatus 10 is filled with clothes and the electric motor 16 is started to rotate the drum 14. Direct current is switched on to send current through cathodes 40 and anodes 42. Any water in the drum 14 or in the clothing is disassociated into hydrogen and oxygen gases that are carried out of the drum 14 through vent 36. As the moisture is driven out of the clothing the electrolysis action is reduced perhaps to the point that no more moisture is removed. If the clothing is dry the apparatus 10 is shut off. However, if the clothing is still damp, the direct current is turned on. Current is passed through heating coil element 60, FIG. 1, to heat the air, thereby finishing the drying process.
The source of direct current is not shown, however, there are several sources for producing direct current known in the prior art. Therefore, any inexpensive source will do.
FIG. 6 shows a washer drum 70 with the agitator removed to show electrodes 38. Electrodes 38 are cathodes 40 and anodes 42, similar to the electrodes in drum 14. Either the agitator or drum 70 oscillates to agitate the clothes and soapy water. There is a water fill tube 72 and a water removal tube 74. A water pump 76 draws the water from the drum. Once a majority of the water is removed, the washer is turned off and direct current is turned on. Air is forced into the drum 70 as in drum 14, if necessary the air can be heated to finish the clothes drying. The difference in drum 70 and drum 14 is that drum 70 is rotated about the vertical, while in drum 14 it rotates horizontally.
It will, of course, be understood that various changes may be made in form, details and proportions of the various parts without departing from the scope of the invention. | A clothing drying apparatus using electrolysis to remove moisture from the clothing where there are cathode and anode electrodes mounted in a rotating drum. Air is circulated through the drum to remove moisture and hydrogen and oxygen gases produced by the electrolysis. | 3 |
CROSS-REFERENCE TO RELATED APPLICATIONS
The present application contains subject matter in common with copending U.S. patent applications, Ser. No. 09/580,261, filed on May 26, 2000, and a divisional of Ser. No. 09/580,261, filed on or about May 9, 2002.
BACKGROUND OF THE INVENTION
The present invention relates to a method for continuous thermal treatment of a textile product web, in particular for dye fixing, as well as to an arrangement for performing the inventive method.
During coloring it is necessary to fix a dye applied on the textile product web. The dye fixing can be performed by retaining the product web with applied dye solution at room temperature or the moist or dried product web at higher temperatures. The fixing treatment depends on the material of the product web and the applied dye.
During coloring of chemical fibers with dispersion dyes, for example it is known to first dry the product web with applied dying solution and subsequently to fix the dye at higher temperatures on the product web.
German patent document DE/A 16 35 140 discloses a method of continuous dye fixing of chemical fibers in product webs by a high temperature treatment with convective heat transfer, for example from nozzle-aerated fixing tension frames. For blending of the fixing effect first a fast heating and subsequently a tension treatment is performed. During the fast heating the product web is guided in tensioning chains and during the retention treatment over normal guiding rollers.
During coloring of cotton or cellulose with reactive dyes it is for example known to first dry the product web with the dye solution applied to it and subsequently to let the dye react at higher temperatures with the fibers of the product web. For this first purpose a promoter, such as urea, is required, which is mixed to the dye solution. The promoter holds the dye in solution during drying and evaporates during fixing. As a treatment gas, heated air is used. The use of an aggressive promoter, such as urea, can be reduced or avoided by treatment of the product web with applied dye solution with a steam-air mixture.
From the patent document EP/A 0 864 683 it is known to impregnate a product web of cellulose knit or woven fabric with an aqueous dye solution of a fiber-reactive dye at a temperature of 20-25° C. to compress it, and to fix it without intermediate drying in an unsaturated water steam-air mixture, with 10-80 vol. percent of water steam, at a temperature of 100-160° C. and with an adjustable wet temperature of the moist product between 50 and 95° C. The product is guided with a speed, which is regulated by the measured residual moisture of the product after exit from the fixing device. The residual moisture amounts to 10-25 weight percent with respect to the product weight.
The patent document WO 97/14839 discloses a corresponding method and a device for dye fixing of cellulose products with reactive dyes, in which an optimal dye yield is obtainable without aggressive promoter quantities. In a padder the dying solution is applied on the product, and is subsequently guided in a chamber of an air dryer. In this chamber a steam contact is maintained in the order of 25 vol. percent of air and is supplied so that the product of the outlet of the chamber has a reaction-ready residual moisture. For this purpose two regulating circuits are used, namely one for the steam content and another for the residual moisture of the product web. In other words during this process expensive measuring and regulating devices are needed. This fixing method requires, due to the retention time of the order of two minutes in a continuous process with a product web speed of for example 40 m/min, a product extent in the retention aggregate, here a hot flue, of at least 80 m. It is therefore not efficiently usable for small quantities to be colored (small meter lengths).
SUMMARY OF THE INVENTION
Accordingly, it is an object of present invention to provide a method of continuous thermal treatment, in particular for dye fixing, in which the treatment gas contains hot steam and which can be used efficiently for smaller meter length.
In keeping with these objects and with others which will become apparent hereinafter, one feature of the present invention resides, briefly stated, in a method of continuous thermal treatment of a textile product web for dye fixing, comprising the steps of applying a dye solution to a product web; transporting the resulting moist product web with the dye solution applied to it through at least one treatment chamber; bringing the moist product web with the applied dye solution in contact with a treatment gas in the treatment chamber. The treatment gas contains hot steam, i.e. overheated water steam.
It is another object of present invention to provide an arrangement with which the new method of thermal treatment can be performed efficiently and faster.
In keeping with these objects, another feature of the present invention resides, briefly stated, in an arrangement for continuous thermal treatment of a textile product web for dye fixing, comprising a steam-tight housing with at least one treatment chamber having at least one circulating device with at least one circulating fan, nozzle boxes arranged above and below the product web; a transporting device for substantially flat guidance of the product web through the housing, the transporting device including at least one roller conveyor arranged at a distance from a front wall of the housing. In the inventive method for continuous thermal treatment of a textile product web, the moist product web provided with dye solution is transported through at least one treatment chamber and is brought Into contact in the treatment chamber with a treatment gas, which is composed of hot steam. The treatment gas is at least 80 vol. percent, preferably 95-120 vol. percent, or, in other words, approximately pure hot steam. The temperature of the hot steam amounts to 105-230° C. The hot steam used in the method according to the invention is overheated water steam substantially at atmospheric pressure.
With a higher steam content, higher temperatures of the product web are reachable during the thermal treatment. In particular with pure hot steam the product web temperature is increased to substantially 100° C. The higher treatment temperature accelerates the reaction of the dye with the fibers during fixing of reactive dye on cotton or cellulose. This leads to lower fixing times, correspondingly lower retention times in a treatment device, and possibly smaller devices.
A higher steam content of the treatment gas accelerates, due to the condensation ability of the hot steam, the heating, which leads to a further reduction of the required retention time. In a surprising manner the inventive treatment method, despite the higher steam content and the higher product temperature, and thereby increased drying, leads to good fixing results. In other words, it leads to a good dye yield and a good coloring quality, which correspond to the results of the prior art.
The drying of the moist product web during the treatment with hot steam provides lower fixing times for complete fixing. This is achieved by an acceleration of the fixing process, i.e. the reaction of the reactive dye with natural fibers, such as cotton and cellulose, by the drying.
The input moisture of the product web provided with the dye solution of the reactive dye amounts to 40-80%. For many reactive dyes the use of urea can be dispensed with.
The temperature of the hot steam can be preferably 160-230° C. The higher temperature of the treatment gas and thereby the higher the temperature difference between the treatment gas and the product, the greater the heat transfer and thereby faster the heating time of the product web and the drying of the product web.
The retention time of the product web in the arrangement is 50-60 seconds, preferably 10-30 seconds. This time is sufficient for complete fixing for good dye yield and makes possible to have an arrangement with a smaller structural dimension.
In a surprising manner it has been determined that with the inventive method optimal fixing results are provided with a residual moisture of the product web smaller or equal to the equilibrium moisture under normal conditions, or in other words approximately 10% moisture to the weight of the product for cellulose and approximately 8% moisture for cotton. This can be explained by the above mentioned accelerated action of the drying for the dye fixing. Regulation of the residual moisture of the product web in the arrangement is not needed.
In principle all processes, with which the product web can be brought in contact with hot steam, can be used for the inventive method.
For this method, a guidance of the product web through the chamber filled with hot steam can be performed in form of suspending loop or a meandering guidance of the product web in two rows of guiding or transporting rollers, as far as it is suitable for transportation of a moist, colored and unfixed product web.
For improving the heat transfer from hot steam to the product web and thereby reducing the retention time, the product web in accordance with the present invention can be brought into contact with hot steam which is guided in a circulating process, through nozzles which are oriented toward the product web. This is possible in the inventive method without dye running, since because of the high steam content and in some cases the high steam temperature, a fast drying of the product web and thereby of the dye is provided.
Devices with a meandering guidance of the product web two rows of rollers or on nozzles oriented toward the product web are known as hot flu. The above mentioned devices have however as disclosed in the patent document WO 97/148 39 a very high product extent and are, for example due to untightness, not suitable for an operation with hot steam.
A further improvement of the heat transfer can be obtained when the product web is transported substantially flat through the treatment chamber and is brought in contact with hot steam From nozzle boxes arranged above and below the product web.
Devices, by which the product web is transported flat and brought in contact with a treatment gas by nozzle boxes, namely nozzle-equipped fixed tension frames, are known for fast heating during dye fixing of chemical fibers, such as thermal insulation, for example from the German patent document DE/A 16 35 140.
Devices of this type, in which hot steam can be suitably used as treatment gas are disclosed in the German patent document DE 35 11 95. In particular a suspension dryer and a tension frame dryer.
During a suspended guidance of the product web in a suspension dryer the danger of producing wavy portions of the product web which can lead during fixing to dye running is high. Tension chains during at dye fixing have the disadvantage that the edge markings are caused.
A further, corresponding device, namely a tension frame dryer usable for hot steam treatment is disclosed in the German patent document DE 195 46 344. The inlet slot and the outlet slot of this dryer are arranged in a bottom of its housing. The product web is guided through the dryer from the inlet region to the outlet region flatly and therefore horizontally.
Preferably the product web in the inventive method is transported by means of a roller conveyor arranged at a distance to a front wall of the housing with a longitudinal tension, in particular of 10-100 N/M through the treatment chambers. The distance from the front wall amounts to at least 20% preferably 30% of the length of the horizontal transporting path of the product web through the treatment chambers. The product web first is guided by the roller conveyor when it and thereby the dye is dried. During the drying and during the total fixing process the product web in view of the longitudinal tension is guaranteed to have a uniform fixing and thereby a uniform dye yield. A guidance of the product web by a roller conveyor moreover is a simple transporting method, when for example compared with a tension chain guidance, and makes possible simpler inlet and outlet in the treatment chamber.
An arrangement for continuous thermal treatment of a textile product web, in particular for dye treatment, comprises a steam-tight housing with at least one treatment chamber having a circulating device, i.e. a device for providing hot steam in a circulation process, at least one circulating fan, nozzle boxes arranged above and below the product web in each treatment chamber, a transporting device for a substantially flat or horizontal guidance of the product web through the housing, and at least one roller conveyor, as an essential part of the transporting device, arranged at a distance to the front wall of the housing. The distance to the front wall amounts to at least 20%, preferably 30%, of the length of the horizontal transporting path of the product web through the treatment chamber or chambers.
A rolling conveyor can have two rollers which are offset relative to one another. They are adjustable relative to one another by producing a longitudinal tension. A roller conveyor can have two rods or rollers which guide the product web in its transportation plane, and a pulling roller arranged between both rods or rollers above and below of the transporting plane and adjustable perpendicular to the transporting plane. In this case the product web is guided in form of the loop around the pulling roller and held by deviation of the pulling roller perpendicular to the transporting plane and the longitudinal tension. This device is especially suitable for the inventive method.
In the inventive device having at least two treatment chambers arranged one after the other, the roller conveyor is arranged in the region in which both treatment chambers abut against one another. In other words the distance of the roller conveyor to the front wall amounts to substantially 50% of the length of the horizontal transporting path of the product web through the treatment chambers. The treatment chambers are also Galled fields and the regions between the treatment chambers are also called field abutments.
The roller conveyor can have two guiding rollers and one vertically adjustable pulling roller. The guiding rollers are arranged closely one after the other and the pulling roller is arranged in the center under the guiding rollers. This arrangement of the guiding rollers and pulling rollers makes possible a small abutment region of the treatment chambers, or in other words the region of the regions in which no nozzle boxes are arranged.
The pulling roller can be formed simultaneously as an orienting roller. Therefore, additional means for orienting of the product web are dispensed with.
In accordance with a further feature of the present invention, the arrangement has locks before and after the housing. The locks extend from the bottom to above the transporting plane of the product web and have deviating rollers near the bottom end at the height of the transporting plane. The locks are subdivided into a lower, downwardly open pre-chamber and a further main chamber arranged over it. Suction passages or suction boxes can be connected with the pre-chambers. When compared with the known inlet and outlet slots with suction boxes disclosed in the German patent document DE-A 195 46 344, due to the separate locks with the pre-chamber and suction devices, the penetration of air and thereby condensation of steam to water is reliably prevented. A lock disclosed in the German patent document DE 198 58 839, in which steam is blown on the product web before the inlet slot of the housing, is less suitable for fixing of dye because of the danger of dye running.
The novel features which are considered as characteristic for the present invention are set forth in particular in the appended claims. The invention itself, however, both as to its construction and its method of operation, together with additional objects and advantages thereof, will be best understood from the following description of specific embodiments when read in connection with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic side cross-sectional view showing a device for continuously dyeing a product web with a dye solution, which has an inventive arrangement for dye fixing; and
FIG. 2 is a view showing an input lock, a first treatment chamber and the roller conveyor of the inventive arrangement.
DESCRIPTION OF PREFERRED EMBODIMENTS
A device for dyeing a textile product web 1 , for example of cotton or cellulose, with a reactive dye has several units arranged in a transporting direction one behind the other and including a product storage 2 , a supply device 3 , a dye device 4 , an air passage 5 , a device for dye fixing 6 , a further supply device 7 and a further product storage device 8 . In this example the front product storage 2 is formed as a container, the dye device 4 is formed as a padder, the rear product storage 8 is formed as a winding roller and the supply devices 3 , 7 are formed as booms. The device for dye fixing 6 has an inlet lock 9 , a steam-tight heat insulated housing 10 and an outlet lock 11 . The housing 10 includes at least one, preferably two to five, and in the embodiment shown here, two modular treatment chambers 12 , 13 arranged one after the other in a row. The interior of the housing 10 is subdivided by the treatment chambers 12 , 13 , into two fields arranged one after the other. The housing 10 is not subdivided and surrounds all treatment chambers 12 , 13 .
A circulating device, or in other words a device for guiding wet steam in a circulation which is identified as a circulating process is provided in each treatment chambers 12 , 13 . It has a circulating fan 14 . Each treatment chamber also has a heating device which is not shown in FIG. 2 and nozzle boxes 15 with nozzle openings directed toward the product web 1 . In one treatment chamber 12 , 13 , several, for example two nozzle boxes 15 can be arranged above and below the product web 1 transversely over the product web. The nozzle openings are preferably formed as slots.
A transporting device has guiding rollers 16 , 17 in the inlet lock 9 and guiding rollers 18 , 19 , 20 in and downstream of the outlet lock 11 . In addition, the transporting device has a roller conveyor with two guiding rollers 21 , 22 and a pulling roller 23 in the region in which the both treatment chambers 12 , 13 abut against one another. The roller conveyor thus extends over the half of the transporting path of the product web 1 from the inlet slot 27 in the front wall 26 to the outlet slot 29 in the rear wall 28 . The both guiding rollers 21 , 22 have identical sizes and are arranged close to each other at the same height. The arrangement of the guiding rollers 21 , 22 , the last guiding roller 17 of the inlet lock, and the first guiding roller of the outlet lock 11 Is such that the transporting plane of the product web 1 in the treatment chambers 12 , 13 is flat and horizontal.
The pulling roller 23 is arranged in the center, under the guiding rollers 21 , 22 so that it is vertically adjustable. It is formed simultaneously as an orienting roller, in other words it is adjustable in a plane extending through its axis parallel to the transporting plane. The height adjustment of the pulling roller 23 is identified by the arrow 24 and the orienting ability by the arrow 25 . The pulling roller 23 is moreover connected with a not shown drive. The housing 10 has an inlet slot 27 on the front wall of the first treatment chamber 12 and an outlet slot 29 on the rear wall 28 of the last treatment chamber 13 , through which the product web 1 is introduced into the housing 10 and withdrawn from it.
The inlet lock 9 has a front plate 31 which extends parallel to the front wall 26 in the vicinity of a lower edge 30 to above the inlet slot 27 , a cover plate 32 and two side plates, which are not shown. The plates 31 , 32 of the inlet lock 9 are connected steam-tight with one another and with the front wall 26 . The inlet lock 9 is subdivided into an upper main chamber 36 and a lower pre-chamber 37 by intermediate plates 33 , 34 that extend from the front plate 31 and from the front wall 26 into the interior of the inlet lock 9 and leave a gap 35 for passage of the product web 1 . The pre-chamber 37 is open downwardly. A suction device is connected with the pre-chamber 37 and in this example by a suction passage 38 , which is connected with a not-shown fan In some cases, as in this example, a suction box 39 to which the suction passage 38 is connected is located in the pre-chamber 37 . The first guiding roller 16 of the transporting device is located below the prechamber 37 and the second or the last guiding roller 17 is located before the inlet slot 27 . The outlet lock 11 is formed analogously to the inlet lock 9 . The first and second guiding rollers 18 , 19 are arranged analogously to the inlet lock 9 and the third guiding roller 20 is arranged behind the outlet slot 11 .
For dyeing the product web 1 is taken from the product storage device 2 via the supply device 3 formed as a boom, and supplied through the dye device 4 formed as a padder and the air passage 5 to the device 6 for dye fixing, The product web 1 is transported over the guiding roller 16 of the transporting device from below into the pre-chamber 37 of the inlet lock 9 , through the pre-chamber 37 and through the gap 35 in the main chamber 36 and through the inlet slot 27 in the first treatment chamber 12 of the device 6 . The transportation of the product web 1 through the treatment chambers 12 , 13 is performed by the roller conveyor arranged between the first and second chambers 12 and 13 in a horizontal plane and under a longitudinal tension of 10-100 N/m.
In the roller conveyor the product web 1 is guided meanderingly, one after the other and over the guiding roller 21 , the driven pulling roller 23 and the guiding roller 22 . The desired longitudinal tension is adjusted by height adjustment of the pulling roller 23 . In some cases occurring displacements of the product web 1 are compensated by the adjustment of the pulling roller 23 , and in particular by an angular adjustment of the axis of the pulling roller 23 parallel to the transporting plane.
The product web 1 leaves the device 6 through the outlet slot 29 and the outlet lock 11 . It is supplied via the supply device 7 formed as a boom to the product storage device 8 formed as a winding roller. The product web speed amounts to, for example, 40 m/nin. In the dye device 4 the dye solution is applied on the product web 1 . In the air passage 5 a blending of the dye solution on the product web 1 is performed.
The moist product web 1 during its transportation on the roller conveyor flatly through the treatment chambers 12 , 13 of the device 6 is subjected to the action of hot steam from the nozzle boxes 15 arranged above and below the product web 1 with the nozzle openings oriented toward the product web 1 . The nozzle pressure amounts to 200-1000 PA and the heat transfer power to substantially 240 W/m 2 .
The temperature of the hot steam amounts to 160-230° C. and the retention time of the product web 1 in the treatment chambers 12 , 13 amounts to 5-60 seconds, preferably 1014 30 seconds. The residual moisture of the product web 1 on leaving the housing 10 is approximately equal to or less than the equilibrium moisture content under normal conditions or, in other words, less than or substantially equal to 10%. In the treatment chambers 12 , 13 and in the main chambers 36 , the inlet and outlet locks 9 , 11 are maintained at a slight overpressure. The steam content, preferably between 95-100 vol. percent, is maintained by changing the quantity of the aspirated treatment gas through the suction passages 38 of the pre-chambers 37 of the inlet and outlet locks 9 , 11 . Regulation of the residual moisture content of the product web is not needed.
It will be understood that each of the elements described above, or two or more together, may also find a useful application in other types of methods and constructions differing from the types described above.
While the invention has been illustrated and described as embodied in method of and an arrangement for continuous thermal treatment of a textile product web, in particular for dye fixing, it is not intended to be limited to the details shown, since various modifications and structural changes may be made without departing in any way from the spirit of the present invention.
Without further analysis, the foregoing will so fully reveal the gist of the present invention that others can, by applying current knowledge, readily adapt it for various applications without omitting features that, from the standpoint of prior art, fairly constitute essential characteristics of the generic or specific aspects of this invention.
What is claimed as new and desired to be protected by letters patent is set forth in the appended claims: | The method of continuous thermal treatment of a textile product with steam simultaneously provides optimum dye fixing and drying of a product web treated with a dye solution. This method includes applying a water solution of a dye to a product web to form a moist product web with the applied dye solution; transporting the moist product web with the applied dye solution through at least one treatment chamber in which the heat treatment takes place; bringing the moist product web with the applied dye solution into contact with a treatment gas including hot steam, preferably at 160-230° C., for preferably from 10 to 30 seconds, to simultaneously perform drying and dye fixing, so that the residual moisture content of the moist product web is less than or equal to its equilibrium moisture content under normal conditions. | 3 |
REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority of U.S. Provisional Patent Application Ser. No. 60/205,157, filed May 18, 2000; and PCT/US00/25211, filed Sep. 15, 2000; and is a continuation-in-part of U.S. patent application Ser. No. 09/532,432, filed Mar. 23, 2000, the entire contents of each application being incorporated herein by reference.
FIELD OF THE INVENTION
[0002] The present invention relates generally to fabrication of objects and prototypes through the sequential deposition of material. More particularly, the invention relates to ultrasonic consolidation.
BACKGROUND OF THE INVENTION
[0003] Conventional machine tool such as lathes, mills, EDM machines etc. use various methods to remove material from a block or billet to produce an object of a desired shape. This process is highly efficient and accurate in many applications, but has shortcomings when certain types of features, such as deep narrow slots, or complex internal features are required. In these situations multiple machine set ups may be required, or conventional machining may be combined with EDM to produce the desired features. In some cases, it may be necessary to produce a casting in order to obtain the desired geometry. The ability to add and remove material on the same machine can address many of these issues, and allow objects to be produced more quickly and efficiently than current methods.
[0004] Many technologies are now being marketed to perform additive manufacturing. Generally known as rapid prototyping technologies these include stereolithography, fused deposition modeling, selective laser sintering, laser powder deposition and others. Most of these processes have only been robustly commercialized for use with polymer, wax or paper feedstocks. As a result, they cannot be used commercially, alone or with subtractive processing, to produce objects from engineering metals.
[0005] Some researchers have developed techniques to apply metals via welding methods, and to machine away excess material (Prinz, U.S. Pat. Nos. 5,301,415; 5,281,789; and 5,207,371) either using or without a support material (Kovacevic). These systems involve using arc welding, or laser metal deposition (with either powder of wire feedstocks) to deposit molten metal droplets. Another approach is droplet generation by various metal melting and droplet formation techniques (as described by Starrett, Prinz, Chen, Tseng, Visnawathan and others). Incorporating molten metal droplet deposition in such a system presents certain problems, including the presence of high voltage, smoke and fume, eye safety issues, the retention of molten metal etc. associated with welding and foundry operations. These issues have inhibited adoption of welding, laser deposition and other molten metal techniques as a means of adding material to an object prior to or during machining.
[0006] As described in U.S. patent application Ser. No. 09/532,432, ultrasonic object consolidation is a technique for performing additive manufacturing which avoids most of the problems associated with other metal deposition methods. The solid state, low energy nature of this process eliminates hazards such as molten metal, high intensity arcs, high power, dust and smoke, etc.
SUMMARY OF THE INVENTION
[0007] This invention is directed to a practical machine tool for combining material addition via ultrasonic object consolidation, including subtractive techniques for imparting high-dimensional accuracy to a finished object. Broadly, a system according to the invention includes a material supply and feeder, ultrasonic horn, and feedstock cutting device. These components are integrated with a material removal subsystem preferably including a cutting tool and an excess material removal system.
[0008] Any metal, plastic or composite material suitable for ultrasonic joining may be employed as a feedstock, and these materials may assume the form of tapes, sheets, wires, filaments, dots or droplets, with the feeding and material cutting components being designed for the specific feedstock employed. The cutting tool for excess material removal may be a knife, drill/mill, grinding tool, laser or other tool capable of accurately cutting the external contour of a cross section of the part being built, and of removing excess feedstock remaining following the application process. The material removal could consist of a vacuum or blower system, chip auger, or other suitable apparatus.
[0009] A machine disclosed as part of the preferred embodiment is able to deposit material in one step, and optionally and selectively remove it in another. Through the expeditious combination of deposition and removal, the fabrication of objects of arbitrary shape may be realized. This embodiment of the invention feeds raw material in the form of metal tape to the deposition head, where it is bonded layer by layer in an upward fashion.
[0010] In terms of apparatus, a preferred embodiment includes a deposition head for adding raw material mounted adjacent to a device which removes material, both of which move in X-Y-Z motion with respect to a material deposition plane. Both the deposition head and removal device are connected to a Z-carriage which provides a fall range of orthogonal motion for both devices using a single motion structure. Motion in the +/−X and +/−Y directions is effected by separate gantry/carriage mechanisms. A movable track carries electrical power and signal lines to and from the moving units. A tool holder permits on-the-fly switching of tool profiles.
[0011] In a different embodiment, the material feeder, removal unit, or both may advantageously be mounted on separate multi-axis robots. The robot design may be conventional rotary axis industrial robots, Cartesian robots, or other designs suitable for effecting flexible, programmable motion. Advantages of robotic mounting include the ability to include one or more robots in a single work cell, to separate various functions such as material feeding, material consolidation, and material trimming so as to increase throughput, and to enable incorporation of material feeding, consolidation and trimming into other manufacturing operations. A robotic arm may also be mounted on a gantry type carriage of the type described previously providing the advantages of robotic flexibility over the large travel areas provided by gantry type systems.
[0012] Alternatively, the feeder may be mounted relative to a multi-axis mill or other machining center functioning as the removal unit. The object being fabricated may also be fixtured enabling fabrication from the center outward to realize particular advantages such as the minimization of residual stress accumulation. To minimize “stairstepping” the material removal unit may be operative to perform two trimming operations, including a high-speed trimming operation and a contouring trim to provide material increments in two or more directions. The material feeder may include multiple sources to deposit increments in multiple directions, or to fabricate the using dissimilar materials and/or varying thicknesses.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] [0013]FIG. 1 is a simplified illustration of a machine according to the invention;
[0014] [0014]FIG. 2 is a drawing which shows an ultrasonic consolidation for fabrication of metal matrix composites;
[0015] [0015]FIG. 3 is a drawing which shows an ultrasonically consolidated metal matrix composite specimen;
[0016] [0016]FIG. 4 is a drawing which shows a System incorporating a system for optionally adding fibers to an object being additively manufactured using ultrasonic object consolidation (UOC);
[0017] [0017]FIG. 5 is a drawing that depicts a preferred embodiment of system in gross scale according to the invention with the protective cover removed;
[0018] [0018]FIG. 6 provides a closer look at the z-carriage and related components;
[0019] [0019]FIG. 7 provides details of the lower portion of the z-carriage;
[0020] [0020]FIG. 8A is a drawing which shows a rotating horn design applicable to the invention; and
[0021] [0021]FIG. 8B is depicts an alternative embodiment of an ultrasonic horn assembly based on a reed-wedge design.
DETAILED DESCRIPTION OF THE INVENTION
[0022] A simplified illustration of a machine according to the invention is illustrated in FIG. 1. The system incorporates the elements of an ultrasonically powered material addition subsystem employing a feedstock 30 of tape 31 to a horn 32 , with a milling tool 33 for trimming and removing excess material. Although illustrated with a tape feedstock 30 , and a milling type material removal tool 33 supported on masts 34 , alternative material delivery and removal subsystems may be used in accordance with the description herein.
[0023] A table 36 capable of providing the workpiece with XYZ motion is integrated within a rigid frame 40 . The build object 42 rests on a base plate 44 . A controller 38 receives CAD descriptions of objects to be produced and slices the files to produce cross sections of the object used to generate path instructions for both material addition and removal. Not illustrated in this figure is a system for purging removed excess material from the work area; however, a blower or vacuum system may be employed for such purpose.
[0024] The system may also be modified to include a supply of reinforcing fibers, enabling the apparatus to fabricate continuously reinforced metal matrix composite components, including the type shown in FIG. 2. Reinforcement fibers 50 are delivered to previously deposited layer(s) 52 . Using an aluminum-based composite as an example, an aluminum powder 54 may be used, over which aluminum foil 56 is laid down. An ultrasonic welding horn 58 applies a compressive load 60 through the horn in the direction of travel shown, thereby consolidating the structure. It will be appreciated by those of skill in the art that different material combinations may be used according to the invention to produce alternative laminate, reinforced, ceramic and metal matrix composite (MMC) structures.
[0025] High cost manufacturing techniques which are not robust are a major reason for low use of continuously fiber reinforced metal matrix composites in aerospace, automotive and sporting goods applications. Although many techniques exist for particulate and discontinuously reinforced MMCs, producing a continuously MMC generally involves production of thin tapes which must then be assembled into a desired shape and HIP'ed to full density. Numerous difficulties are encountered at each stage of the process resulting in high costs and low yields.
[0026] Through appropriate selection of processing parameters such as horn pressure, vibration amplitude, horn speed and fiber volume, the foil layers can be consolidated around the fiber layers, providing a low cost, high productivity means of producing layers of metal matrix composites. FIG. 3 is a micrograph of such a multilayer specimen. Since the specimen was produced by applying fibers manually, rather than automatically as described herein, the fiber placement is irregular, and the fiber volume is low. Automation is used to address these issues.
[0027] When combined with the object formation methods described above for the ultrasonic object consolidation system, complex objects can be produced. Furthermore, MMC sections can be added to sheets or other components, to act as stiffeners or to supply locally higher mechanical properties.
[0028] By adding a layer of reinforcing fibers between the layers of feedstock of the machine illustrated in FIG. 1 (where tape is preferably the feedstock employed) an economical, high productivity technique for fabricating continuously reinforced metal matrix components results. The general concept, depicted schematically in FIG. 4, integrates a fiber handling system for adding metal matrix composite fabrication capability to an ultrasonic consolidation system. The added subsystem includes a fiber supply 64 feeding fibers from individual creels or as a tow 66 to tape and fiber handling rolls 68 . The fiber handling and placement subsystem can be viewed as an optional feature on an ultrasonic object consolidation machine. Addition of this capability allows the same unit to be employed to produce either monolithic or composite objects.
[0029] [0029]FIG. 5 is a drawing that depicts a preferred embodiment of the system in gross scale according to the invention with the protective cover removed. A deposition head ( 1 ), which adds raw material, is mounted adjacent to a material removal unit, both of which move in X-Y-Z motion with respect to a material deposition plane ( 3 ). In this case, the material removal unit is a routing head ( 2 ), though, again, alternatives described herein may be substituted as appropriate. Both the deposition head and the routing head are connected to a z-carriage ( 4 ), which provides a full range of orthogonal motion for both devices using a single motion structure.
[0030] A robust motion base ( 5 ) constructed of tubular metal extrusions rests on leveling pads ( 6 ). A tubular gantry ( 7 ) travels along +/−Y on rails ( 8 ). It is actuated by a ball screw ( 9 ) and nut ( 10 ), driven by a servo-motor ( 11 ). Likewise, motion in the +/−X direction is effected by an x-carriage ( 12 ) riding on rails ( 13 ), actuated by a screw and nut combination ( 14 ), and driven by a servo motor ( 15 ).
[0031] The z-carriage ( 4 ) also rides on rails ( 16 ). It is also actuated by a screw and nut ( 17 ) and driven by a servo-motor ( 18 ). In addition, a counter force actuator ( 19 ) serves to balance the static loading of the total weight of the z-carriage, thus minimizing energy requirements of the z-motor.
[0032] A movable track ( 20 ) carries electrical power and signal lines to and from the moving units. A tool holder ( 21 ) permits on-the-fly switching of tool profiles. Five tool positions are shown in the tool holder. More or fewer posts may be used according to the ultimate application of the machine.
[0033] [0033]FIG. 6 provides a closer look at the z-carriage ( 1 ) and related components. It is divided into three primary sections: The upper portion ( 102 ) is concerned with bulk material feed, the middle section ( 103 ) houses force control, z-axis steering, and electrical and pneumatic valves, the lower portion ( 104 ) is the deposition head that contains the ultrasonic components, as well as tape feed and cutting elements.
[0034] Combined functioning of sections ( 102 - 104 ) enables feeding of metal tape from bulk feed rolls ( 105 , 106 ), with controlled tension, down to the deposition head assembly. Since the rear tape roll and related tape pathways are functionally identical to the front pathway, only one will be reviewed.
[0035] Tape begins its route at the bulk feed roll ( 105 ) which can be readily accessed from the front. The tape roll swivels to the left to provide access to the rear roll ( 106 ). As tape leaves the roll it travels over guide rollers ( 107 , 108 ) supported by a roller weldment ( 109 ). It then travels downward between sideways guides ( 110 ) which provide alignment side to side prior to engaging the pinch roller mechanism ( 111 ). The pinch roller is driven by a servo motor ( 112 ).
[0036] As the tape leaves the pinch point, it travels past a tape sensor ( 113 ) that senses presence/absence and over a tensioning roller ( 114 ). The roller is actuated up and down by a linear actuator ( 115 ) traveling on a linear guide assembly ( 116 ) whose rails are stabilized at their ends by a stabilizing plate ( 117 ). A linear sensor built into the guide assembly ( 116 ) outputs the vertical position of the tensioning roller. With the linear actuator providing constant force output, the servo-motor acts in concert with the linear sensor to keep the tensioning roller in the same relative position.
[0037] Once the tape leaves the upper section, it is directed outward by guide rollers ( 118 ) and through another set of sideways guides ( 119 ). It then hits the final guide roller ( 120 ) and is directed inward towards the final process area ( 121 ). The second bulk tape feed ( 106 ) directs tape in a similar fashion to the opposite side of the deposition zone so that the machine can deposit tape in two directions.
[0038] The process area includes a tape feed, driven by a feed motor ( 122 ), and a tape cutter, driven by a rotary actuator ( 123 ). The ultrasonics are driven by a converter ( 124 ).
[0039] The entire lower assembly ( 104 ) rotates on hinges best seen in FIG. 7, and is counterbalanced by a tension strut and actuator ( 125 ). Likewise, a force actuation system ( 126 ) exerts controllable force downward on the lower assembly. A steering actuation means ( 127 ) provides rotary motion about the central z axis. Initial leveling of the flat ultrasonic contact line is enabled by rotation of the lower section ( 104 ) about a y axis pivot point, and is precisely controlled using a micrometer ( 128 ).
[0040] [0040]FIG. 7 provides details of the lower portion of the z-carriage. It contains the deposition head and related support assemblies. Metal tape supplied by bulk feed is ultrasonically bonded at the contact point of the ultrasonic welding horn ( 201 ) by producing an atomically clean faying surface between the material increments without melting the material in bulk. Tape is fed to both sides of the horn. It is fed to the process by pinch rollers ( 202 ) and cut to length by cutting blades ( 203 , 204 ). Servo motors ( 122 ) drive the pinch rollers. Rotary actuators ( 207 , 208 ) actuate the cutters through a cam mechanism ( 209 ).
[0041] [0041]FIG. 7 also shows items previously discussed, such as the lower guide roller ( 120 ), the bottom sideways guide ( 119 ), the ultrasonic converter ( 124 ), and the leveling micrometer ( 128 ).
[0042] A drive means ( 204 ) powered by a servo motor (not shown) actuates the ultrasonic horn ( 201 ) about its central axis. In this way the surface speed of the rotating horn is made to match the y axis speed of the moving gantry.
[0043] The front cover of the z-carriage is shown here ( 215 ), so the force actuation assembly ( 216 ) is viewable only through the front access port ( 217 ). FIG. 7 provides a clear view of the hinge points ( 218 , 219 ) for rotation of the lower assembly. The force actuation assembly controls motion about these pivots.
[0044] An alternative embodiment of the invention is based on flexible work cell concepts. This arrangement preferably incorporates a tape (or other feedstock) application head mounted on a multi-axis (i.e., 6 ) robot, with a second robot arm carrying one or more cutting devices such as a spindle, knife, laser, water jet cutter, or other tool, as appropriate. The robotic system would preferably incorporate coordinated motion methods to eliminate collisions, and would be applicable to simultaneous feedstock lay-up and trimming.
[0045] In this configuration, material feeding concepts such as those used in welding workcells or for stamping presses, incorporating decoiling and feeding may serve as an appropriate means of material supply mounting and feeding. Alternatively, a robotic end effector allowing the mounting and alternating use of two workheads may be employed with the tape application and cutting mounted on a single robot.
[0046] Yet a further embodiment involves retrofitting an ultrasonic metal tape or feedstock application apparatus to an existing machining center such as a vertical three- or five-axis mill. In this case, a secondary tape feeding and mounting apparatus is required.
[0047] Still another arrangement of a system according to the invention involves building up a component through tape or other applied feedstock in the vertical direction. In such an embodiment, the system is preferably fixtured so that the part is built from the center outward, rather than from the bottom up, as is typically the case in additive manufacturing or tape lay-up systems.
[0048] This approach could complicate the build system, since there would either be two deposition and material trimming heads for applying and removing material on both sides of the center axis of the part, or a means of rotating the part through 180 degrees in order to present the two sides to a single deposition and trimming device. However, such a configuration would also afford some important advantages. For one, since the major axes of the part are now built in either the Z and X axes, or the Z and Y axes, rather than X and Y, this will result in a taller machine with a smaller footprint. It may also facilitate feedstock locating, feeding and handling.
[0049] Another significant benefit would be the uniform distribution of residual stresses in the part being built. Most additive manufacturing processes produce residual stresses as each material layer is applied, typically as a result of transformation and thermal contraction stresses. As layers are added, these layers often produce warping of a part, and, in some cases, cracking. Depending on the process, a heat treatment or other processing may be required to prevent the problem, adding time, cost and complexity to the process.
[0050] In contrast, a technique for building objects from the center will result in a balanced residual stress distribution, with less opportunity for gross warping of the parts. Although ultrasonic object consolidation as described in this specification produces significantly lower bulk residual stress than other build techniques involving liquid to solid transformation, this balancing of stresses can still be beneficial.
[0051] For any of the machine configuration and material application approaches described above, it is possible to trim the component being fabricated following each material application, i.e., each application of tape or wire, following deposition of each layer, or following the application of several layers. Furthermore, it may be desirable to conduct two trimming operations, where the first is a high-speed trimming operation, and the second is a contouring trim, designed to produce highly accurate and smooth surfaces on curved components, thereby eliminating the so-called stairstepping often found in additively manufactured components.
[0052] If the feedstock is applied using an ultrasonically activated roller, it is highly desirable to be able to apply material as the roller moves in either direction, effectively increasing the duty cycle of the system from 50% to 100%. This invention is not limited in this regard, and may use two feedstock sources, each feeding from a different direction which is fed under the roller at the beginning of the run. However, multiple additional rolls or other types of feeders may also be employed, with the objective of minimizing operator intervention, or in the interests of employing multiple materials to produce functionally gradient materials.
[0053] For example, if it is desired to produce an object from different materials such as stainless steel and copper, using the copper in location where good thermal conductivity is required, and stainless steel for strength and wear resistance, four material sources could be used, two on each side of the axis of material deposition. Additional material sources may also be used, depending upon the ultimate implementation.
[0054] Although numerous researchers in the additive manufacturing field have noted the potential benefits of using layers of varying thickness to increase deposition rate (by using thicker layers) or improve resolution (by decreasing layer thickness), there have been relatively few practical means of implementing this on commercially available machines for techniques which employ lamination. The current system is relatively well suited to this process, however, since multiple tapes or other feedstocks may be provided having varying thickness. The possible thicknesses will depend on a combination of the materials used and the power capacity of the system.
[0055] Although feedstocks have been illustrated as being fed primarily from above, horizontal mounting, or floor mounting is possible, and may be desirable in certain applications. In addition, palletizing the feedstock, or feeding from a coil shipped in barrels may be convenient. Pallet decoiling apparatus may be used in conjunction with material supplied in such a form.
[0056] Horn Design Considerations
[0057] Various types of horn designs and ultrasonic power trains will be apparent to those of skill in the art, and this invention is not limited in this respect. If an ultrasonically activated roller is employed to bond the metal layers together, such a roller should provide an axial motion of 5 to 60 microns at 10 to 60 kHz with minimal radial motion. The preferred embodiment is configured with a horn that is excited directly; however, alternate approaches including wedge-reed type designs, or systems where a roller is indirectly excited through a bearing system and a clevis arrangement may be desirable.
[0058] It may additionally be possible to configure a system wherein the sonotrode is non-rotating, but can traverse the feedstock in such a way as to produce bonding at the faying surfaces of the component. The use of a rotating sonotrode is convenient rather than necessary according to this invention.
[0059] [0059]FIG. 8A is a drawing which shows a rotating horn design applicable to the invention. FIG. 8B depicts an alternative embodiment of the ultrasonic horn assembly based on a reed-wedge design. The design also incorporates an ultrasonic welding horn suitable for the object consolidation process. In FIG. 8B, a wedge ( 81 ) us ultrasonically driven in the direction shown. It is attached to a reed ( 82 ) that conveys the motion down to the ultrasonic welding horn ( 83 ). A motor ( 84 ) drives the major axis of the horn through a suitable means ( 85 ). Not shown is a mechanism for feeding tape to the active contact zone of the horn. A mechanism such as that depicted in FIGS. 5 - 7 would be suitable, however.
[0060] Software Considerations
[0061] The current art in this field is generally based on the use of the .STL file type data format to generate machine instructions. In addition, laminated-type systems have used full width sheets, which produces difficulty in creating a uniform tension, but allows ease of programming. A further unique aspect of this invention includes the capability of determining how to apply tapes (or other feedstocks) so as to minimize the number of very narrow pieces of material which must be applied, a means of ensuring that the Z axis joints are staggered while accomplishing the foregoing, and means of distinguishing between internal and external boundaries when determining where to start and stop tape deposition. | Machine tools combine material addition via ultrasonic object consolidation and subtractive techniques for imparting high-dimensional accuracy to a finished object. A material supply and feeder, ultrasonic horn, and feedstock cutting device are integrated with a material removal subsystem preferably including a cutting tool and an excess material removal system. Any metal, plastic or composite material suitable for ultrasonic joining may be employed as a feedstock, and these material may assume the form of tapes, sheets, wires, filaments, dots or droplets, with the feeding and material cutting components being designed for the specific feedstock employed. The cutting tool for excess material removal, may be a knife, drill/mill, grinding tool, or other tool capable of accurately cutting the external contour of a cross section of the part being built, and for removing excess feedstock remaining following the application process. The material removal could consist of a vacuum or blower system, chip auger, or other suitable apparatus. A machine disclosed as part of the preferred embodiment is able to deposit material in one step, and optionally and selectively remove it in another. Through the expeditious combination of deposition and removal, the fabrication of objects of arbitrary shape may be realized. | 1 |
FIELD AND BACKGROUND OF THE INVENTION
The present invention relates in general to continuous control valves and in particular to a new and useful continuous control valve in which various flow rate displacement characteristics are adjustable and in which a definite rate of flow of hydraulic fluid under a definite pressure is continuously controllable in accordance with a continuously and smoothly rising flow force to flow rate characteristic.
Continuous control valves, particularly those comprising a cylindrical body or slide in which grooves with a rectangular cross section are provided, are known both in the rotary slide and the lengthwise or axial slide design (for example of rotary slide see German OS No. 27 30 652; and for lengthwise slide see German OS No. 24 04 524). Usually, and unlike in the last mentioned reference, the rectangular grooves extend in their length, parallel to the axis of the slide casing and to the axis of symmetry of the cylindrical slide coinciding therewith. The length of the grooves is determined by the spacing of the inside openings of adjacent ports. In a four-way valve, two grooves are needed which extend on diametrally opposite sides of the cylindrical slide.
It is further known (from British patent No. 134,759 FIGS. 1 and 2, and from U.S. Pat. No. 3,477,472, FIG. 1) to provide the control piston of control valves with a step in order to reduce the flow forces, or to provide such a step close to the control edge of the control piston. Continuous control valves of the above mentioned kind are type provide means for a continuous control in most various applications. These control means become increasingly important as transducers or transformers, and at the same time amplifiers, in a so called pneumo-hydraulic control system. This system has been developed in the paper and textile industries for controlling the run of material web edges or center lines. The basic element of this system is a pneumo-hydraulic controller, comprising a pneumo-hydraulic transformer and a unit for supplying pressure oil and compressed air.
The pneumo-hydraulic transformer, designed as a servo-valve, comprises a double-diaphragm which is exposed to a differential pressure corresponding to the deviation from a desired position, for example, of a web edge. Under the differential pressure, a diaphragm drive executes a lengthwise stroke and causes a corresponding rotary motion of the rotary slide of the servo-valve, whereby a working oil flow is continuously controlled to reduce the deviation of the web through an actuator.
A valve for continuous control or a continuous control valve designed and employed as a part of a pneumo-hydraulic transformer or for other purposes, has a definite flow rate-displacement characteristic determining the control characteristic. Therefore, to obtain continuous control valves with varying characteristics, the slide and/or slide casing must be manufactured in various sizes. This entails the necessity of manufacturing many valve sets in small numbers since valves of this kind are sometimes needed with a rotary slide and other times with a lengthwise slide and with considerably differing characteristics. On the other hand, if a continuous control valve is designed as a pneum-hydraulic transformer, its property and function as an amplifier is also utilized, to be able to control a hydraulic power output (output of the continuous control valve) which is greater than, for example, the force actuating the rotary slide (input power). The mentioned diaphragm drive of the pneumo-hydraulic transformer designed as a servo valve has only a small actuating power, so that the power input of the servo valve is small.
Continuous control valves in which steps, similar to those of the above mentioned prior art are provided at the flow entrance, downstream of the control edges, for compensating or reducing the hydraulic flow force, are already commercially available and employed. At these steps, a "compensating force" acting against the flow force tending to close the valve is produced, so that a smaller force for controlling the slide and a smaller control power input are needed than in valves without a flow force reduction, provided that the considered power output is identical. Prior art methods of reducing the flow force in valves are not satisfactory in this regard.
SUMMARY OF THE INVENTION
The present invention is directed to a continuous control valve, particularly for a pneumatic transformer, in which various flow rate-displacement characteristics are adjustable and with which a definite rate of flow of hydraulic fluid under a definite pressure is continuously controllable in accordance with a continuously and monotonously rising flow force to flow rate characteristic.
Accordingly, an object of the present invention is to provide a continuous control valve comprising, a casing having a valve slide cavity and a plurality of ports each with an opening communicating with said cavity, each port opening bounded by a plurality of limiting edges. At least one of the ports is an inlet port and at least one other of the ports is an outlet port with additional ports provided for flow in the cavity from the inlet port and to the outlet port. A valve slide is provided and movable in the cavity in a control direction to vary a flow passage cross sectional area in each port opening.
The slide has a plurality of grooves each with, for instance, a rectangular cross section and a control plane transverse to the plane containing the control direction, a pair of control edges extending transverse to the control direction and a pair of connecting edges connecting ends of the control edges. The slide is movable in the control direction to move the control edges past at least some of the limiting edges. This slide is also positionable in the cavity in a selected position in a direction transverse to the control direction to vary an amount of overlap between the control edges and the limiting edges. The grooves are shallow in the vicinity of the inlet and outlet ports and wider in the vicinity of the additional port with an angle between the grooves and an outer surface of the slide being acute in the vicinity of the outlet port.
A further object of the invention is to provide a control valve wherein the valve slide is cylindrical and the control direction comprises rotation of the valve slide, the control edges being parallel to an axis of the cylindrical valve slide and to at least some limiting edges also being parallel to the axis, the slide being positionable at a selected axial location with respect to the casing to provide the selected amount of overlap between the control edges and the limiting edges.
A further object of the invention is to provide a control valve wherein the valve slide is cylindrical and the control direction is along the axis of the valve slide. In this embodioment the control edges are circumferential edges of the grooves with the valve slide being movable by a selected amount of rotation to provide a selected amount of overlap between the circumferential control edges and the limiting edges of the port openings.
In a rotary or lengthwise slide system of the invention, ports may be provided having a square inside opening with limiting edges extending at angles between but exclusive of 0° and 90° relative to, the axis of the slide casing. A definite angular position of square ports may thus be used in either of these systems to obtain a flow rate verses displacement characteristics of a definite, even not strictly linear shape. At the same time, the limiting edges, for example and edges of the rectangular grooves may form any angle between 0° and 90° with the limiting edges of the square openings.
It is generally practical to use square or circular inside openings of the ports in the slide casing and corresponding grooves in the slide for adjusting other characteristics, particularly with a non-linear, monotonously increasing displacement.
A primary advantage of the invention is that the features relating to the arrangement and shape of the slide are applicable independently of each other, so that the respective effect on the flow rate-displacement characteristics or the flow force-flow rate characteristic is obtained with either of those features in and of themselves. However, they may be used in combination, without thereby reducing their combined effect.
Another advantage is an improved closed-loop control of the hydraulic circuits in which continuous control valves in accordance with the invention are employed as continually effective control elements. However, the continuous control is not the sole effect of this design. Due to the reduction of the flow force needed at the control edges of the valve and the simultaneously rising flow force-flow rate characteristic, the inventive control valve is actuated and produces its effect even upon a very small power input, so that in addition to the controlling effect, the amplification capacity of the valve is utilized as well.
A further object of the invention is to provide a continuous control valve which is simple in design, rugged in construction and economical to manufacture.
The various features of novelty which characterize the invention are pointed out with particularity in the claims annexed to and forming a part of this disclosure. For a better understanding of the invention, its operating advantages and specific objects attained by its uses, reference is made to the accompanying drawings and descriptive matter in which preferred embodiments of the invention are illustrated.
BRIEF DESCRIPTION OF THE DRAWINGS
In the drawings:
FIG. 1 is a sectional view of a rotary slide system comprising a casing with two square opening ports and two circular opening ports forming a four-way valve according to the invention;
FIG. 2 is a side elevational view of a rotary slide alone used in the embodiment of FIG. 1;
FIGS. 3 and 4 are axial sectional views each showing a continuous control valve comprising a rotary slide in accordance with FIGS. 1 and 2;
FIG. 5 is an axial sectional view of a lengthwise slide system comprising a casing with six square-opening ports and four circular-opening ports forming a four-way valve in parallel connection according to the invention;
FIG. 5a is an enlarged detail of FIG. 5 showing the relationship of a control edge and a limiting edge in closed valve position;
FIGS. 6 and 7 are cross sectional views of a system in accordance with FIG. 5, being in an open position;
FIG. 8 is a graph showing the flow rate-displacement characteristic of a rotary and a lengthwise slide according to the invention;
FIG. 9 is a cross-sectional view of an inventive rotary slide in a corresponding casing;
FIG. 10 is an axial sectional view of an inventive lengthwise slide in a corresponding casing; and
FIG. 11 is a graph showing the flow force-flow rate characteristic according to the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to the drawings in particular, the invention embodied therein, in FIGS. 1 to 4 comprise a rotary slide 2' rotatable in a casing 1' having four ports P,T,A and B extending through the wall thereof and at right angles to each other. Two pairs of ports are aligned with each other. In their portion adjacent the valve slide cavity 30' inside the casing 1', two of the ports (P and T) have their circular cross sections changed to square cross sections 1a, 1b by which they open into the cylindrical inside surface of casing 1' where slide 2' is received. The square inside openings of the ports enclose a rectangle, more particularly a square, and have four limiting edges of substantially equal length. These edges are in two parallel facing and opposite pairs for the two ports, designated 10a,10c, and 10b, and 10d (See FIG. 2). The slide 2' is movable (rotatable) in a control direction indicated by arrow 40'. Rotary slide 2' is provided with two diametrally opposite grooves 8a', 8b' having rectangular cross sections, as shown in FIG. 2. The end edges 9a, 9c and 9b, 9d of these grooves limit and define the groove length. These edges are equally long and they form the control edges which, in FIG. 1, are designated 6a, 6c and 6b, 6d. As shown in FIG. 2, the limiting edges 10a, 10c and 10b, 10d of the square openings are parallel to the casing axis 5. They also are parallel to the mentioned end edges 9a, 9c and 9b, 9d of the rectangular grooves, and are of equal length therewith.
The central portion of rotary slide 2' (see FIG. 2) is reduced by the two opposite rectangular grooves 8a', 8b' to a web which is shown in FIG. 1 in section. FIG. 2 shows the rotary slide in a position in which the valve is closed, i.e. the supply of fluid through port P and its discharge through port T are blocked. In FIG. 3, the rotary slide 2' is shown in the same (closed) position and provided with two diametrally opposite rectangular grooves 8a', 8b' which have the same dimension as those of FIGS. 1 and 2. In FIG. 3, rotary slide 2' is shown in its orthodox operating position fixed by means of three spacer discs 11 to 13 which are inserted in the casing and surround the upper portion of the slide shaft. FIG. 4 shows other arrangements in which the rotary slide, upon being axially shifted, is fixed in two different, non-orthodox operating positions relative to ports P or T. This is done by means of two spacer discs 12 and 13 inserted above the central, grooved portion of the slide and one disc 11 below (right hand part of FIG. 4), or by means of one spacer disc 13 inserted above said portion and two spacer discs 11 and 12 inserted below said portion (left hand part of FIG. 4).
By comparing FIGS. 3 and 4, it becomes evident that in the non-orthodox, axially shifted operating position of the rotary slide, the effective lengths of control edges 6a,6d and thus also those of control edges 6b, 6c which are not visible in these figures, are shorter than the corresponding lengths in the orthodox operating position in which these effective lengths are substantially equal to the actual full length of the edges.
The term "effective length" (i.e. effective in performing the continuous control function of the valve) is used to designate the total length of a control edge (6a, 6d or 6b, 6c) that overlaps the corresponding parallel limiting edge of an inside opening of a port (10a, 10d or 10b, 10c). This definition may also be applied in instances in which arcuate control edges and limiting edges oppose and are parallel to each other, or even where non-parallel, straight or arcuate control edges which oppose and cooperate with each other according to other embodiments of the invention.
In the last mentioned instances, the effective length is the projection of a portion of the designed total length of a control edge upon a portion of the corresponding limiting edge. In general, the effective length thus defined, of a control edge, depending on the controlling angular position of the rotary slide, and the stationary limiting edge of the inside opening of a port, determine together, in the manner of a diaphragm aperture, the size of the flow passage of the valve, thus the rate of flow. The more remote the fixed operating position of the rotary slide is from the orthodox operating position (in which the control edges produce their maximum effect), the smaller is the area of the mentioned flow passage and the controlled rate of flow. The relation between the rate of flow and the angular position of the rotary slide, which angular position is called displacement and is measured in the degrees of angle or arc lengths, is shown in FIG. 8 for three operating positions of the rotary slide. The three characteristics or curves 1 to 3 in FIG. 8 are rather linear. Curve 1 characterizes the operation of the valve with the rotary slide in orthodox operating position in which the control edges have maximum effective lengths. The family of curves as shown is a parametric representation of the wide variety of flow rate controls which can be effected with a single valve in accordance with the invention.
In the foregoing, the invention has been explained with reference to a rotarv slide. While applying the invention to a lengthwise or axial slide (see FIGS. 6,7), nothing changes in principle. In FIGS. 5-7, like elements are designated as in FIGS. 1 to 4.
The four-way valve for continuous control shown in FIG. 5 comprises a lengthwise slide 2 provided with two pairs of diametrally opposite rectangular grooves 8a, 8b. Again, the slide is shown in its position shutting the valve off. In this position, the square inside openings of ports P, P and T,T are closed by the non-grooved portions of the slide surface, while parts A,A and B,B thus the connections to and from the operated devices (not shown), communicate with each other through the rectangular grooves. One pair of opposite limiting edges 10c, 10d of the square inside port opening 1b extends perpendicularly to the axis 5 of slide casing 1, These edges (unlike in the rotary slide valve) cooparate to control edges 6c and 6d which, in the lengthwise slide, are formed by arcuate portions of the circumferential edges 9c and 9d of the slide (see detail of FIG. 5 and FIGS. 6,7) by which the grooves are limited in their length and which therefore are the end edges of the grooves.
In FIG. 6, lengthwise slide 2 is shown in its orthodox operating position in which the controlling displacement (of the slide, i.e. the displacement in accordance with FIG. 8) is effected in the axial direction of the casing. In FIG. 7 the lengthwise slide is shown in an operating position which is angularly offset relative to the orthodox one. It is evident that in this operating position, the effective length of control edges 6c are shorter than in the orthordox operating position according to FIG. 6, where the control edge has its maximum effective length. This is the case in any operating position reached by the lengthwise slide being turned out of the orthodox operating position. In the adjusted operating position, lengthwise slide 2 is fixed in casing 1 by suitable locking means to secure the slide against rotation without hindering its controlling mobility in the axial direction of casing 1. In FIG. 8, the characteristics 1 to 3 which are almost straight lines, are obtained if the lengthwise slide of one and the same inventive valve is fixed in three different operating positions. This fully corresponds to what is explained above in connection with a rotary slide.
Referring now to FIGS. 9 to 11, the inventive features relating to the shape or cross section of a rotary slide (FIG. 9) or lengthwise slide (FIG. 10) are illustrated. Due to the shape of the slides shown the flow force in the flow sectors (of the zones 4a', 4b' or 4a, 4b; grooves 8a', 8b' or 8a, 8b; between ports P as flow entrance and B or A, the zones of the grooves between ports A or B and T as flow exit) are changed in such a way that with a small flow force (curve 3 in FIG. 11), the flow force-flow rate characteristic still rises monotously even at a high rate of flow. This shape is substantially identical for both a rotary and a lengthwise slide and is provided in the bottom of each of the associated rectangular grooves, or otherwise formed grooves. The shape is determined in the following way:
Downstream of each of the control edges 6c, 6d at the flow entrance P (plus-control edges) a narrow zone or channel 4a, 4b, 4a', 4b' starts in which the flow causes a pressure drop, so that a compensation force F k builds up counteracting the flow force F SK+ acting on the control edges in the valve-closing direction so that as a function of the rate of flow Q, the resultant F R of these forces shows the shape indicated by curve 1 in FIG. 11. With the position of slides 2', 2 shown in FIGS. 9 and 10, the mentioned channel ends in the zone of the inside opening of ports A or B. This is followed by a recess or bay in the bottom of grooves 8a, 8b or 8a', 8b'. In front of each of the control edges 6a, 6b, this recess terminates by a steep slope, so that at the control edge, the bottom surface of the grooves and the tangential plane of the non-grooved cylindrical outer surface of the slide form an angle α in the range of 0° to 90°. The groove surface thus extends in a direction to increase the size of each groove near the parts T.The shape given to the slides at the flow exit T produces the effect that in the inside opening of the respective port, a flow angle θ between the mean outflow direction and the mentioned tangential plane is sufficiently large already at small rates of flow Q, but smaller than 90°, so that the flow force F Sk- at the minus control edge 6a, 6b is small, and that with an increasing rate of flow Q, the flow angle θ increases, so that the flow force F Sk- increases far less than in proportion to Q, in accordance with the shape of curve 2 in FIG. 11. The flow force-flow rate characteristic of the continuous control valve comprising a rotary slide or lengthwise slide and having a cross-sectional shape as described in the foregoing, is obtained by point by point addition of curves 1 and 2 to form curve 3 which rises monotonously within a wide range of the rates of flow Q. This characteristic may then further be varied without changing its character, by varying the depths of channels 4a, 4b, 4a', 4b' and also by providing a small step st as shown, behind the plus control edge 6c, 6d.
While specific embodiments of the invention have been shown and described in detail to illustrate the application of the principles of the invention, it will be understood that the invention may be embodied otherwise without departing from such principles. | A continuous control valve is disclosed which comprises a casing having a cylindrical cavity therein with two pairs of ports extending therethrough. Each port has a preferably square opening communicating with the cavity. A cylindrical valve slide is movable both axially and rotatably in the casing cavity. The valve slide includes a pair of rectangular cross section grooves which have control edges movable with respect to limiting edges of the port openings to vary the cross sectional area of the port openings opening into the groove. Each groove is shallow in the vicinity of inlet and outlet port openings and deeper in the vicinity of additional port openings in the casing. The cylindrical valve is movable either axially or rotationally in a controlled direction to vary the cross-sectional area of the passages and also movable into a selected position to establish a selected overlap between the control edges of the valve slide and the limiting edges of the port openings. | 8 |
FIELD OF THE INVENTION
This invention relates to an apparatus and method to assess cardiac function in a subject.
BACKGROUND OF THE INVENTION
Non-invasive methods of determining cardiac functioning include the following:
a) Mechanical methods that include pulse recording of the jugular, carotid artery or apexcardiogram. This group also includes sound recordings, for example, use of the stethoscope and phonocardiographic techniques.
b) Electrical techniques which are best exemplified by the electrocardiogram (ECG).
c) Relatively more recent techniques include imaging techniques, for example echocardiography, nuclear cardiography, radiographic techniques and magnetic resonance imaging (MRI).
All of the above the mechanical methods, which rely on vibration and sound recording, involve measuring the movements of the body resulting from cardiac activity. This means that the mass of the body is part of the recording means. This is not desirable. Chest movements, for example, are dependent upon chest shape, and sound recording is dependent upon the amount of fat and the condition of the lung tissue for its amplitude. An accurate trace pattern is difficult to achieve and these techniques are therefore of limited diagnostic value.
Electrical methods measure only the electrical field generated by the heart. This cannot provide a direct measure of the cardiac forces generated by the heart and therefore these methods are incapable of evaluating the heart's function as a pump.
Imaging techniques have limited ability to evaluate the force of the heart's contraction.
Thus none of the above methods is capable of measuring the force of the heart's contraction. As a result the evaluation of the condition of the myocardium is not possible. Heart attack risk cannot be determined by any known non-invasive method. A patient may be diagnosed as normal and yet die of a heart attack shortly after the diagnosis.
Relevant literature includes the following text books: Clinical Phonocardiography and External Pulse recording by Morton E. Tavel, 1978 Yearbook, Medical Publishing Inc.; Non-Invasive Diagnostic Techniques in Cardiology by Alberto Benchimol, 1977, The Williams and Wilkins Co.; and Cardiovascular Dynamics by Robert F. Rushmer, 1961, W.B. Saunders Company.
Rushmer first postulated that acceleration and deceleration of the various structures of the heart and blood explain heart sounds as well as their modifications with changing dynamic conditions. As acceleration is a function of force, the aortic blood acceleration is a manifestation of the force that sets the cardiac structures in motion. Other forces originate from the pressure gradient between the aorta and the left ventricle, which acts over the closed semilunar valve. The valve behaves like a circular, stretched membrane in which the thin, flexible leaflets can be stretched in all directions by the differential aorta—ventricular pressure. The energy of the rapid ejection phase of the left ventricle expands the aorta and the stored energy is in direct relationship to its wall elasticity. Measurement of the amplitude of the wave created after the maximum ejection rate, is a measure of the elasticity of the wall of the aorta. The elasticity of the aortic valve can also be measured by measuring the amplitude of the wave created after the valve is closed. The most sensitive indicators of performance are the rates of change of momentum as indicated by changes in velocity of the blood and heart mass. This acceleration is directly indicative of myocardial contractility which is one of the most difficult parameters to measure. In 1964 Rushmer established a direct relationship between the initial ventricular impulse and the peak flow acceleration during the systolic ejection—see Circulation—Volume 29: 268-283 1964.
Commonly owned U.S. Pat. No. 5,865,759 discloses a method and apparatus for measuring cardiac function using an external sensor positioned against the thyroid cartilage in the neck. The subject matter of U.S. Pat. No. 5,865,759 is incorporated herein by reference. The sensor detects the response of the thyroid cartilage to heart function and generates a signal that is fed to a signal processing unit to generate a waveform signal characteristic of heart function for assessment by a user. The apparatus and method of U.S. Pat. No. 5,865,759 provide reliable, accurate and inexpensive assessment of cardiac function.
SUMMARY OF THE INVENTION
The present invention provides an improved apparatus and method for assessment of cardiac activity by directly measuring the movement of the trachea. The apparatus and method rely on introduction of a sensing apparatus into the throat of the user to engage with the trachea. This arrangement is sensitive to very small movement forces and permits accurate measurement of cardiac function with even finer details.
Accordingly, the present invention provides apparatus to assess cardiac function in a subject comprising:
a probe insertable and supportable in the trachea to transmit movement of the trachea in response to cardiac function through the probe;
a sensor to detect the transmitted movement of the trachea and generate a signal indicative of the movement of the trachea; and
a signal processing unit to receive the signal from the sensor and generate a waveform signal characteristic of the cardiac function.
The probe can be a hollow tube having an internal passage to deliver air to the subject and whereby movement of the hollow tube serves to transmit the movement of the trachea.
Alternatively, the apparatus can employ an endotracheal tube for housing the probe in which case the probe comprises a tubular member having an inner end adapted to protrude from the endotracheal tube and engage against the carina region at which the trachea bifurcates into the lungs.
The present invention also provides apparatus to assess cardiac function in a subject comprising:
a tube insertable into the mouth of a subject such that a first end extends into the trachea and a second end protrudes from the mouth;
a flexible support extendable from the tube to engage the trachea and suspend the tube within the trachea for movement of the tube along the longitudinal axis of the tube;
a rigid anchor extendable from the tube to engage the trachea and transmit movement of the trachea due to cardiac function to the tube;
a sensor to sense the movement of the tube and generate a signal indicative of the movement of the trachea; and
a signal processing unit to receive the signal from the sensor and generate a waveform signal characteristic of the cardiac function.
In a still further aspect, the present invention provides a method of assessing cardiac function in a subject comprising:
supporting a probe in the trachea to transmit movement of the trachea in response to cardiac function;
sensing the movement transmitted by the probe;
generating and displaying a waveform signal based on movement transmitted by the probe; and
assessing the waveform signal to determine cardiac function.
The apparatus and method of the present invention are intended to be used primarily with human patients, however, the subject matter also finds application with animal subjects. The apparatus and method can be used with a conscious subject or when the subject is anaesthetised, for example, during surgery.
BRIEF DESCRIPTION OF THE DRAWINGS
Aspects of the present invention are illustrated, merely by way of example, in the accompanying drawings.
FIG. 1 is a schematic view of a first embodiment of the apparatus of the present invention which relies on movement of a tube within the trachea to transmit movement of the trachea due to cardiac function;
FIG. 1 a is a detail view showing the manner of attachment of the sensor to the tube of FIG. 1;
FIG. 2 a is a detail view of the anchor for coupling the tube to the trachea in the folded position;
FIG. 2 b is a detail view of the anchor in the expanded position;
FIG. 3 is a detail view of the retaining strap for holding the tube of the first embodiment in place;
FIG. 4 shows a second embodiment of the apparatus of the present which relies on a probe inserted through an endotracheal tube to measure the movement of the carina region of the trachea;
FIG. 5 is a detail section view through the mounting assembly that supports one end of the probe of the second embodiment via a movable carriage;
FIG. 5 a is a detail view of an alternative sensor that can be used in apparatus of the second embodiment;
FIG. 5 b is a detail view taken along line 5 — 5 in FIG. 5 showing the wheel arrangement that permits movement of the carriage;
FIG. 6 shows an endotracheal tube used with the probe of the second embodiment;
FIGS. 7 a and 7 b show the probe with an inner end having locating fingers in a collapsed position to facilitate insertion through the endotracheal tube and an extended position to locate the inner end on the carina region;
FIG. 8 shows the probe and mounting assembly of the second embodiment prior to insertion into the endotracheal tube of FIG. 6; and
FIG. 9 is a schematic view of the display unit used with the apparatus of the present invention to show typical cardiac events and inputs from the sensors.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The apparatus and method of the present invention are directed to a new system for assessing cardiac function in a subject. Essentially, the apparatus of the present invention comprises a probe 4 insertable and supportable in the trachea of a subject to transmit movement of the trachea due to cardiac function. The transmitted movement of the trachea is detected by a sensor which generates a signal indicative of the trachea movement. This signal is passed to a signal processing unit which generates a waveform signal characteristic of the cardiac function. Details of the processing of the signal are disclosed in commonly owned U.S. Pat. No. 5,865,759 which also discloses externally monitoring the movement of the thyroid cartilage in order to monitor heart function. The present invention is directed to a n improved system which relies on internal monitoring of the movement of the trachea to provide an even more accurate picture of the heart function. The trachea is the passage reinforced by rings of cartilage through which air reaches the bronchial tubes from the larynx.
FIGS. 1-3 b illustrate a first embodiment of the apparatus of the present invention in which the probe is a hollow tube 4 insertable through the mouth and throat of a user into the trachea and supportable therein. Movement of the tube itself serves to transmit the movement of the trachea.
Referring to FIG. 1, hollow tube 4 has a structure similar to a conventional intubation device in that there is a hollow interior 6 that extends between an outer end 8 and an inner end 10 formed with a structure known as a Murphy Eye which ensures that the inner end does not become blocked. Tube 4 is insertable into the mouth of a subject such that inner end 10 extends into the trachea and outer end 8 protrudes from the mouth. Outer end 8 includes an attachment for ready connection to a ventilator unit (not shown) which can deliver air through tube interior 6 to inner end 10 and the trachea to allow a subject to breathe while the tube is in place.
A flexible support in the form of inflatable cuffs 14 and 16 are extendable from the tube to engage the anatomy of the subject and suspend tube 4 within the trachea for longitudinal movement. Lower cuff 14 is positioned to engage with the trachea. Upper cuff 16 is positioned within the mouth of the subject to prevent opposition to tube motion by mouth structures such as the teeth or tongue Cuffs 14 and 16 are shown in their inflated state in FIG. 1 extending radially outwardly from tube 4 . As with a conventional intubation device, the side walls of tube 4 include sealed embedded air passages to permit inflation and deflation of cuffs 14 and 16 . A separate syringe 18 or 20 is connected via line 18 ′ or 20 ′, respectively, to embedded air passages for independent control of each cuff. Syringes 18 and 20 include a check valve 19 to ensure that the cuffs remain inflated. Cuffs 14 and 16 are formed from soft, pliable plastic and dimensioned to be inflatable to a diameter that securely engages with the walls of the trachea or the mouth of the subject to reliably suspend tube 4 in place within the trachea. Two spaced cuffs 14 and 16 are shown supporting each end of tube in FIG. 1, however, it will be readily apparent to a person skilled in the art that additional cuffs may used intermediate the ends of the tube.
Cuffs 14 and 16 are sealably mounted to the external surface of tube 4 by annular end walls 22 that extend generally radially from the external surface. Transverse flexing of end walls 22 permits longitudinal movement of tube 4 in the direction indicated by arrow 24 within the trachea. On deflation, cuffs 14 and 16 collapse against external surface of tube 4 to permit ready insertion or removal of tube 4 from the trachea and mouth of the subject.
In order to ensure that tube 4 moves with the trachea in response to cardiac function, tube 4 also includes a rigid anchor in the form of at least two hinged flanges 30 that are extendable radially outwardly from the external surface of tube 4 to engage the trachea. Each flange 30 is pivotally connected via a hinge joint to collar 32 which encircles tube 4 . Preferably, an inflatable bladder 34 is provided inside flanges 30 between the flanges and tube 4 . Bladder 34 acts to pivot the flanges between a folded position against the tube and a radially expanded position extending between the tube and the trachea. FIG. 1 and FIG. 2 a show flanges 30 in the folded position in which the flanges lie substantially flat against the side of tube 4 . FIG. 2 b shows the flanges in the radially expanded position due to inflation of bladder 34 . When in the expanded position, flanges 30 , which are preferably formed from a rigid plastic, engage against the walls of the trachea to anchor tube 4 to the trachea such that tube 4 moves with the trachea. Tube 4 is supported by cuffs 14 and 16 within the trachea for longitudinal movement so that any movement of the trachea due to beating of the heart is transmitted by flanges 30 to tube 4 . Inflation of cuff 34 is controlled manually by syringe 36 via line 36 ′ (FIG. 1 ). A check valve 19 is also provided. Alternatively, a small air pump 38 can be programmed under computer control to vary pressure in bladder 34 so that the pressure is increased to a predetermined value for a period and reduced to a different pressure for another period. Operating in this manner prevents tissue necrosis in the trachea due to pressure of rigid flanges 30 against the trachea for extended periods.
When inserted into the trachea, tube 4 has a tendency to move outwardly and must be restrained from doing so. In the apparatus of the present invention, a retainer member 39 is preferably provided adjacent outer end 8 of tube 4 to prevent excess outward movement of tube 4 . FIG. 3 shows retainer 39 in the form of a strap and buckle connectable about the neck of the subject. The strap includes a circular opening 41 dimensioned to permit free movement of outer end 8 of tube 4 therethrough while preventing passage of cuff 16 . Therefore, abutting of cuff 16 against the strap serves to prevent excess outward movement of tube 4 .
Movement of tube 4 is detected by sensor 40 attached to the outer end 8 of tube 4 . As best shown in FIG. 1 a , sensor 40 can be clipped to the tube via arms 40 a to permit convenient interchange of sensors. In all cases, sensor 40 is selected to generate a signal indicative of movement of the tube and thus the trachea. Sensor 40 is preferably an accelerometer which senses the acceleration or velocity of tube 4 . Alternatively, sensor 40 can be selected to measure displacement of tube 4 . The signal generated by sensor 40 is sent via data line 42 to a data acquisition unit 44 . The data acquisition unit includes a signal processing unit 45 to receive the signal from sensor 40 and generate a waveform signal characteristic of cardiac function. Signal processing unit 45 includes an amplifier to amplify the signal from the accelerometer and a digitizer to digitize the amplified signal. A signal analysis unit is then used to analyze the amplified signal and generate a waveform signal characteristic of cardiac function. The resulting waveform signal is displayed on a monitor 46 for ease of inspection. The data acquisition unit 44 , signal processing unit 45 and display unit 46 are preferably organized into a control unit 50 . Control unit 50 includes a computer with keyboard 55 running appropriate software to acquire, manipulate, store and display the data provided by sensor 40 . As shown in FIG. 9, control unit 50 can also include inputs for additional sensor data and electrocardiogram (ECG) readings for simultaneous display on monitor 46 for comparison purposes.
In use, tube 4 is lubricated and manipulated according to standard procedures of intubation to insert the tube through the mouth of the user into the trachea with cuffs 14 and 16 collapsed and flanges 30 in the folded position. Cuffs 14 and 16 are then inflated using syringes 18 and 20 . Cuff 16 is located in the mouth and cuff 14 seals the airway between the tube and trachea. Together the cuffs co-operate to suspend tube 4 within the trachea for free vibratory movement in response to movement of the trachea. Flanges 30 are moved to the expanded position to contact the trachea and lock the tube and trachea together so that tube 4 transmits any movement of the trachea due to the heart's motion. Movement of tube 4 is sensed by sensor 40 clipped to the outer end of the tube. Sensor 40 is used to generate a waveform signal based on movement of the tube which is used to determine cardiac function. By inserting a tube directly into the trachea and using the tube itself to detect movement of the trachea, more accurate and reliable data regarding cardiac function can be acquired than was previously possible.
FIGS. 4-8 illustrate a second embodiment of the present invention in which the probe for insertion into the trachea comprises a tubular member 8 which is inserted through an endotracheal tube 50 to directly engage and monitor the movement of the carina region 52 where the trachea 54 bifurcates into the bronchial tubes 56 .
Referring to FIGS. 4 and 5, the apparatus of the second embodiment includes a mounting structure comprising a box housing 60 that supports one end of tubular member 8 to manipulate and manoeuvre the tubular member for insertion into the trachea of a subject via the mouth. Housing 60 includes tubular port 61 from which tubular member 8 protrudes. Housing 60 also includes an encircling clamp 62 and ball joint coupling 63 for connecting the housing to mounting bracket 64 . Bracket 64 supports the entire apparatus and permits the apparatus to be oriented for ease of insertion of tubular member 8 into the trachea of a subject.
FIG. 5 is a detail section view through housing 60 . Housing 60 includes a movable carriage 66 to receive the outer end 74 of tubular member 8 . Carriage 66 is movably supported by wheels 68 on rails 70 to permit adjustment of the position of tubular member 8 so that the member is biased against carina region 52 of the subject as will be explained in more detail below. To further support tubular member 8 , wheels 68 are preferably mounted to the tubular member in the region of tubular port 61 to engage rails 70 mounted to the inner walls of the port. FIG. 5 b is a section view taken along line 5 — 5 of FIG. 5 showing details of a preferred arrangement in which each wheel 68 includes a central channel to engage rail 70 .
Tubular port 61 includes a window 61 a to monitor the position of an indicator 100 fixedly mounted to tubular member 8 . Indicator 100 in window 61 a allows a user to determine the position of tubular member 8 within housing 60 .
Referring to FIG. 6, there is shown an endotracheal tube 50 used with the apparatus of the present embodiment. Tube 50 includes an inflatable cuff 15 that is controlled by syringe 53 via line 53 ′ to retain tube 50 in the trachea of a subject. Tube 50 includes a main port 57 to receive end 72 of tubular member 8 . Tubular member 8 is fed through the interior of endotracheal tube 50 via port 57 to protrude from end 58 for positioning against the carina. Endotracheal tube 50 also includes an auxiliary port 59 connectable to a ventilator for providing air to the subject through the interior of tube 50 . As best shown in FIG. 4, port 57 of endotracheal tube 50 is releasably connectable to tubular port 61 of housing 60 to form a continuous passage to house tubular member 8 when inserted into the trachea of a subject.
As best shown in FIG. 5, the positioning of movable carriage 66 and thus the position of the tubular member in the trachea of the subject is preferably controlled by a spring biasing system. In the illustrated embodiment, the biasing system relies on spring loaded clamps 65 arranged in opposed pairs at each end of housing 60 . Each clamp 65 controls a line connected to movable carriage 66 . Fixed length lines 67 (preferably of nylon cord) extend from one side of carriage 66 while elastic lines 69 extend from the opposite side to exert a biasing force that tends to move the carriage and the attached tubular member 8 toward the subject. Lines 67 are connected to handle 73 . Each clamp 65 includes a control knob 71 that is normally biased inwardly to grip and hold the line extending through the clamp. Pulling the control knob releases the clamp to allow movement of the lines. In use, the clamps controlling lines 67 are released and handle 73 is pulled to move carriage 66 and tubular member 8 to a predetermined position as shown by indicator 100 in port window 61 a . Carriage 66 is moved against the return force exerted by stretching of elastic cords 69 . The clamps for lines 67 are then engaged to hold the lines in place. This procedure locks the movable carriage 66 into a parked position for initial insertion of the tubular member into the trachea of a subject via endotracheal tube 50 . After insertion of tubular member 8 , the clamps 65 controlling lines 67 are released with the result that tubular member 8 mounted to carriage 66 will be biased against the carina of the subject by the tension force in stretched elastic lines 69 . The clamps 65 controlling elastic lines 69 are provided to permit adjustment of the tension in the elastic lines.
As best shown in FIGS. 7 a and 7 b , tubular member 8 comprises an inner end 72 adapted to protrude from the endotracheal tube 50 and engage against carina region 52 , and outer end 74 supported in movable carriage 66 of housing 60 . Tubular member 8 has substantially rigid side walls 76 defining a sealed interior filled with a fluid 78 communicating the inner and outer ends. Preferably, side walls 76 include a bendable region 80 formed with corrugations to accommodate curvature of the trachea.
Inner end 72 and outer end 74 of tubular member 8 include resilient surfaces 82 and 84 , respectively, that communicate via the fluid in sealed interior 78 . Movement of resilient surface 82 at inner end 72 due to movement of the carina region 52 is transmitted by fluid 78 to resilient surface 84 at outer end 74 . To assist in locating inner end 72 of tubular member 8 on the carina region, collapsible locating fingers 86 are provided. Fingers 86 are movable between a collapsed position shown in FIG. 7 a and a extended position shown in FIG. 7 b . In the collapsed position, fingers 86 are aligned with the side walls of tubular member 8 to facilitate insertion through endotracheal tube 50 and the trachea. In the extended position, fingers 86 are positioned to engage the carina region to maintain resilient surface 82 on the carina region.
Fingers 86 are movable between the collapsed and extended positions by hydraulic pressure created by withdrawing fluid 78 from or injecting fluid 78 into the interior of tubular member 8 . The inner and outer ends of tubular member 8 are formed as collapsible bulbs 77 and 79 that include resilient surfaces 82 and 84 . A syringe 87 with check valve 19 communicates with the interior of tubular member 8 via line 87 ′ to withdraw or inject fluid to collapse or inflate the bulbs. At inner end 72 , bulb 77 acts to bias fingers 86 between the collapsed and extended positions.
As best shown in FIG. 5, resilient surface 84 of outer end 74 of tubular member 8 is positioned against sensor 90 which is mounted to carriage 66 by resilient lines 87 . Any movement of resilient surface 82 at inner end 72 of member 8 is transmitted by fluid 78 to resilient surface 84 for detection by sensor 90 . In FIG. 5, sensor 90 comprises an accelerometer to measure the acceleration and velocity of resilient surface 84 in response to movement of resilient surface 82 at the carina region. Alternatively, as shown in FIG. 5 a , sensor 90 can be a pressure transducer mounted directly to the end of tubular member 8 to replace bulb 84 and to detect pressure changes at the inner end 74 .
In the arrangement of the second embodiment, it is also possible to include an additional sensor 94 mounted to the rigid side walls of tubular member 8 to detect acoustic energy transmitted through the side walls of the tubular member by the beating heart. In this manner, the sounds associated with cardiac function can also be recorded.
The various sensors 90 and 94 of the second embodiment are connectable via data lines 90 ′ and 94 ′ to the data acquisition unit shown in FIG. 9 for analysis and display of the collected data relating to cardiac function. As best shown in FIGS. 4 and 8, housing 60 is provided with ports 96 to permit syringe line 87 ′ and data lines 90 ′ and 94 ′ to extend from the interior of housing 60 to the exterior. Syringe line 87 ′ connects to syringe 87 via check valve 19 .
Using the apparatus of the second embodiment involves lubricating endotracheal tube 50 with a water soluble gel and intubating the subject in a conventional manner. When cuff 51 is well within the trachea and within a few centimeters of the carina, the cuff is inflated by syringe 87 . Tubular member 8 is positioned within housing 60 using handle 73 . FIG. 8 shows the apparatus prior to insertion of tubular member 8 into endotracheal tube 50 with fingers 86 in the collapsed position. Tubular member 8 is inserted through endotracheal tube via port 55 . The inner end 72 of tubular member 8 is pushed forward until the end exits the endotracheal tube about 2 cm at which point the endotracheal tube 50 is connected to tubular port 61 of housing 60 . Fluid 78 is injected into tubular member 8 by syringe 87 via line 87 ′ resulting in fingers 86 separating. Clamps 65 controlling lines 67 are slowly released and movable carriage 66 is moved by the biasing force of elastic lines 69 to carry tubular member 8 into engagement with the carina region. Resilient surface 82 of tubular member 8 abuts the carina while fingers 86 contact the sides of the carina region to assure proper positioning. Global movement of the heart is transmitted by the carina to the resilient surface 82 . As the carina moves in response to the forces of the heart, resilient membrane 82 transmits its acceleration and deceleration through fluid 78 to resilient surface 84 at outer end 74 . Accelerometer 90 is elastically attached and outputs to the data acquisition unit. An additional accelerometer sensor 94 having a higher frequency response outputs the acoustic energy received through the rigid walls 76 of tubular member 8 . This sound energy is fed to the data acquisition system via data line 94 ′.
When using the apparatus or method of the present invention, certain body positions are preferable for optimal recording of cardiac functions as follows:
1) Head bent slightly towards the chest. This position frees the trachea for movement.
2) Diaphragm pushed upwards. This position forces the heart against the bronchus for better transmission.
3) Sitting Position with the feet placed up on a rail 4″ higher than chair. This position compresses the diaphragm. The head is preferably bent towards the chest to free the trachea for movement.
4) Supine Position
5) On back with cushion under head inflated bag around abdomen with knees up.
6) Decubitus Position—legs folded against abdomen.
Although the present invention has been described in some detail by way of example for purposes of clarity and understanding, it will be apparent that certain changes and modifications may be practised within the scope of the appended claims. | A method and apparatus to assess cardiac function in a subject involves supporting a probe in the trachea for transmitting movement of the trachea in response to heart function. The transmitted movement is detected by a sensor which generates a waveform signal. The waveform signal is displayed and assessed to determine cardiac function. By directly engaging the trachea, the apparatus and method of the present invention are sensitive to very small accelerations, velocities or displacements of the trachea to permit accurate measurement of cardiac function. | 0 |
BACKGROUND OF THE INVENTION
Both natural and synthetic elastomers usually require the use of processing aids to assist mechanical breakdown and compounding. Materials such as mixtures of oil soluble sulfonic acids of high molecular weight with a high boiling alcohol, paraffin oils, blends of sulfonated petroleum products and selected mineral oils are conventionally used as processing aids. Additional examples include petroleum, paraffinic and vegetable oils, coal tar, petroleum residues or pitches and naturally occurring or synthetic resins.
One advantage in using processing aids is they assist the incorporation of fillers and other ingredients with low power consumption since they reduce internal friction in calendering and extrusion. By reducing the amount of friction during compounding, the temperature of the rubber will remain lower and thus minimize the possibility of scorch.
Various types of rosin acids have been used as extenders for high molecular weight SBR. See Properties of GR-S Extended With Rosin Type Acids, L. H. Howland, J. A. Reynolds, and R. L. Provost, Industrial and Engineering Chemistry, Vol. 45, No. 5, May 1953. Whereas reasonably good cured physical properties can be obtained with the rosin type acids, there are problems associated with their use which include cure retardation, high tack and poor low temperature performance, which limit their use as an extender in rubber formulations.
U.S. Pat. No. 4,478,993 discloses the use of decarboxylated rosin acid also known as thermal oil as a total or partial replacement for oil in a rubber formulation. Compared with the use of aromatic extending oils in rubbers, decarboxylated rosin acids provide comparable processing and low temperature performance and superior abrasive resistance.
U.S. Pat. No. 4,775,496 discloses a reaction product of a rosin acid and a polyfunctional compound having at least one functional group capable of reacting with a carboxylic acid functionality and another functional group having antidegradant properties.
SUMMARY OF THE INVENTION
The present invention relates to bis-amide linked rosin acid derivatives of the formula: ##STR1## wherein R 1 and R 3 may be the same or different and are selected from the group consisting of: ##STR2## or mixtures thereof and wherein R 2 is a divalent organic radical selected from the group consisting of (1) aromatic hydrocarbon radicals having from 6 to about 12 carbon atoms and halogenated derivatives thereof, (2) cycloalkylene radicals having from 2 to about 20 carbon atoms, C.sub.(2-8) alkylene terminated polydiorganosiloxane, and (3) divalent radicals included by the formula: ##STR3## where Q is a member selected from the group consisting of divalent radicals of the formulae: ##STR4## wherein x is whole number from 1 to 5.
DETAILED DESCRIPTION OF THE INVENTION
There is also disclosed a process for preparing rubber compositions which comprises admixing a rubber selected from the group consisting of natural rubber, homopolymers of conjugated diolefins, copolymers of conjugated diolefins and ethylenically unsaturated monomers or mixtures thereof with bis-amide linked rosin acid derivatives.
There is also disclosed a rubber composition which comprises (1) a rubber selected from the group consisting of natural rubber, homopolymers of conjugated diolefins, copolymers of conjugated diolefins and ethylenically unsaturated monomers or mixtures thereof and an amide linked rosin acid derivative of the formula: ##STR5## wherein R 1 and R 3 may be the same or different and are selected from the group consisting of: ##STR6## or mixtures thereof and R 2 is a divalent organic radical selected from the group consisting of (1) aromatic hydrocarbon radicals having from 6 to about 12 carbon atoms and halogenated derivatives thereof, (2) cycloalkylene radicals having from 2 to about 20 carbon atoms, C.sub.(2-8) alkylene terminated polydiorganosiloxane, and (3) divalent radicals included by the formula: ##STR7## where Q is a member selected from the group consisting of divalent radicals of the formulae: ##STR8## wherein x is whole number from 1 to 5.
Preferably R 2 is phenylene.
The bis-amide linked rosin acid derivative is prepared by reacting a diamine compound with abietic acid or dehydroabietic acid. Abietic acid and dehydroabietic acid are derived from rosin. Rosin is a solid resinous material that occurs naturally in pine trees. The three major sources of rosin are gum rosin, wood rosin and tall oil rosin. Gum rosin is from the oleoresin extrudate of the living pine tree. Wood rosin is from the oleoresin contained in the aged stumps. Tall oil rosin is from the waste liquor recovered as a by-product in the Kraft paper industry.
The aged virgin pine stump is the source of wood rosin. The stump is allowed to remain in the ground for about ten years so that its bark and sapwood may decay and slough off to leave the heartwood rich in resin. It is known that production of pine stump rosin can be artificially stimulated by injecting the herbicide, Paraquat, into the lower portion of the tree. This treatment of the stump produces Pinex™ rosin.
Rosins derived from both oleoresin and aged stump wood are composed of approximately 90% resin acids and 10% nonacidic components. Chemical treatment of rosins, such as hydrogenation, dehydrogenation, or polymerization are known which produce modified resins.
Rosin acids are monocarboxylic acids having the typical molecular formula, C 20 H 30 O 2 . The two major rosin acids that may be used to prepare the bis-amide linked rosin acid derivative are abietic acid of the structural formula: ##STR9## and dehydroabietic acid, having the structural formula: ##STR10##
These acids are generally in a mixture with various amounts of other rosin acids including levopimaric, neoabietic, palustric, tetrahydroabietic, pimaric, isopimaric, Δ-isopimaric, elliotinoic and sandaracopimaric. These acids can be used in combination with the abietic or dehydroabietic acid to form the compositions of the present invention. Therefore, in connection with the above formula, R 1 and R 3 may contain the moiety derived from levopimaric, neoabietic, palustric, tetrahydroabietic, pimaric, isopimaric, Δ-isopimaric, elliotinoic or sandaracopimaric acid.
The acid number for the rosin acid may vary. Generally the acid number ranges from about 160 to about 175. Preferably the acid number is below 170 with a range of from about 165 to about 168 being particularly preferred.
The rosin acid is reacted with a diamine under suitable conditions to form a compound having two rosin moieties connected by two amide linkages. Representative diamines which may be used include m-phenylenediamine, p-phenylenediamine, 4,4'-diaminodiphenylpropane, 4,4'-diaminodiphenylmethane (commonly named 4,4'-methylenedianiline), 4,4'-diaminodiphenyl sulfide, 4,4'-diaminodiphenyl sulfone, 4,4'-diaminodiphenyl ether (commonly named 4,4'-oxydianiline), 1,5-diaminonaphthalene, 3,3'-dimethylbenzidine, 3,3'-dimethoxybenzidine, 2,4-bis(β-amino-t-butyl)toluene, bis(p-β-amino-t-butylphenyl)ether, bis(p-β-methyl-o-aminopentyl)benzene, 1,2-bis(3-aminopropoxy)ethane, benzidine, m-xylylenediamine, p-xylylenediamine, 2,4-diaminotoluene, 2,6-diaminotoluene, bis(4-aminocyclohexyl)methane, 1,4-cyclohexanediamine, bis(3-aminopropyl)sulfide, bis(3-aminopropyl)tetramethyldisiloxane, bis(4-aminobutyl)tetramethyldisiloxane and mixtures of such diamines.
The rosin acid may be reacted with the diamine in a variety of mole ratios. Generally the mole ratio of rosin acid to diamine ranges from about 1.5:1 to about 2.5:1 with a range of from about 2.1:1 to about 1.9:1 being preferred.
An organic solvent may be used to dissolve the rosin acid and the diamine. The solvent is preferably inert to the amidation reaction. Illustrative of solvents suitable for use in the practice of this invention include: saturated and aromatic hydrocarbons, e.g., hexane, octane, dodecane, naphtha, decalin, tetrahydronaphthalene, kerosene, mineral oil, cyclohexane, cycloheptane, alkyl cycloalkane, benzene, toluene, xylene, alkyl-naphthalene, and the like; ethers such as tetrahydrofuran, tetrahydropyran, diethylether, 1,2-dimethoxybenzene, 1,2-diethoxybenzene, the mono- and dialkylethers of ethylene glycol, propylene glycol, butylene glycol, diethylene glycol, dipropylene glycol, oxyethyleneoxypropylene glycol, and the like: fluorinated hydrocarbons that are inert under the reaction conditions such as perfluoroethane, monofluorobenzene, and the like. Another class of solvents are sulfones such as dimethylsulfone, diethylsulfone, diphenolsulfone, sulfolane, and the like. Mixtures of the aforementioned solvents may be employed so long as they are compatible with each other under the conditions of the reaction and will adequately dissolve the rosin acid, dissolve the diamine and not interfere with the amidation reaction.
The amidation reaction may be conducted in the presence of a catalyst to speed up the reaction. Examples of catalysts that may be used include acid catalysts such as sulfuric acid, hydrochloric acid and toluenesulfonic acid. The amount of catalyst that may be used will vary depending on the particular catalyst that is selected. For example, when an acid catalyst is used, from about 5% to about 10% by weight of the rosin acid is recommended.
The amidation reaction may be conducted over wide temperatures. The temperatures may range from moderate to an elevated temperature. In general, the amidation reaction may be conducted at a temperature of between about 150° C. to about 300° C.
The preferred temperature range is from about 175° C. to about 275° C., while the most preferred temperature range is from about 200° C. to about 250° C.
The amidation reaction may be conducted under a variety of pressures. Pressures ranging from about 0 psig to about 100 psig may be used to conduct the amidation reaction.
The amidation reaction is conducted for a period of time sufficient to produce the desired bis-amide linked rosin acid derivatives. In general, the reaction time can vary from minutes to several hours. If the more sluggish reaction conditions are selected, then the reaction time will have to be extended until the desired product is produced. It is appreciated that the residence time of the reactants will be influenced by the reaction temperature, concentration and choice of catalyst, total gas pressure, partial pressure exerted by its components, concentration and choice of solvent, and other factors. Desirably, the amidation reaction is conducted until the acid number of the products range from about 5 to about 30.
The process for the preparation of the bis-amide linked rosin acid derivatives may be carried out in a batch, semi-continuous or continuous manner. The amidation reaction may be conducted in a single reaction zone or in a plurality of reaction zones, in series or in parallel. The reaction may be conducted intermittently or continuously in an elongated tubular zone or in a series of such zones. The material of construction of the equipment should be such as to be inert during the reaction. The equipment should also be able to withstand the reaction temperatures and pressures. The reaction zone can be fitted with internal and/or external heat exchangers to control temperature fluctuations. Preferably, an agitation means is available to ensure the uniform reaction. Mixing induced by vibration, shaker, stirrer, rotating, oscillation, etc. are all illustrative of the types of agitation means which are contemplated for use in preparing the composition of the present invention. Such agitation means are available and well known to those skilled in the art.
The bis-amide linked rosin acid derivatives may be added to sulfur vulcanizable elastomers, for example, as an antidegradant or processing aid. The term "rubber" or "elastomer" as used herein embraces both natural rubber and all its various raw and reclaim forms as well as various synthetic rubbers. Representative synthetic elastomers are the homopolymerization products of butadiene and its homologues and derivatives, as for example, methylbutadiene, dimethylbutadiene, chloroprene (neoprene synthetic rubber) and pentadiene as well as copolymers such as those formed from butadiene or its homologues or derivatives with other unsaturated organic compounds. Among the latter are acetylenes, e.g., vinyl acetylene: olefins, for example, isobutylene, which copolymerizes with isoprene to form butyl rubber; vinyl compounds, for example vinylchloride, acrylic acid, acrylonitrile (which polymerizes with butadiene to form NBR), methacrylic acid and styrene, the latter compound polymerizing with butadiene to form SBR, as well as vinyl esters and various unsaturated aldehydes, ketones and ethers, e.g., acrolein, methyl isopropenyl ketone and vinylethyl ether. Also included are the various synthetic rubbers prepared by the homopolymerization of isoprene and the copolymerization of isoprene with other diolefins and various unsaturated organic compounds. Additionally, included are the synthetic rubbers such as 1,4-cis polybutadiene and 1,4-cis polyisoprene and similar synthetic rubbers such as EPDM. The preferred rubbers for use with the bis-amide linked rosin acid derivatives are natural rubber, polybutadiene, SBR and polyisoprene.
The rubber vulcanizates containing the bis-amide linked rosin acid derivatives may be used in the preparation of tires, motor mounts, rubber bushings, power belts, printing rolls, rubber shoe heels and soles, rubber floor tiles, caster wheels, elastomer seals and gaskets, conveyor belt covers, wringers, hard rubber battery cases, automobile floor mats, mud flaps for trucks, ball mill liners, and the like.
The bis-amide linked rosin acid derivatives may be used in a wide variety of proportions in the rubber and may be a substitute, in whole or part for conventional extender or process oils. By the term "extender or process oils", it is meant oils such as aromatic oils, naphthenic oils, paraffinic oils and the like as well as blends thereof. Specific examples of such oils include those largely composed of naphthenic and alkylated naphthenic hydrocarbons and mixtures thereof with various aromatic hydrocarbons. Such oils may be obtained from the high boiling fractions of the so-called naphthenic or mixed crude oils. They may comprise distillate fractions boiling above about 200° C. Suitable fractions are those at least 90 percent of which boil above about 250° C. as more volatile members may be lost during or after compounding and curing the rubber. Generally, the level of bis-amide linked rosin acid derivatives that may be added to the rubber composition may range from about 2 phr (parts per hundred rubber) to about 50 phr. Preferably the amount of bis-amide linked rosin acid derivatives that is added ranges from about 5 phr to about 35 phr.
Cure properties were determined using a Monsanto oscillating disc rheometer which was operated at a temperature of 150° C. and at a frequency of 11 hertz. A description of oscillating disc rheometers can be found in the Vanderbilt Rubber Handbook edited by Robert O. Babbit (Norwalk, Connecticut, R. T. Vanderbilt Company, Inc., 1978), pages 583-591. The use of this cure meter and standardized values read from the curve are specified in ASTM D-2084. A typical cure curve obtained on an oscillating disc rheometer is shown on page 588 of the 1978 edition of the Vanderbilt Rubber Handbook.
In such an oscillating disc rheometer, compounded rubber samples are subjected to an oscillating shearing action of constant amplitude. The torque of the oscillating disc embedded in the stalk that is being tested that is required to oscillate the rotor at the vulcanization temperature is measured. The values obtained using this cure test are very significant since changes in the rubber or the compounding recipe are very readily detected.
The following table reports cure properties that were determined from cure curves that were obtained for the two rubber formulations that were prepared. These properties include a torque minimum (Min Torque), a torque maximum (Max Torque), the total increase in torque (Delta Torque), minutes to 25% of the torque increase (t25 min.), and minutes to 90% of the torque increase (t90 min.).
Peel adhesion testing was done to determine the interfacial adhesion between various rubber formulations that were prepared. The interfacial adhesion was determined by pulling one compound away from another at a right angle to the untorn test specimen with the two ends being pulled apart at a 180° angle to each other using an Instron machine. The area of contact was determined from placement of a Mylar sheet between the compounds during cure. A window in the Mylar allowed the two materials to come into contact with each other during testing.
The following examples are presented in order to illustrate but not limit the present invention.
EXAMPLE 1
150 grams (0.5 mole) of tall oil rosin (crude abietic acid) with an acid number of 165 and 27 grams (0.25 mole) of p-phenylenediamine were added to 11 grams of toluenesulfonic acid in 100 ml of toluene. The mixture was added to a 3-neck, 1-liter flask equipped with a Dean-Stark trap, a pot thermometer and sealed with a nitrogen balloon. After 8 hours at a pot temperature of 240° C. with reflux, 11 ml of water was removed. Infrared spectroscopic analysis showed the disappearance of the acid function and formation of the bis-amide linked rosin acid derivative. The resulting heavy oil, after vacuum-oven drying at 100° C. for 8 hours, showed a high degree of tack and had a melting point just below 100° C.
EXAMPLE 2
Rubber compositions containing the materials set out in Table I were prepared in a BR Banbury using two separate stages of addition. The processing oils (naphthenic/paraffinic oil, bis-amide linked rosin acid derivative) were added to the Banbury during the first stage of mixing. The bis-amide linked rosin acid derivative was prepared in accordance with Example 1. Table II below sets out the cure behavior and vulcanizate properties for the control and the compound containing the bis-amide.
TABLE I______________________________________ Weight BanburyMaterial Parts Stage______________________________________Natural Rubber 40.00 1BUD 1207 ®.sup.(1) 60.00 1Carbon Black 50.00 1Antiozonant/Antioxidant 4.00 1Rosin/Fatty Acids 3.00 1Wax 1.50 1Zinc Oxide 3.00 1Tackifier 4.00 1Processing Oil.sup.(2) 5.00 1Sulfur/Accelerator 2.85 2______________________________________ .sup.(1) A high cis1,4-polybutadiene rubber commercially available from The Goodyear Tire & Rubber Company. .sup.(2) Naphthenic/paraffinic oil or bisamide linked rosin acid derivative.
TABLE II______________________________________Cure Behavior and Vulcanizate Properties______________________________________ Processing Oil Bis-Amide______________________________________Rheometer, 150° C.Max. Torque 34.3 35.5Min. Torque 8.1 8.6Delta Torque 26.2 26.9t90, minutes 20.8 21.1t25, minutes 8.0 8.2Stress StrainTensile Strength, MPa 10.9 10.1Elongation at Break, % 438 471300% Modulus, MPa 6.8 5.8Peel Adhesion, 95° C. 60 60To Itself, NewtonsZwick Rebound 67.7 64.9100° C., %Static Ozone.sup.(1) C3 B225% Strain, 48 hoursCyclic Ozone.sup.(2)104 hours (density/severity) 4/3 3/1152 hours Broken 4/3248 hours -- Broken______________________________________.sup.(1) Static0 = No cracking F = Complete FailureNumber of cracks of cracksA = very few 1 = small (hairline)(less than 1/4 surface)B = few 2 = medium(1/4 to 1/2 surface)C = moderate 3 = large(1/2 to 3/4 surface)D = heavy 4 - severe (open)(3/4 to all surface).sup.(2) Cycle D3395 - using a cycled ozone on/off procedureDensity Severity 0 = none 0 = none 1/2 = edge 1 = .01 in. 1 = 1/8 surface 3 = .03 in. 2 = 3/8 surface 5 = .10 in. 3 = 5/8 surface 10 = .25 in. 4 = 3/4 surface 12 = +.25 in.15 = broken
The bis-amide containing compound exhibits cure behavior, stress-strain properties and peel adhesion to itself similar to the control containing processing oil. The bis-amide containing compound exhibits improved static ozone resistance and superior cyclic oxone resistance when compared to the control. This result is unexpected but highly desirable incured rubber compositions. | The present invention relates to bis-amide linked rosin acid derivatives which are useful as a rubber additive. In one embodiment, the amide linked rosin acid derivative may serve as a total or partial replacement for antiozonants. The bis-amide linked rosin acids are prepared by reacting abietic acid and/or dehydroabietic acid with a diamine under amidation conditions. | 2 |
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of priority from U.S. Provisional Application Serial No. 60/400,345 filed Jul. 31, 2002.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates generally to a photochromic laminate that can be applied to polymeric surfaces or can be used by itself as a photochromic element. The invention also relates to a photochromic laminate that is capable of withstanding high temperatures and can be incorporated into plastic lenses by means of injection molding. The invention further relates to a photochromic laminate that exhibits dimensional stability and high-fidelity replication of an internal mold cavity and is suitable for making multi-focal lenses with segment lines.
[0004] 2. Description of the Related Art
[0005] Photochromic articles, particularly photochromic plastic materials for optical applications, have been the subject of considerable attention. In particular, photochromic ophthalmic plastic lenses have been investigated because of the weight advantage and impact resistance they offer over glass lenses. Moreover, photochromic transparencies, e.g. window sheets, for vehicles such as cars, boats and airplanes, have been of interest because of the potential safety features that such transparencies offer.
[0006] There are several existing methods to incorporate photochromic properties into plastic lenses. One method involves applying to the surface of a lens a coating containing dissolved photochromic compounds. For example, Japanese Patent Application 3-269507 discloses applying a thermoset polyurethane coating containing photochromic compounds on the surface of a lens. U.S. Pat. No. 6,150,430 also discloses a photochromic polyurethane coating for lenses.
[0007] Another method involves coating a lens with a base coating, then imbibing a solution containing photochromic compounds into the base coating material. The most commonly used base material is polyurethane.
[0008] However, the two methods described above, which involve coating the lens after it is molded, have significant shortcomings. For example, typically a coating of about 25 μm or more is needed to incorporate a sufficient quantity of photochromic compounds into the base in order to provide the desired light blocking quality when the compounds are activated. This relatively thick coating is not suited for application on the surface of a segmented, multi-focal lens because an unacceptable segment line and coating thickness nonuniformity around the segment line are produced and the desirable smooth surface quality is affected as illustrated at numerals 100 and 200 , respectively, in FIG. 1 b.
[0009] A third conventional method, applicable only to cast resin lenses, is referred to as “in-mass” technology. Photochromic compounds are first dissolved in a liquid lens resin material. The liquid resin is then cast and cured into a photochromic lens blank. The in-mass photochromic technology is primarily used in lenses with a smooth and continuous surface design, i.e., no segments. However, in-mass technology is not suitable for segmented, multi-focal lenses because the different segments have different thicknesses. When the photochromic compounds are activated the different thicknesses, i.e., segments, of the lens result in different visible light transmission.
[0010] The use of polycarbonate lenses, particularly in the United States, is widespread. The demand for sunglasses that are impact resistant has increased as a result of extensive outdoor activity. These lenses are produced by an injection molding process and insert injection molding is used to incorporate photochromic properties into the lenses. Insert injection molding is a process whereby a composition is injection molded onto an insert in the mold cavity. For example, as disclosed in commonly assigned U.S. Pat. No. 6,328,446, a photochromic laminate is first placed inside a mold cavity. Polycarbonate lens material is next injected into the cavity and fused to the back of the photochromic laminate, producing a photochromic polycarbonate lens. Because the photochromic function is provided by a thin photochromic layer in the laminate, it is practical to make photochromic polycarbonate lenses with any kind of surface curvature by the insert injection molding method.
[0011] Transparent resin laminates with photochromic properties have been disclosed in many patents and publications, for example, Japanese Patent Applications 61-276882, 63-178193, 4-358145, and 9-001716; U.S. Pat. No. 4,889,413; U.S. Patent Publication No. 2002-0197484; and WO 02/093235. The most commonly used structure is a photochromic polyurethane host layer bonded between two transparent sheets. Although the construction of photochromic polyurethane is known, photochromic laminates designed especially for making photochromic polycarbonate lenses through the insert injection molding method are unique.
[0012] Problems associated with conventional insert injection molding techniques in the manufacture of photochromic lens are polyurethane bleeding and poor replication of segment lines. “Bleeding” occurs from the deformation of the polyurethane layer during processing. In particular, bleeding occurs when the polyurethane layer melts and escapes from its position between the two transparent sheets of the laminate during the injection molding process. The inventors have discovered that bleeding most frequently results from an excess amount of polyurethane and from using too soft a material. The inventors have also discovered that poor replication of segment lines occurs when the layer of polyurethane is too thick and movement of the laminate occurs as pressure from the mold is applied. These two problems and the resultant multi-focal lens product with unacceptable segment line is illustrated at 300 in FIG. 1 a.
[0013] Therefore, the need exists to overcome the problems and shortcomings associated with existing polyurethane laminates having photochromic properties and methods of making these laminates. In particular, a need exists to reproducibly manufacturer very sharp, very clear segment lines in photochromic, multi-focal lenses. More particularly, a need exists to reproducibly manufacture photochromic, multi-focal lenses using the insert injection molding process that produces a lens with a sharp segment line and results in little or no bleeding.
BRIEF SUMMARY OF THE INVENTION
[0014] The need and shortcomings of the existing laminates and methods of manufacturing these laminates are met by the polyurethane laminate and method in accordance with the present invention.
[0015] It has been discovered that photochromic polycarbonate lenses of high optical quality, with or without segment line(s), can be economically produced from a photochromic laminate comprising a polyurethane layer of from about 5 μm to about 80 μm. The polyurethane may be a thermoplastic polyurethane or a thermoset polyurethane. In a preferred embodiment, the polyurethane is thermoset polyurethane. In addition, it has been discovered that depending on the type of polyurethane used, controlling the thickness of the photochromic layer and certain thermo-mechanical properties play an important role in producing very sharp, very clear segment lines.
[0016] It is an object of the present invention to provide an improved transparent resin photochromic laminate that can be used to produce plastic photochromic lenses with or without a segment, multi-focal optical design using insert injection molding.
[0017] It is a further object of the present invention to provide a photochromic, polyurethane laminate that exhibits dimensional stability and high-fidelity replication of an internal mold cavity.
[0018] It is a further object of the present invention to provide a photochromic, polyurethane laminate that resists the high temperatures and pressures associated with the injection molding process.
[0019] It is a further object of the present invention to provide a photochromic, polyurethane laminate that is resistant to bleeding.
[0020] It is a further object of the present invention to produce a photochromic, multi-focal lens with sharp segment lines.
[0021] These and other objects are achieved by the transparent resin laminate in accordance with the present invention. The present invention comprises a polyurethane layer including photochromic compounds having first and second sides, a front transparent resin sheet bonded to the first side of the polyurethane photochromic layer, and a back transparent resin sheet bonded to the second side of the polyurethane photochromic layer. The front and back transparent resin sheets may be bonded to the polyurethane layer with or without additional adhesive such as epoxies and the acrylate types. The front and back transparent resin sheets are preferably made of the same material as the lens base. That is, if the lens base material is polycarbonate, it is preferred to have polycarbonate resin sheets bonded to the polyurethane photochromic layer. If the lens base material is cellulose acetate butyrate, then it is preferred to have cellulose acetate butyrate resin sheets bonded to the polyurethane photochromic layer. Any clear, transparent plastic resin may be used for the base and resin sheets, for example, polysulfones, polyacrylates and polycycloolefins. The term “front resin sheet” means that the resin sheet is facing the mold cavity to duplicate the front (convex) surface of the whole lens. By the term “back”, we mean that the resin sheet is facing the lens base. The term “lens base” meant the portion of the lens that is molded onto the laminate to form the main portion of the lens.
[0022] The objects of the present invention are further achieved by the following technical aspects: (i) a thermoset or thermoplastic polyurethane; (ii) a thickness of the polyurethane photochromic layer of from about 5 μm to about 80 μm; (iii) in thermoplastic polyurethanes, a melting point of from about 150° C. to about 250° C. and an number average molecular weight of from about 150,000 to about 500,000; (iv) a material for the front transparent resin sheet that has a lower glass transition temperature or softening temperature than the back resin sheet.
[0023] It has been found that a polyurethane photochromic layer thickness of preferably from about 5 μm to about 80 μm and most preferably from 25 μm to about 50 μm is the best compromise between being thick enough to get enough loading of photochromic compounds in the polyurethane for the desired light blocking at the activated state and being thin enough to eliminate polyurethane bleeding and give the desired sharp replication of the mold cavity.
[0024] The photochromic laminate of this invention can be directly used in the insert injection molding process. For lenses having a high diopter front (convex) surface, it is preferred to pre-form the laminate into wafers, or laminates pre-formed into spherically curved shapes, with the given diopter.
[0025] Although the photochromic laminate according to this invention is especially suitable for making photochromic polycarbonate lenses through the insert injection molding process, other non-limiting uses include photochromic transparencies such as goggles and face shields.
BRIEF DESCRIPTION OF THE DRAWINGS
[0026] [0026]FIG. 1 a is a cross sectional view of a multi-focal lens illustrating the problems encountered in the prior art insert injection molding processes when a photochromic laminate is too thick.
[0027] [0027]FIG. 1 b is a cross sectional view of a multi-focal lens illustrating the lack of a sharp segment line and coating thickness nonuniformity when a photochromic material is applied onto multi-focal lenses.
[0028] [0028]FIG. 2 is a cross sectional view illustrating details of the photochromic polyurethane laminate in accordance with the present invention.
[0029] [0029]FIG. 3 a is a cross sectional view illustrating the insert injection molding process of the utililizing the laminate of the present invention.
[0030] [0030]FIG. 3 b is a cross sectional view of a multi-focal lenses illustrating the sharp segment line produced utilizing the laminate of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0031] Referring to FIG. 2, there is shown an element 10 in accordance with the present invention. The element 10 comprises a transparent photochromic laminate 12 including a polyurethane layer 14 having dissolved, dispersed or suspended therein a photochromic compound(s, which provides the photochromic functionality, and two transparent resin sheet layers 18 , 20 bonded to each side of the polyurethane photochromic layer, with or without additional adhesive. The front and back 18 , 20 transparent resin sheets are preferably made of the same material as the lens base. That is, if the lens base material is polycarbonate, it is preferred to have polycarbonate resin sheets bonded to the polyurethane photochromic layer 14 . If the lens base material is cellulose acetate butyrate, for example, then it is preferred to have cellulose acetate butyrate resin sheets bonded to the polyurethane photochromic layer 14 . Any clear, transparent plastic resin may be used for the lens material and resin sheets, for example, polycarbonates, cellulose esters, polysulfones, polyacrylates, polyamides, polyurethanes, copolymers of acrylates and styrenes and combinations of any of the foregoing. The term “front resin sheet” means that the resin sheet is facing the mold cavity to duplicate the front (convex) surface of the whole lens. By the term “back resin sheet,” we mean that the resin sheet is facing the lens base. The term “lens base” meant the portion of the lens that is molded onto the laminate to form the main portion of the lens.
[0032] Suitable photochromic compounds in the context of the invention are organic compounds that, in solution state, are activated (darken) when exposed to a certain light energy (e.g., outdoor sunlight), and bleach to clear when the light energy is removed. They are selected from the group consisting essentially of benzopyrans, naphthopyrans, spirobenzopyrans, spironaphthopyrans, spirobenzoxzines, spironaphthoxazines, fulgides and fulgimides. Such photochromic compounds have been reported which, for example, in U.S. Pat. Nos. 5,658,502, 5,702,645, 5,840,926, 6,096,246, 6,113,812, and 6,296,785; and U.S. patent application Ser. No. 10/038,350, all commonly assigned to the same assignee as the present invention and all incorporated herein by reference.
[0033] Among the photochromic compounds identified, naphthopyran derivatives are preferred for optical articles such as eyewear lenses. They exhibit good quantum efficiency for coloring, a good sensitivity and saturated optical density, an acceptable bleach or fade rate, and most importantly good fatigue behavior. These compounds are available to cover the visible light spectrum from 400 nm to 700 nm. Thus, it is possible to obtain a desired blended color, such as neutral gray or brown, by mixing two or more photochromic compounds having complementary colors under an activated state.
[0034] More preferred are naphtho[2,1b]pyrans and naphtho[1,2b]pyrans represented by the following generic formula:
[0035] Substituents on various positions of the aromatic structure are used to tune the compounds to have desired color and fading rate, and improved fatigue behavior. For example, a photochromic dye may contain a polymerizable group such as a (meth)acryloyloxy group or a (meth)allyl group, so that it can be chemically bonded to the host material through polymerization.
[0036] The quantity of photochromic compound(s) incorporated into the polyurethane layer 14 of the present invention is determined by the desired light blockage in the activated state and the thickness of the polyurethane layer 14 itself. The preferred outdoor visible light transmission of sunglasses is preferably between 10% to 50%, more preferably between 10% to 30%, most preferably between 10% to 20%. Preferably, the amount of total photochromic substance incorporated into or applied on the polyurethane layer may range from about 0.05 wt. % to about 5 wt. % and more preferably from about 0.5 wt. % to about 3.0 wt. %. If the thickness of the polyurethane layer is 80 μm, between about 0.5 wt. % to about 1 wt. % of photochromic compound(s) is needed to achieve a outdoor light transmission of between 10% to 20%. The amount of photochromic compound(s) needed is inversely proportional to the thickness of the polyurethane layer. In other words, to achieve the same outdoor light transmission the thicker the polyurethane layer, the lower the concentration of photochromic compound(s) needed. The concentration of the photochromic compound(s) also depends on the color intensity of the photochromic compound(s) at the activated state.
[0037] According to the first technical aspect of the present invention, a desired thickness of from about 5 μm to about 80 μm is required for the photochromic polyurethane layer in order to eliminate or reduce bleeding to an acceptable level in production, and to produce an acceptable segment line replication for segmented multi-focal lenses. As discussed previously, both poor segment line replication and polyurethane bleeding relate to the deformation of the polyurethane layer. During the injection molding cycle, temperatures of from about 250° F. to about 400° F., or from about 121° C. to about 204° C., may be reached. Assuming that the polyurethane material does not melt during the molding cycle, it is still significantly softer than the polycarbonate or other transparent resin sheet materials. According to Lindley (Lindley, P. B., 1978, “Engineering Design With Natural Rubber,” Malaysian Rubber Producer's Research Association, Hertford, GB), the apparent compression modulus, E c , of a thin rubbery disc can be estimated by the following semi-empirical equation:
E c =3 G (1+2 S 2 )
[0038] where G is the shear modulus, and S is the shape factor of the disc:
S=D /(4 h o )
[0039] where D is the diameter of the disc, and h 0 is the thickness of the disc. When the normal compression deformation of the polyurethane layer is small, the simple Hookean formula can be used to estimate its normal strain, ε′.
ε=σ/ E c
[0040] where σ is the compression pressure. Thus, reducing the thickness of the polyurethane layer will significantly increase its stiffness, and decrease its compression deformation. Consequently, for a given mold clamping, the front transparent resin sheet will be pushed harder against the mold cavity to give better replication of the surface and segment line. Similarly, because polyurethane is nearly incompressible, decreasing the compression deformation of the polyurethane layer means less material bulging laterally, that is, less bleeding.
[0041] A photochromic laminate having a polyurethane layer of from about 5 μm to about 80 μm in accordance with the present invention may be produced through processes known to those skilled in the art. Depending on the nature of the starting material to the polyurethane, processes such as casting—lamination (also referred to in the art as coating—lamination), and extrusion—lamination may be used. The polyurethane layer utilizing a thermoplastic polyurethane (TPU) can be obtained by either casting or extrusion. To cast the TPU, selected photochromic compounds and other necessary additives are first dissolved in a suitable solvent or in a mix of solvents to produce a solution. The solution is then cast on a release liner, dried, and transferred to a first transparent resin sheet through hot-lamination. The second resin sheet is laminated next. For most TPUs, hot-lamination at a temperature close to the softening point should provide sufficient adhesion so that no additional adhesive is needed.
[0042] The polyurethane solution may be cast with methods known to those skilled in the art, including knife-over-roll, reverse-roll, gravure, etc. If the solvent selected to dissolve the polyurethane does not whiten the resin sheet, a direct cast on the resin sheet may be employed.
[0043] Examples of suitable solvents that may be used to dissolve polyurethanes include cyclohexane, toluene, xylene and ethyl benzene, esters such as ethyl acetate, methyl acetate, isopropyl acetate, n-propyl acetate, isobutyl acetate, n-butyl acetate, isoamyl acetate, methyl propionate and isobutyl propionate, ketones such as acetone, methylethyl ketone, diethyl ketone, methylisobutyl ketone, acetyl acetone and cyclohexyl ketone, ether esters such as cellosolve aetate, diethylglycol diaetate, ethyleneglycol mono n-butylether acetate, propylene glycol and monomethylether acetate, tertiary alcohols such as diacetone alcohol and t-amyl alcohol and tetrahydrofuran. Ethyl acetate, methyl ethyl ketone, tetrahydrofuran, toluene and combinations thereof are preferable.
[0044] When utilizing the solution casting—lamination process, it is desirable to keep solvent retention in the polyurethane layer and the resin sheet layers at a minimum level. The solvent retention should preferably be less than 3 wt. %, more preferably less than 2 wt. %, and most preferably less than 1 wt. %. Conventional methods such as hot air dryers may be used to evaporate the solvent before lamination.
[0045] In an alternative process, the photochromic layer from a TPU may be extruded and laminated between the two transparent resin sheets. The photochromic compounds and other additives may be incorporated into the polyurethane during the resin synthesis stage or melt-mixed prior to extrusion.
[0046] As will be described in detail, a thermoset polyurethane is preferably used to make the photochromic polyurethane layer in the laminate of the present invention.
[0047] Japanese Patent Application 2002-196103 discloses a process that may be used to produce the transparent resin laminate with photochromic property in accordance with the present invention. A photochromic organic compound and other additives are mixed, with given weight percentage loading, with a polyurethane prepolymer while stirring. The prepolymer may be diluted with an organic solvent selected from the aforementioned solvent group to aid in the solubility of the photochromic compound and additives. A curing agent is added in an I/H ratio of isocyanate group (I) to hydroxyl group (H) of from about 0.9 to 20 and preferably from about 1 to 10. The mixture is stirred to form a solution. It is suitable that the polymer concentration in the solution thus obtained is from about 40 wt. % to about 95 wt. %. The solution is coated on one side of a transparent resin sheet with a coating thickness of from about 5 μm to 500 μm. The coating is then substantially heat-dried at from about 40° C. to about 100° C. for 5 to 60 minutes in order to evaporate any solvent remaining on the coated surface. The second transparent resin sheet is laminated to the coated surface of the first resin sheet in a sandwich form. The laminate sheet thus obtained is heated at a temperature of from about 60° C. to about 140° C. for 2 hours to 1 week to cure the polyurethane prepolymer containing the curing agent, whereby a transparent synthetic resin laminate is obtained.
[0048] The thickness variation of the photochromic polyurethane layer should be controlled in order to produce a uniform light blockage at the activated state. A thickness variation of less than 20% over the width of the laminate is required and preferably less than 15% and more preferably less than 10%.
[0049] According to the second technical aspect of the laminate in accordance with the present invention, if a thermoplastic polyurethane material is used for the photochromic layer, a melting point of from about 150° C. to about 250° C. and a number average molecular weight of from bout 150,000 to about 500,000 is preferred. More preferably the number average molecular weight of the thermoplastic polyurethane will be from about 150,000 to about 350,000. During the mold cavity filling period, melted polycarbonate is injected into the mold, and the polyurethane layer is subjected to temperatures from 120° C. to 2000° C. It is necessary for the particular polyurethane selected to withstand these high temperatures and to maintain the mold cavity filled shape. If the polyurethane melts during the filling period, substantial bleeding will occur. A laminate in accordance with the melting point and molecular weight characteristics of present invention will produce a bleed-free and thin segment line photochromic lens. It is desirable that the thermoplastic polyurethane selected has a higher melting point than the mold temperature. Because a thermoset polyurethane will not melt before decomposition, a thermoset polyurethane photochromic layer in the laminate of this invention is most preferred. As mentioned previously, if a thermoplastic polyurethane is used that does not have the desired melting point and molecular weight characteristics the normal compression deformation of the polyurethane layer will prevent the exact replication of the mold cavity surface; and if a segmented multi-focal lens is being produced, a thick segment line will develop as depicted in FIG. 1 a.
[0050] Thermoplastic polyurethanes may be made from a diisocyanate, a polyol, and a chain extender. The polymerization can be carried out in one-pot fashion, that is, all starting materials are initially added into the reaction vessel. However, a prepolymer approach is more preferred in order to yield a high molecular weight polyurethane. In this preferred approach, a polyurethane prepolymer is first obtained by reacting a stoichiometrically in excess diisocyanate with a polyol. A chain extender of diol or diamine is then mixed with the prepolymer. The ratio of hydroxyl or amine groups to isocyanate groups in the mixture is close to unity, but may vary from 1.0 to 1.2.
[0051] A thermoset polyurethane may also be obtained with a prepolymer approach as in making thermoplastic polyurethanes. Thermoset (i.e., cross-linking) may be achieved by using a curing agent that has a functionality higher than 2, e.g., a triol or mix of a diol and a triol, or by having an significant excess of diisocyanate. The excess isocyanate will form cross-linking points with urethane and urea groups to prevent the melting of the polyurethane.
[0052] The polyol is selected from a group consisting of polyester polyol, polyether polyol, and polycarbonate polyol. It is preferable to use polycaprolactone polyol having an average molecular weight from 300 to 3,000, and preferably from 1,000 to 2,000. The resulting polyurethane prepolymer will have an average molecular weight from 1,500 to 6,000.
[0053] The diisocyanate component is preferably an aliphatic diisocyanate. The aliphatic diisocyanate is selected from the group consisting of 1,4-tetramethylene diisocyanate, 1,6-hexamethylene diisocyanate, 2,2,4-trimethyl-1,6-hexamethylene diisocyanate, 1,12-dodecamethylene diisocyanate, cyclohexane-1,3- and -1,4-diisocyanate, 1-isocyanato-2-isocyanatomethyl cyclopentane, 1-isocyanato-3-isocyanatomethyl-3,5,5-trimethyl-cyclohexane (isophorone diisocyanate or IPDI), bis-(4-isocyanatocyclohexyl)-methane, 2,4′-dicyclohexylmethane diisocyanate, 1,3- and 1,4-bis-(isocyanatomethyl)-cyclohexane, bis-(4-isocyanato-3-methylcyclohexyl)-methane, .alpha.,.alpha.,.alpha.′,.alpha.′-tetramethyl-1,3- and/or -1,4-xylylene diisocyanate, 1-isocyanato-1-methyl-4(3)-isocyanatomethyl cyclohexane, 2,4- and/or 2,6-hexahydrotoluylene diisocyanate, and mixtures thereof. Bis-(4-isocyanatocyclohexl)-methane is the preferred diisocyanate in occurrence with the method of the present invention.
[0054] The curing agent may be a polyol selected from the group consisting of polyurethane polyol, polyether polyol, polyester polyol, acryl polyol, polybutadiene polyol and polycarbonate polyol. Polyurethane polyol with an end-group hydroxyl obtained from specific isocyanate and specific polyol is preferable. The number average molecular weight of the curing agent is preferably from about 500 to about 5,000, more preferably from about 1,500 to about 4,000, and most preferably from about 2,000 to about 3,000.
[0055] The curing agent may also be a low molecular weight diol or triol. Suitable diols and triols with number average molecular weights from about 60 to about 500 that may be used in accordance with the present invention include the polyhydric alcohols listed above to form polyester polyols. Triols such as trimethylolpropane (TMP), glycerine or low molecular weight polypropylene oxide polyols prepared from these or similar trifunctional starters are preferred.
[0056] The curing agent may also be a non-yellowing aliphatic or aromatic diamine or triamine.
[0057] Photochromic compounds, additives such as a light stabilizer and an antioxidant, and a curing catalyst are added into the polyurethane prepolymer before curing.
[0058] Additives such as antioxidants and light stabilizers are incorporated into the polyurethane layer in order to improve the fatigue resistance of the photochromic compounds. Hindered amines are usually used as light stabilizers, and hindered phenols are usually used as antioxidants. Preferred hindered amine light stabilizers include, bis(1,2,2,6,6-pentamethyl-4-piperidinyl)-sebacate, or a condensation product of 1,2,2,6,6-pentamethyl-4-piperidinol, tridodecyl alcohol and 1,2,3,4-butanetetra caboxylic acid as tertiary hindered amine compounds. Preferred phenol antioxidants include, 1,1,3-tris(2-methyl-4-hydorxy—5-t-butylphenyl)butane, tetrakis-[methylene-3-(3′,5′-di-t-butyl-4′-hydroxy-phenyl)propionate]methane, and 1,3,5-tris(3,5-di-t-butyl-4-hyroxybenzyl)-1,3,5-triazine-2,4,6-(1H,3H,5H)-trione. Phenol antioxidants that contain 3 or more hindered phenols are preferable.
[0059] According to a third technical aspect of the present invention, the transparent resin sheets of a photochromic laminate may be made from the same resin material as the base lens or may be different. Preferably, the resin material is thermally fusible to the lens base material so that a photochromic lens will have its photochromic laminate tightly integrated with the lens base when produced with the insert injection molding process as can best be seen in FIG. 3 b at 40 . Thus, it is preferred to have the same or substantially similar materials for both the lens base and the transparent resin sheets. It also is desirable to have the front resin sheet softer than the back resin sheet under the mold temperature to provide better replication of the mold cavity surface. By the term “softer,” we mean that the front sheet resin has a lower glass transition temperature or softening temperature or melt viscosity or molecular weight than the back sheet resin, and/or that the front sheet resin is thinner than the back resin sheet. It is also preferred to have the lens base resin softer than the back sheet resin so that the rigidity of the laminate can be maintained during the molding process. When polycarbonate comprises the sheet resin, for example, the molecular weight of the back sheet resin should be 25,000 or greater and the molecular weight of the front sheet resin and the injected resin should be from 15,000 to 25,000.
[0060] Suitable sheet resin materials include polycarbonate, polysulfone, cellulose acetate butyrate (CAB), polyacrylates, polyesters, polystyrene, copolymer of an acrylate and styrene, blends of compatible transparent polymers. Preferred resins are polycarbonate, CAB, polyacrylates, and copolymers of acrylate and styrene. A polycarbonate-based resin is particularly preferred because of high transparency, high tenacity, high thermal resistance, high refractive index, and most importantly, compatibility with the polycarbonate lens base material. A typical polycarbonate based resin is polybisphenol-A carbonate. In addition, examples of the polycarbonate based resin include homopolycarbonate such as 1,1′-dihydroxydiphenyl-phenylmethylmethane, 1,1′-dihydroxydiphenyl-diphenylmethane, 1,1′-dihydroxy-3,3′-dimethyldiphe-nyl-2,2-propane, their mutual copolymer polycarbonate and copolymer polycarbonate with bisphenol-A.
[0061] While the thickness of a transparent resin sheet is not particularly restricted, it is typically 2 mm or less, and preferably 1 mm or less but not less than 0.025 mm.
[0062] Although the photochromic laminate according to the present invention is especially suitable for making photochromic polycarbonate lenses through the insert injection molding process described in commonly assigned U.S. Pat. No. 6,328,446, it can also be used as-is for other photochromic transparencies such as goggles and face shields. The photochromic laminate may also be incorporated into other types of eyewear lenses such as cast resin lenses. In the case of cast resin lenses, the laminate is usually formed as a curved wafer having a spherical surface. The wafer can then be integrated with the lens base material by insert casting as described in U.S. Pat. No. 5,286,419.
[0063] Referring to FIGS. 3 a and 3 b , to produce a photochromic polycarbonate lens 22 with the photochromic layer 14 of the present invention utilizing an insert injection molding process, photochromic discs are cut out of the photochromic laminate. The size of the discs is defined by the injection molding lens cavity 26 . The cut can be made in a number of ways, including by rolling knife cutter, reciprocal stamping cutter, straight-edge cutting knife moved translationally along a cut-line, a rotary or swing die traversed along a line or by laser cutter.
[0064] The discs are then formed into wafers of a given diopter. The base curve diopter of the wafers is determined by the convex side curvature of the finished photochromic lenses. The forming process may be performed thermally with or without pressure or vacuum. It is convenient to utilize a platen having a forming surface that corresponds at least substantially or precisely to, the predetermined curvature of the convex side of the lens to be formed. This permits the convex side of the thermoformed lens blank to have substantially or precisely the refractive power desired in the finished lens and avoids the need to surface or grind the convex side of the lens blank. The temperature for forming will vary with the material of the transparent resin sheets. In general, the thermoforming temperature is close to but lower than the glass transition temperature of the resin material. For example, a suitable forming temperature for the photochromic laminate with polycarbonate resin sheets will be from about 125° C. to 150° C. Often it will be beneficial to preheat the blank, for example, in the case of polycarbonate sheets, to a temperature from about 80° C. to 120° C. for 5 to 20 minutes.
[0065] The formed wafer 28 is then placed in the mold cavity 26 and lens base resin material 30 is injection molded on the back of the wafer 28 as follows.
[0066] Once the formed wafer has been placed into the mold cavity 26 , the two mold halves 34 , 36 close and molten base lens resin material 30 is injected into the mold through gate 32 . The combined action of high temperature from the molten resin and high pressure from the injection screw confirm the wafer 28 to the surface of the mold cavity 26 , which results in the finished product, a photochromic lens 22 having sharp segment lines 32 .
[0067] After a photochromic lens is made, the front layer may be coated with functional coatings such as with an abrasion resistant coating, antireflective coating, and/or an anti-fog hard coating.
[0068] The photochromic polyurethane laminate in accordance with the present invention will now be illustrated with reference to the following examples, which are not to be construed as a limitation upon the scope of the invention in any way. In the examples, all values are expressions of weight %. CR49 and CR59 are tradenames of photochromic dyes available from Corning Incorporated (Corning, N.Y.), Uvinul® 3040 available from BASF (Mount Olive, N.J.) and Tinuvins® available from CIBA (Tarrytown, N.Y.) are UV absorbers and stabilizers.
EXAMPLE 1
[0069] A photochromic polyurethane laminate having two 300 μm thick polycarbonate sheets bonded to a 38 μm cross-linked polyurethane layer was made Mitsubishi Gas Chemicals (Tokyo, Japan). The laminate was cut into a 76 mm disc and used to make a segmented multi-focal lens. After the insert injection molding process with common molding parameters, the finished lens has an acceptable thin, crisp segment line. No polyurethane bleeding from the laminate is observed.
Example 1A
[0070] A photochromic polyurethane laminate as in Example 1, having two 300 μm thick polycarbonate sheets bonded to a 51 μm cross-linked polyurethane layer, was cut in a 76 mm disc and used to make a segmented multi-focal lens. After the insert injection molding process with common molding parameters, the finished lens had an acceptable thin, crisp segment line. No polyurethane bleeding from the laminate was observed.
Example 1B
[0071] A photochromic polyurethane laminate as in Example 1, having two 300 μm thick polycarbonate sheets bonded to a 76 μm cross-linked polyurethane layer, was cut into a 76 mm disc and used to make a segmented multi-focal lens. After the insert injection molding process with common molding parameters, the finished lens had an acceptable thin segment line. Slight, but still acceptable, polyurethane bleeding from the laminate is observed.
COMPARISON EXAMPLE 1
[0072] A photochromic polyurethane laminate as in Example 1, having two 300 μm thick polycarbonate sheets bonded to a 102 μm cross-linked polyurethane layer was cut into a 76 mm disc and used to make a segmented multi-focal lens. After the insert injection molding process with common molding parameters, the finished lens had an unacceptable thick segment line. Polyurethane bleeding from the laminate was observed.
EXAMPLE 2
[0073] A 5% polyurethane solution in tetrahydrofuran is obtained from a thermoplastic polyurethane having a number average molecular weight of 260,000. To the solution are also dissolved 3.0% of a gray photochromic dye, 2.0% of Tinuvin® 144, and 2.0% of Tinuvin® 765. The solution is cast with a doctor blade on a silicone release liner. The cast film is dried at 60° C. for 10 minutes on a hot plate and then 100° C. for another 30 minutes in a hot air dryer. The dried film is transfer-laminated to two 380 μm thick sheets of polycarbonate (GE, New York, N.Y.) on a hot-roll laminator at 130° C.
[0074] The laminate had a polyurethane layer of 25 μm thick. It was cut into a 76 mm disc and used to make a segmented multi-focal lens. After the insert injection molding process with common molding parameters, the finished lens had an acceptable thin, sharp, crisp segment line. No polyurethane bleeding from the laminate was observed.
EXAMPLE 3
[0075] The procedure of Example 2 was followed, except the polyurethane had a number average molecular weight of 70,000 and a 20% solution was obtained. The photochromic polyurethane layer was 25 μm thick. The finished lens had a thick segment line that was not acceptable. Polyurethane bleeding from the laminate was observed.
COMPARISON EXAMPLE 3
[0076] The same polyurethane material as Example 2 was extruded into a 178 μm thick film. The polyurethane also contained the following additives: CR49 0.66%, CR59 0.10%, Uvinul® 3040 0.30%, Tinuvin® 144 2.00%, Tinuvin® 765 2.00%.
[0077] Two sheets of 380 μm thick polycarbonate (GE) were bonded to the two sides of the polyurethane film through a vacuum lamination process. The laminate so obtained was formed into a wafer of 5.7 diopter. The wafer was used to make a segmented multi-focal lens. After the insert injection molding process with common molding parameters, the finished lens had a thick segment line that was not acceptable. Sever polyurethane bleeding was also observed.
EXAMPLE 4
[0078] To 10 g of Hysole (Loctite) U-10FL urethane adhesive resin are dissolved 1.5% of a gray photochromic dye, 2.0% of Tinuvin® 144, and 2.0% of Tinuvin® 765. 9.1 g of Hysol® (Loctite) U-10FL urethane adhesive hardener is mixed in to form a uniform liquid adhesive. The solution is used to laminate a 380 μm thick polycarbonate sheet to a 300 μm thick poly(methyl methacrylate) (PMMA) sheet on a roll laminator. The adhesive is allowed to cure at room temperature overnight, then is post cured at 65° C. for 10 hours. The glass transition temperatures are 150° C. and 100° C. for the polycarbonate and PMMA, respectively.
[0079] The photochromic polyurethane laminate obtained is subjected to insert injection molding to make a segmented multi-focal lens. The PMMA sheet faces the front mold cavity surface. An optical quality polycarbonate resin available from GE (New York, N.Y.) is used as the injection lens material. With molding conditions know to those skilled in the art, the PMMA sheet replicates the cavity well, and the finished photochromic lens has a thin and acceptable segment line.
[0080] The foregoing detailed description of the preferred embodiments of the invention has been provided for the purposes of illustration and description. They are not intended to be exhaustive or to limit the invention to the precise embodiments disclosed. Many modifications and variations will be apparent to practitioners skilled in the art to which this invention pertains. The embodiments were chosen and described in order to best explain the principles of the invention and its practical application, thereby enabling others skilled in the art to understand the invention for various embodiments and with 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. | A photochromic polyurethane laminate that is constructed to solve certain manufacturing difficulties involved in the production of photochromic lenses is disclosed. The photochromic laminate includes at least two layers of a transparent resinous material and a photochromic polyurethane layer that is interspersed between the two resinous layers and which contains photochromic compounds. The photochromic layer has a thickness of from 5 μm to 80 μm. The photochromic host material may be a thermoset or thermoplastic polyurethane. A laminate of this construction can be conveniently incorporated into a plastic lens through an insert injection molding process. | 1 |
GOVERNMENT SPONSORSHIP
This invention was made with Government support under PHS Grant No. AI82687 awarded by the National Institutes of Health. The Government has certain rights in the invention.
FIELD OF INVENTION
This invention relates to a novel in vitro method of testing antiviral activity of various agents. More specifically, it describes a method of testing effectiveness of anti-papillomavirus agents which act early in the infection process. The method is useful in testing effectiveness of existing and potential antiviral drugs, in particular, future drugs directed to treatment of human papilloma virus infections.
BACKGROUND OF THE INVENTION
Testing of the antiviral effectiveness of the new and existing agents against human papillomavirus are still performed in the in vivo testing involving use of laboratory animals and human subjects. These studies are expensive, time consuming and altered by individual differences among subjects.
A demonstration of efficacy prior to in vivo animal model testing would limit the candidate in vivo agents to the ones with increasing potential for in vivo effectiveness. This is especially important for those newer, more speculative agents for which purer antiviral effects are lacking. In vitro demonstration of efficacy would support a decision for expensive testing in animal model systems. In vitro studies are also useful for exploring drug-virus interactions which are awkward or infeasible in whole animal systems. In vitro testing offers the following advantages: 1) preliminary data on efficacy; 2) rapid turn around time; 3) economy; 4) ability to precisely control environmental conditions; 5) elimination of pharmacokinetics and variability of whole animal systems; and 6) small amounts of drugs are required.
Unfortunately, there are no established systems for in vitro papillomavirus testing. There have been some recent, encouraging developments, elsewhere and in our laboratory. Broker's laboratop/has recently suggested that the xenograft system, which we originated, might be useful for antiviral testing (S. Dollard, et al., 1992, Gene Dev., 6:1131-1142).
In that one approach, fragments of HPV-11 infected human foreskin tissue is excised from the papillomatous cysts, growing beneath the renal capsule, and the fragments are placed onto a collagen gel "raft" culture. HPV-11 replication continues in the tissue fragment, as cells migrate laterally across the surface of the gel. We have explored the use of this system as a possible target for antiviral testing, and we have found that there is a high degree of regional variability in the extent of cell migration, tissue growth, and HPV-11 replication. We do not believe that this in vitro system is sufficiently consistent or precise to form a basis for tests. Further, since preliminary xenografts are required, the cost of the test includes their preliminary growth for three months, so some of the theoretical advantages of in vitro tests, economy and rapid turn-around are lacking.
Another in vitro system with potential was recently described by Laimins'group (Meyers, et al., 1992, Science, 257:971-973). In this system, human cervical cells, bearing HPV-31b episomal DNA are placed on collagen gel raft cultures and biosynthesis of complete virions occurs in the differentiating cells. It seems likely that this system may also be affected by regional variability.
Many of the disadvantages of the prior art methods of testing antiviral activity are overcome by the method of the present invention which precisely measures antiviral activity without the interferences of the regional variability, since the cell cultures are evenly dispersed monolayers.
SUMMARY OF THE INVENTION
In accordance with the present invention, a new in vitro method of testing of the antiviral activity of the potential agents in the initial stages of papillomavirus infection is presented.
In our laboratory, we have recently developed a monolayer cell culture system in which we have conducted antiviral testing. The monolayer is a uniform cell sheet with no regional variability. The system can use, alternatively, two rabbit epithelial cell lines: RK-13, derived from domestic rabbit kidney, and SF1Ep, derived from cottontail epidermis. The cells are planted in vitro, infected with cottontail rabbit papillomavirus CRPV virion, and this is soon followed by a wave of CRPV DNA replication and mRNA synthesis, probably ORFs E6 and E7. Under these conditions, the epithelial cells do not complete cytodifferentiation, a requisite for complete virion synthesis, so the papillomavirus infection is abortive, and the CRPV DNA is lost after 3-5 passages. However, only a few days post-infection is sufficient for antiviral testing.
Testing of the antiviral activity involves exposing cells to the various amount of the agent and measuring the effect on the level of CRPV transcription and cell proliferation/viability.
Our studies showed that CRPV infection of an established cottontail epidermal cell line (Sf1Ep) resulted in the production of CRPV-specific transcripts without concomitant morphological transformation (M. Angell, et al., J. Vir. Meth., 1992, 39:207-216). The most abundant transcripts corresponded in size to those of the E6 and E7 open reading frames (ORFs) which are also among the most abundant in domestic and cottontail rabbit papillomas. CRPV RNA production was both time and dose-dependent with RNA production diminishing with decreasing viral dose and increasing culture passage. Infected cultures contained episomal CRPV DNA which did not appreciably change in abundance with time but was significantly reduced with culture passage. All features of in vitro infection, especially RNA production, were inhibited by CRPV-neutralizing but not HPV-11-neutralizing monoclonal antibodies. Much of this inhibition could be attributed to a blockage of vital penetration as indicated by the reduction of CRPV DNA within virus-neutralized cultures. Our results indicated that although CRPV infection of SflEp cells was abortive, it serves as a useful model for analysis of early infection events.
Substituting the neutralizing antibody with an antiviral agent has proven to be a useful way of measuring the effectiveness of the antiviral agents and formed the basis for the novel method of testing the antiviral activity of unknown agents.
OBJECTS OF THE INVENTION
An object of this invention is to provide a novel method of in vitro testing of the antiviral activity of potential antiviral agents.
This and other objects and advantages of the invention over the prior art and a better understanding of its use will become readily apparent from the following description and are particularly delineated in the appended claims.
DESCRIPTION OF THE DRAWINGS
FIG. 1. Northern hybridization of CRPV-infected Sf1Ep cultures. Each sample represents 10 micrograms of total cellular RNA. Samples represent infected cultures days 1-7 after infection as well as cultures passaged (1:2 split every 3rd day) 3, 5 or 7 times after infection (ppl). Cottontail and NZW (A0100) represent RNA isolated from a CRPV-infected cottontail rabbit earskin papilloma cyst and New Zealand White (domestic) rabbit papilloma respectively. Mock indicates RNA isolated from mock infected Sf1Ep cells. Transcript sizes were based on the migration of RNA standard ladders.
FIG. 2. Detection of CRPV DNA within infected Sf1Ep cultures. Each sample o represents 5 micrograms of total cellular DNA from cultures depicted in FIG. 1. All samples were digested with Sall. Full-length CRPV isolated from pLA2-CRPV was used to reconstruct 1, 10, and 100 copies per diploid genome equivalent (6.55, 65.5, 655 pg respectively). NZW (A0100) and mock represent DNA isolated from a New Zealand White (domestic) rabbit papilloma, and mock-infected cultures, respectively.
FIG. 3. Northern hybridization of total cellular RNA (10 μg) from Sf1Ep cultures infected with ten fold dilutions of CRPV. Cultures received 200 μl, 20 μl or 2 μl of CRPV stock in 2 ml total volume of media (10 -1 , 10 -2 , or 10 -3 respectively) Cottontail and NZW (A0100) represent RNA isolated from a CRPV-infected cottontail rabbit earskin papilloma cyst and New Zealand White (domestic) rabbit papilloma, respectively. Mock indicates RNA isolated from mock infected Sf1Ep cells. Marker positions indicate the migration of RNA standard ladders.
FIG. 4. Rabbit papilloma growth resulting from infection with serial dilutions of CRPV stock. Measurements are expressed as the geometric mean diameter of the lesion. Papillomas were generated with 50 μl of 10-fold serial dilutions of CRPV as in Materials and Methods.
FIG. 5. Northern analysis of cellular RNA (10 μg) isolated from Sf1Ep cultures infected with CRPV preincubated 1 hour with: lane A) media only, lane B) CRPV-neutralizing monoclonal Ab (CRPV4B) 1:10 final dilution, lane C) CRPV-neutralizing monoclonal Ab (CRPV4B) 1:100 final dilution, or lane D) HPV-11 neutralizing monoclonal Ab (H11.B2) 1:10 final dilution. Mock indicates uninfected Sf1Ep cells. Cultures were harvested either 3 days or 5 days after infection. Cottontail and NZW (A0100) represent RNA isolated from a CRPV-infected cottontail rabbit earskin papilloma cyst and New Zealand White (domestic) rabbit papilloma respectively.
FIG. 6. Southern analysis of Sall-cleaved cellular DNA (5 gg) from Sf1Ep cultures infected with CRPV preincubated with the monoclonal Abs listed in FIG. 5. Lane A) CRPV preincubated with media only; lane B) CRPV preincubated with CRPV4B 1:10 final dilution; lane C) CRPV preincubated with H11.B2 1:10 final dilution. NZW (A0100) indicates CRPV DNA isolated from a New Zealand White (domestic) rabbit papilloma. Spleen represents spleen DNA isolated from a NZW rabbit.
FIG. 7. Comparison of CRPV transcripts produced in CRPV-infected cultures treated with either PMEG or HPMPC.
FIG. 8A Presents growth rates from CRPV-infected Sf1Ep cells treated with HPMPC.
FIG. 8B Presents growth rates from CRPV-infected Sf1Ep cells treated with PMEG.
FIG. 8C Presents growth rates of the uninfected Sf1Ep cells treated with HPMPC.
FIG. 8D Presents growth rates of the uninfected RK-13 cells treated with HPMPC.
FIGS. 9A and B Present the level of BRdU-labeled (replicated) viral DNA in mock-treated CRPV-infected Sf1Ep cells at 90 hours post-infection.
FIGS. 9C and D Present the level of BRdU-labeled (replicated) viral DNA in interferon-treated Sf1Ep cells 130 hours post- infection.
DETAILED DESCRIPTION OF THE INVENTION
The present invention describes the scientific basis as well as preferred way of performing the novel method of testing effectiveness of potential antiviral agents. During the course of detailed studies involving the investigation of the replication of the infected by papilloma virus cells and the effect of various antiviral agent on that process, we have developed a novel method of growing cells in a monolayer cell culture system which allows for conducting the said novel antiviral tests.
A detailed embodiment of this invention involving cells RK-13 and Sf1Ep and CRPV as the studied virus is herein disclosed. However it is understood that the preferred embodiment is merely illustrative of the invention which may be embodied in various forms and applications accordingly, specific functional details disclosed herein are not to be interpreted as limiting, especially the type of virus, but merely as a support for the invention as claimed and as appropriate representation for teaching one skilled in art to variously employ the present invention in any appropriate embodiment.
An In Vitro Model System for Studying the Initial Stages of Cottontail Rabbit Papillomavirus CRPV Infection
We describe here an in vitro system in which early events in CRPV infection can be studied. This model may be particularly useful in the analysis of additional monoclonal antibodies or other agents which may interfere with viral binding and/or penetration. The system can be used to examine the effectiveness of antiviral agents which act early in the infection process.
Studies with CRPV have been limited due to the lack of an adequate cell culture system. The purpose of the current study was to establish the susceptibility of a cottontail rabbit cell line (Sf1Ep) to infection with CRPV. Our question was whether infection of these cells would result in the production of CRPV-specific RNA and would be inhibitable by virus-neutralizing antibodies.
Previously described in vitro systems for studying CRPV have been based on cell lines derived from CRPV-associated carcinomas (Georges, et al., 1984, J. Virol., 5l:530-538; Georges, et al., 1985, J. Virol., 55:246-250; Seto, et al., 1991, J. Invest. Dermatol., 97:327-333 ), on the transfection or exposure of murine cell lines to virus preparations (Watts, et al., 1983, Virology, 125:127-138), or on the infection/transfection of rabbit keratinocytes (Taichman, et al., 1984, J. Invest. Dermatol., 83:2s-6s; Meyers and Wettstein, 1991, Virology, 181:637-646). Among these, only studies utilizing carcinoma cell lines or transformed 3T3s have been analyzed at the transcriptional level. Both rabbit carcinoma and murine cell lines may be inadequate for use in studies involving virus penetration mechanisms. This is due to the species-specificity inherent in papillomavirus infections and to the potential loss of cell surface receptor expression on carcinoma cells. Primary cottontail (Sylviganus floridanus) rabbit keratinocytes are the best target cells for such studies because they are the natural host cell. Cottontail skin, in contrast to skin from domestic (Oryctolagus cuniculus) rabbits, is permissive for CRPV replication (reviewed by Kreider and Bartlett, 1981, Adv. Cancer Res., 35:81-110). Because of the difficulty in obtaining cottontails and culturing primary rabbit keratinocytes (Breidahl, et al., 1990, Irrununol. Cell Biol., 68:119-126), we chose to examine the response of a cottontail epidermal cell line (Sf1Ep) to infection with CRPV.
We demonstrated that infection of Sf1Ep cells with CRPV virion resulted in the dose-dependent production of two major viral transcripts. Infection of these cells did not result in transformation and vira nucleic acids were lost from infected culture upon extended passage. Previously described neutralizing monoclonal antibodies to CRPV (Christensen and Kreider, 1991, Virus Res., 2l:169-179), reduced both CRPV penetration and transcription.
At least two, but as many as five virus-specific RNA transcripts (1.25, 2.0, 2.5, 3.0 and 3.5 Kb) were detectable subsequent to in vitro CRPV infection while no viral RNA was found in mock-infected cultures (FIG. 1). Although CRPV transcripts were detectable as early as 17 hours post-infection, vira RNA was maximal between 2-6 days. Transcripts were diminished, beginning seven days post-infection, but were still detectable after 7 passages (21 days) post-infection. Two transcripts, 1.25 and 2.0 Kb, were the most abundant in infected cells. These were also the most abundant in domestic rabbit and cottontail papillomavirus lesions and correspond in size to transcripts from the E7 and E6 ORFs respectively. In both the domestic and cottontail lesions, these transcripts were present in nearly a 1:1 ratio. In in vitro infected cells the 2.0 Kb transcript was approximately 2-4 fold less abundant than the 1.25 Kb transcript (FIG. 1 and data not shown).
Restriction digests of CRPV DNA, isolated from infected cultures, with a single cutting enzyme Sall indicated that CRPV was present at between 50 and 100 episomal copies per cell DNA equivalent (FIG. 2). Unlike the RNA transcripts, viral DNA content did not increase with time, and pronounced decreases were seen with passages of infected cultures.
To determine if the amount of vital RNA produced was a reflection of the CRPV copy number within infected cells, we examined the effect of using ten fold serial dilutions of viral stock in the in vitro infection of Sf1Ep cells. CRPV viral RNA was most abundant in cultures infected with a 10 -1 dilution (200 μl) of viral stock. A dilution of 10 -2 produced detectable amounts of RNA while a dilution of 10 -3 did not produce vital RNA by 5 days post-infection (FIG. 3). This coincided with the amount of CRPV DNA within these cultures although cultures receiving a 10 -3 dilution contained detectable, but low amounts of DNA (data not shown). These results correlated with the efficiency at which dilutions of the same viral preparation induced lesions in vivo. Lesions induced with a 10 -1 viral dilution appeared earlier than lesions induced with a 10 -2 dilution while those induced with a 10 -3 dilution appeared much later (FIG. 4).
Prior incubation of CRPV with a neutralizing monoclonal antibody to CRPV (CRPV4B) inhibited viral RNA production in Sf1Ep cells, while another isotype-matched control antibody (H 11.B2), neutralizing for HPV-11, did not (FIG. 5). The initial dilution of the antibody stocks used (1:10) had been previously shown to be neutralizing for HPV-11 or CRPV in vivo. Whereas H11.B2 had no inhibitory activity at this level in our system, CRPV4B was still inhibitory even at a 1:100 dilution. This inhibitory activity did not change with a prolonged culture period of five days. Southern blots of these neutralized cultures show that in most cases persisting CRPV DNA was greatly reduced relative to control and H11.B2 treated cultures (FIG. 6).
The objective of the present study was to establish an in vitro infection system for CRPV in which a marker, in this case RNA production, was dependent upon infection with intact virion. We selected the Sf1Ep cell line for this system for two reasons: a) proper tissue; b) proper host. The source material for this cell line was derived from the epidermis of the natural host, the cottontail rabbit. In addition, this cell line, unlike others, was not previously transformed and contained replicating as well as senescent cell populations.
Other investigators have reported the use of this cell line in CRPV transfection studies (Meyers and Wettstein, 1991, Virology, 181:637-646; Meyers, et al., 1992, J. Virol., 66:1655-1664). These analyses did not involve the use of virion nor was CRPV transcription within transfected cells described. The authors did report transformation-associated changes in transfected cells that represented cell enlargement with the presence of intracytoplasmic inclusions. We occasionally observed this phenomenon within our infected cultures held for at least 30 days without passage. The time course of CRPV RNA production in infected cells was comparable to that reported for abortive infection of bronchial epithelial cells by HPV-1 (Christian, et al., 1987, In: Cancer Cell 5, Cold Spring Harbor Laboratory, N.Y., pp 165-170). The time delay of approximately 24 hours before the accumulation of abundant viral RNA transcripts may be due to the time required for vital uncoating and/or viral DNA replication. The reason for the decline in viral RNA and DNA amounts upon passage is unclear. Previous studies with HPV-1 infections in vitro indicate that infected cells containing a high copy number of viral DNA, detached from the flask and were lost in passage (Reilly and Taichman, 1987, In: Cancer Cells 5. Cold Spring Harbor Laboratory, N.Y., pp 159-164). This may also occur here since infected flasks contained significantly more floating/non-viable cells than comparable confluent, uninfected flasks. Likewise, CRPV viral DNA may be underreplicated with respect to the cell genome as was also described for HPV-1.
The most abundant viral transcripts corresponded in size to those of the E6 and E7 ORFs of CRPV. It is interesting, given the abundance of these transcripts, and despite the reported roles of the E6 and E7 ORFs in transformation, that our infected cells were not immortalized and, thus far, have been unable to form tumors in nude mice (unpublished observations). It is also interesting that the greater relative abundance of the 1.25 Kb transcript, consistently seen in infected Sf1Ep cells, has been associated with transcripts from malignant CRPV lesions. In contrast, the levels of the 1.25 and 2.0 Kb transcripts were approximately equal in our benign papilloma controls.
Infection here, using the production of CRPV transcripts as an indicator, was inhibited by monoclonal antibodies that neutralize CRPV infections in vivo. The reduced amounts of DNA present within infected cultures indicate that neutralization most likely occurred by inhibition of vital binding/penetration. The specificity of this event was demonstrated by the fact that isotype-matched monoclonal antibodies which neutralized HPV-11 had minimal effect on CRPV.
Materials and Methods Cell Lines, Antibodies and Virus
Sf1Ep cells (NBL-11) were obtained through the American Type Culture Collection, Rockville, Md. Cell cultures were maintained in Basal Medium Eagle (GIBCO, Grand Island, N.Y.) supplemented (as complete media) with 1.5 g/l sodium bicarbonate, 10 mM HEPES, 2 mM L-glutamine, 100 μM non-essential amino acids (Sigma, St. Louis, Mo.), 1 mM sodium pyruvate (GIBCO, Grand Island, N.Y.), 100 U/100 μg/ml penicillin/streptomycin, and 10% fetal bovine serum. Sf1Ep cells were utilized at passages 80-90. Monoclonal antibodies H11.B2 and CRPV4B were used as culture supernatants containing Clonetic's media (Clonetics Corp., San Diego, Calif.) and 5% keratinocyte conditioned media. These antibodies neutralize HPV-11 and CRPV respectively in vivo (Christensen, et al., 1990, J. Virol., 64:5678-5681; Christensen and Kreider, 1991, Virus Res., 21:169-179). CRPV was obtained as a crude extract from CRPV-infected cottontail earskin implanted subcutaneously in athymic nude mice. CRPV-producing earskin cysts were homogenized in an extraction buffer (1M NaCl, 20 mM Tris pH 7.4, 2 μg/ml PMSF) on ice in a Virtis homogenizer at 30 K RPM for 5 minutes. The homogenates were centrifuged at 10,000× g for 20 minutes at 4° C. The resulting supernatants were stored at -70° C. Prior to use, viral stocks were quickly thawed, sonicated for 1 minute and centrifuged for 5 seconds.
Nucleic acid extraction
For total RNA, cell monolayers were rinsed with Hank's balanced salt solution, without calcium and magnesium (HBSS), and lysed with 4M guanidinium isothiocyanate, 0.1 mM DTT, 0.5% N-lauroylsarcosine, 20 mM sodium acetate pH 5.2. Lysates were layered over a 5.7M CsCl cushion and centrifuged in a SW55Ti rotor at 35,000 RPM for 20 hr at 18° C. RNA pellets were resuspended in 10 mM Tris-Cl, 5 mM EDTA, 1% SDS followed by subsequent precipitation with 0.3M sodium acetate and absolute ethanol. DNA was extracted from TE-dialyzed guanidiniurn/CsCl supernatants by proteinase K digestion (100 μg/ml) followed by sodium acetate/absolute ethanol precipitation.
Northern blotting and hybridization
Ten micrograms total cellular RNA was size fractionated by electrophoresis through a 1.4% agarose/8% formaldehyde gel and transferred to Zetaprobe nylon membranes (BioRad, Rockville Center, N.Y.) with 10× SSC (1.5M sodium chloride, 0.15M sodium citrate) by capillary action. CRPV genomic sequences were isolated from a pLA2-CRPV construct (Mellon, et al., 1981, Cell, 27:279-288) (obtained from F. Wettstein) by Sall digestion and labelled to a specific activity of at least 5×10 8 CPM/μg by random hexamer 32 P-dATP labelling utilizing the Multiprime labelling system (Amersham, Arlington Heights, Ill.). Filters were prehybridized for 30-60 minutes and then hybridized for 24 hrs at 65° C. utilizing a buffer of 7% SDS, 0.5M NaH 2 PO 4 pH 7.2, 1 mM EDTA. Filters were then washed at 65° C. 2x with 5% SDS, 40 mM NaH2PO4 pH 7.2, 1 mM EDTA followed by two additional washes utilizing the same buffer with 1% SDS.
Southern blotting and hybridization
Five micrograms of total cellular DNA was digested with Sall (CRPV single cutter) using manufacturer's protocol. Digested DNA was sized fractionated on a 0.8% agarose gel and then transferred to Zetaprobe nylon membranes with 0.4N NaOH after depurination with 0.25N HCl. Prehybridization and hybridization conditions were as stated above for northern blots.
In vitro monolayer infection system
Two days prior to infection, 5×10 5 Sf1Ep cells were seeded into T75 flasks with Eagle's complete media. On the day of infection, the cultures were typically 50% confluent. Flasks were rinsed once with HBSS and infected with 2 mls of a ten-fold dilution of CRPV in Eagle's complete media without serum. Infected flasks were incubated for 2 hours at 37° C./5 % CO 2 on a slowly rocking platform. After infection, residual inoculum was removed and the flasks rinsed three times with HBSS. Each flask was then fed 10 mls of Eagle's complete media with 10% FBS.
In vivo CRPV infection
Two New Zealand White rabbits (Hazelton Research Labs, Denver, Pa.) were infected with 10-fold serial dilutions of the CRPV stock prepared as above. Lesions were initiated by the application of 50 μl of neat virus or virus diluted with PBS on abraded areas of the dorsal skin. Two sites per dilution were inoculated per rabbit Tumor measurements were made in three dimensions and the geometric mean diameter (GMD) was calculated per tumor.
Antibody-mediated neutralization
Murine monoclonal antibodies neutralizing for CRPV (CRPV4B) or HPV-11 (H11.B2) were generated and analyzed as previously published (Christensen, et al., 1990; Christensen and Kreider, 1991). Antibody dilutions were made in Eagle's complete media without serum. Prior to infection, 1 ml of 5-fold diluted CRPV stock was incubated with 1 ml of diluted antibody, or media alone, for 1 hr at 37° C. on a rocking platform. After incubation, the antibody-CRPV mixture was added to culture flasks as described above.
Development of the novel method of testing antiviral activity by employing known antiviral agents as the model substrate.
Two well define in other experimental systems agents PMEG (9-(2-phosphonylmethoxy) ethyl-guanine, E. De Clepcq, et al., 1986, Nature, 323:464-467) and HPMPC ((s)-1-(3-hydroxy-2-(phosphonylmethoxy)propyl)-cytosine, A. Merta et al., 1990, Antiviral. Res., 13:209-218) were used to test the effectiveness of this method.
PMEG AND HPMPC Treatments
This system uses the Sf1Ep (rabbit cottontail) cell line as an infection target. Recently the use of another rabbit cell line (RK-13) has been included. Both cell lines are cultured in Eagle's Basal Media (with Earls's Salts) containing L-glutamine, Pen/Strep, non-essential amino acids, HEPES, NaHCO 3 and fetal bovine serum (10% final volume). For each experiment 5×10 5 Sf1Ep cells (or 1×10 6 RK-13 cells) are plated in T75 flasks with the above medium. The cells are incubated for 48 hours and then infected for 2 hours with a standard dilution of CRPV viral stock (2 ml volume of virus in the above medium without FBS). After the infection, the cells are rinsed 2× with PBS and 9 mls of culture media (with FBS) are then added per flask. One milliliter of 10× drug (PMEG or HPMPC) solutions are added to the appropriate flasks. For PMEG, 100 μg, 10 μg and 1 μg/ml stocks were used to yield 10 μg/ml, 1 μg/ml, 1.0 μg/ml final concentrations. HPMPC dosages started 100 fold higher than the PMEG due to the reduced toxicity of this compound. Diluent for both drugs, as well as the drug free control consisted of sterile 0.9% saline solution. The infected cells were incubated for 4-6 days post-infection with the media (± drug) being changed every other day. Cell counts were performed daily or every other day by directly counting adherent cells using an ocular micrometer at a 100× total magnification. After 4-6 days the cells are harvested by lysis with guanidinium thiocyanate and the nucleic acids extracted by conventional methods as described.
CRPV infected Sf1Ep or RK-13 cells were treated with PMEG (0.1-10 μg/ml) or HPMPC (10-1000 μg/ml) for 4-6 days. Effects on CRPV transcription (FIG. 7) and cell proliferation/viability were examined.
Treatment of CRPV-infected Sf1Ep cells with either drug resulted in a reduction of CRPV transcripts at doses found to be growth inhibitory or toxic (FIGS. 8A-D). In contrast, the effects of both drugs on CRPV transcription in infected RK-13 cells were less pronounced even though PMEG and HPMPC at doses of 1.0 μg/ml and 1000 μg/ml respectively were found to be toxic to uninfected cells.
The nature of the inhibitory effect of both drugs is unknown, however generalized suppression of RNA transcription is probably not responsible due to the continued expression of GAPDH in the highest treatment groups. We have previously demonstrated that RNA transcript abundance is dependent upon CRPV DNA copy number. Whether drug treatment results in a reduction in CRPV copy number or whether cells containing a high copy number are more sensitive to drug toxicity is unclear.
Effect of Rabbit Fibroblast Interferon (nRalFN) on CRPV DNA Synthesis In Vitro
We used our CRPV/Sf1Ep infection system to examine the ability of nRaIFN to inhibit CRPV DNA synthesis. CRPV-infected Sf1Ep cells were cultured for up to 6 days in the presence of 1000 U/ml nRaIFN (Lee Biomolecular rabbit fibroblast IFN). At 2, 4, and 6 days post infection, treated and untreated cultures were pulsed with BRdU for 36 hours. The DNA from pulsed cultures was then resolved on a CsCl gradient to separated replicated (BRdU-substituted) and unreplicated DNA. By 90 hours after infection, approximately 93% of the CRPV DNA in IFN treated cells had replicated at least once as compared to 89% in CRPV-infected, IFN-untreated cells. No difference was seen at 130 hours either with approximately 7% of the CRPV DNA being replicated in the IFN treated flask vs. approximately 5% in the untreated flask. No CRPV DNA replication occurred in either group at 6 days post-infection. The drop in CRPV DNA replication between the two time points is most likely due to suppression of cellular DNA synthesis as a result of culture confluency (FIGS. 9A-D).
We believe that these data indicate that this system will be useful to study selected antivirals for their effects on early stages of papillomavirus infections, especially vital DNA synthesis and expression.
The method provides a mean to conduct a preliminary studies of the potential drugs. We also believe that this stage of the infection is critical to viral persistence in the papillomavirus-infected cell and therefore a more relevant target for antivirals than is the formation of complete virions in differentiated cells. This later phase occurs sparsely in most human lesions and not at all in "inapparent" or latent infections, which are the likely source of lesion recurrences post-treatment.
The invention described herein provides a novel model for studying antiviral effectiveness of various agents. We believe that this in vitro system is sufficiently consistent or precise to form a basis for a testing method.
The present invention offers a method which precisely measures antiviral activity without the interferences of the regional variability of organ cultures.
Thus, while I have illustrated and described the preferred embodiment of my invention, it is to be understood that this invention is capable of variation and modification, and I, therefore, do not wish or intend to be limited to the precise terms set forth, but desire and intend to avail myself of such changes and alterations which may be made for adapting the invention of the present invention to various usages and conditions. Accordingly, such changes and alterations are properly intended to be within the full range of equivalents and, therefore, within the purview of the following claims. The terms and expressions which have been employed in the foregoing specification are used therein as terms of description and not of limitation, and thus there is no intention in the use of such terms and expressions of excluding equivalents of features shown and described or portions thereof, it being recognized that the scope of the invention is defined and limited only by the claims which follow.
Thus is described my invention and the manner and process of making and using it in such full, clear, concise, and exact terms so as to enable any person skilled in the art to which it pertains, or with which it is most nearly connected, to make and use the same. | An in vitro method for testing the effectiveness of antiviral agents is provided. The method allows for screening anti-papillomavirus drugs which can interfere with the early and maintenance stages of papillomavirus infection. The method comprises growing epithelial cells susceptible to infection with papillomavirus in a monolayer system and measuring the effectiveness of various agents present in the growing media to interfere with the growth of the virus. The method is free from interferences caused by the regional variability, since the cell cultures are evenly dispersed monolayers. | 2 |
BACKGROUND OF THE INVENTION
The present invention relates to an open-end spinning machine with an impurity-removal device for removing dirt, soil, debris, plant matter and like impurities separated from fibers by sliver opening devices associated with the spinning stations of the machine.
Such impurity-removal devices are generally known in the state of the art, as described, e.g., in German Patent Publications DE Patent 23 56 180, DE-AS 26 34 770 or DE-OS 26 58 752.
German Patent Publication DE Patent 23 56 180 discloses rotor spinning units of an OE (i.e. open end) spinning machine with a conveyor belt arranged below the impurity-discharge opening of the open-end spinning units and traveling in the longitudinal direction of the machine, which conveyor belt receives and removes the impurities released during the opening of the sliver.
A potential problem with such impurity-removal devices is that tufts of fibers may form over the course of time in the area of the impurity-discharge openings by the settling of impurities and fibers. Such fiber tufts could be drawn back by suction into the area of the opening cylinder and possibly delivered therefrom into the spinning unit, which would then significantly disturb the spinning operation. In order to prevent such tufts of fibers from being able to form, a brush-like cleaning element is arranged on the conveyor belt the bristles of which cleaning element extend into the area of the impurity-discharge openings of the spinning units as the belt travels.
In the known spinning machines, the spinning units are arranged in two aligned rows essentially back to back along opposite sides of the machine. At the ends of the machine, the endless conveyor belt in the known impurity-removal device is deflected to reverse its course of travel and move along the opposite side of the machine, thereby for the removal of the impurities accumulating on the other side of the machine. The cleaning element is permanently arranged on the conveyor belt.
A similar impurity-removal device for open-end spinning machines is also described in German Patent Publication DE-OS 26 56 752. In this known device, a tangential belt is provided as a transport means for cleaning elements and serves at the same time as an impurity-removal means. This tangential belt, which is preferably a reciprocating belt, carries several differently designed cleaning elements arranged in series and collected into a group. The cleaning elements are fixed in a detachable and replaceable manner in holders which are permanently arranged on the tangential belt and are delivered during the travel of the tangential belt to the components of the spinning units which are endangered by impurities. That is, the cleaning elements can be removed as needed from the stationary tangential belt and replaced, if necessary, whereas during the travel of the tangential belt the cleaning elements are immovably fixed on the tangential belt.
Moreover, German Patent Publication DE-AS 26 34 770 describes an impurity-removal device for open-end spinning machines in which device an impurity-removal belt is arranged below the impurity-discharge openings of the sliver opening devices. The impurity-removal belt is arranged along the upper side of an air conduit comprising a through slot. The impurity-removal belt has an opening which provides communication between the air conduit and the impurity-discharge openings of the individual sliver opening devices. In addition, an impurity wiper is arranged in the area of this opening via a holder.
During the course of the spinning process both coarse impurity components as well as fine impurity particles and fiber fluff are removed through the impurity-separation openings. The coarse impurity components as well as a portion of the fine impurity particles and the fiber fluff are discharged directly onto the impurity removal belt to be removed immediately as it moves along the air conduit. However, some of the remaining fine impurity particles and the fiber fluff settle at first in the area of the impurity-discharge openings of the sliver opening devices and are removed from there by the wiper.
The wiper is permanently arranged on the impurity-removal belt in the area of aforesaid the impurity-discharge openings and is moved with the conveyor belt along the air conduit. Thus, the wiper passes simultaneously with the opening into the area of a spinning location, where it mechanically separates the fine impurity components and the fluff from the guide walls of the sliver opening device. The separated impurity particles are then removed by suction through the opening into the air conduit.
As is the case in the other known impurity-removal devices, in German Patent Publication DE-AS 26 34 770 the wiper is also permanently arranged on the impurity conveyor belt. That is, the wiper is constantly moved back and forth between reversing points in the area of the end frames of the machine by the conveyor belt driven in a reciprocating manner. The reversal of the direction of motion of the conveyor belt takes place via switching elements which are arranged in the area of the end frames of the machine and are actuated by the holder of the wiping element.
SUMMARY OF THE INVENTION
In view of the above-discussed state of the art, it is an object of the present invention to provide an improved impurity-removal device for open-end spinning machines.
The present invention achieves this objective in an open-end spinning machine basically comprising a plurality of adjacent open-end spinning units each having a sliver opening device with an impurity-discharge opening, by providing an impurity-removal device arranged below the impurity-discharge openings which has an impurity transport belt driven in a reciprocating manner and a cleaning carriage with a wiper device resting on the impurity transport belt by frictional engagement for selective removal from the impurity transport belt.
This basic design of the impurity-removal device in accordance with the present invention has the advantage, among other things, that the frictional resting support of the cleaning carriage on the impurity-removal belt is essentially unaffected by blockages or jams and specifically assures that even if the travel path of the cleaning carriage with the belt is blocked, e.g., by an open cover of an open-end spinning unit, the regular removal of impurities is not adversely affected nor is there any danger of damage to the cleaning carriage or to the spinning unit.
This frictional blockage-resistant fixation of the cleaning carriage makes it possible to reciprocate the impurity-removal belt in set time intervals without having to consider any carriage. Any additional sensors for detecting the position of the cleaning carriage are not necessary. The cleaning carriage moves automatically at the end of each passage against a stop arranged in the area of the end frame of the machine and remains there until the change of the direction of transport of the impurity-removal belt. In this manner a synchronous running of the cleaning carriages is always automatically adjusted at each change of the direction of transport.
An advantageous embodiment of the invention provides that the cleaning carriage rests freely on the impurity-removal belt by a stable support foot. An elastic cleaning lip is fixed to the support foot and extends therefrom into the area of the components of the OE spinning units subject to contamination. On the one hand, a cleaning carriage designed in this manner can be manufactured quite economically and on the other hand such a cleaning carriage assures that all components subject to contamination are reliably cleaned during the normal ongoing operation of spinning. In particular, the support foot preferably has a T-shaped design which represents a very stable, sturdy and simple design.
In order to assure a reliable removal of impurities even in the case of a blockage of the cleaning carriage on the impurity-removal belt, the support foot of the cleaning carriage comprises a portal-like passage opening. The impurities being transported by the belt can thus still be transported and removed through this portal-like passage opening even if the cleaning carriage is blocked, e.g., by a folded-out swiveling cover, as has already been indicated above.
In addition, an advantageous embodiment provides that the cleaning lip is adapted with its outer contour to the form of the components of the sliver opening devices which components are to be cleaned. The cleaning lip thus preferably comprises several differently formed cleaning fingers. The individual cleaning fingers can differ from each other as regards their length, their shape or even their material, in accordance with the design of the sliver opening devices to be cleaned. That is, an appropriate shaping of the cleaning fingers makes possible in an economical manner a reliable cleaning of the critical areas of the open-end spinning units.
Moreover, a further development of the invention provides that a starting device is arranged in the area of each of the impurity-removal belts which starting device makes it possible in a simple manner to lift the cleaning carriage out of frictional resting engagement on the impurity-removal belt. On the one hand, the use of such a starting device can clearly reduce the wear both on the impurity-removal belt and on the cleaning carriage since the cleaning carriage is lifted off of the impurity-removal belt when it is not needed. On the other hand, the cleaning carriage is held in a in an inactive "parked" position by the starting device ready to be used at any time if the degree of contamination of the open-end spinning units of the machine side concerned requires it.
In a preferred embodiment the starting device is mounted in an end area of the impurity-removal belt, preferably at the end opposite a cleaning- and suction-removal device of the impurity-removal belt. The spatial conditions in this area of the machine make possible both a relatively simple and uncomplicated installation of a starting device as well as a parking of the cleaning carriage lifted off from the impurity-removal belt without any adverse effects or hindering of the spinning process of the open-end spinning machine occurring.
The starting device preferably comprises a vertically movable receiving element for the cleaning carriage which element has a receiving means extending approximately parallel to the impurity-removal belt and configured to extend under the cleaning carriage in the area of its passage opening. The starting device can thereby move the receiving element between an active receiving or transferring position adjacent the belt for picking up therefrom or setting down thereon the cleaning carriage and the inactive parked position raised away from the impurity-removal belt by means of a thrust-piston transmission unit which can be loaded in a defined manner.
Further details, features and advantages of the present invention will be described and understood from the following disclosure of a preferred embodiment in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a front elevational view of several serially arranged open-end spinning units of an OE rotor spinning machine with an impurity-removal device in accordance with the present invention arranged below the sliver opening devices of the spinning units.
FIG. 2 is a side elevational view of one of the open-end spinning units of the machine of FIG. 1, taken along section line II--II in FIG. 1.
FIG. 3 is a side elevational view of a cleaning carriage in accordance with the present invention.
FIG. 4 is an end elevational view of the cleaning carriage of FIG. 3 as viewed from the front elevational view of FIG. 1.
FIG. 5 is a schematic perspective view of the impurity-removal device of the open-end spinning machine of FIG. 1 showing the starting devices arranged adjacent the impurity-transport belt for lifting the cleaning carriage off of the impurity-removal belts.
FIG. 5A is a enlarged view of a cleaning carriage of FIG. 5.
FIG. 6 is another schematic perspective view of the impurity-removal device from the same perspective as FIG. 5 depicting the cleaning carriages in the process of being received by the starting devices.
FIG. 6A is a enlarged view of a cleaning carriage and starting device of FIG. 6.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to the accompanying drawings and initially to FIG. 1, several serially aligned open-end spinning units 2 of an open-end rotor spinning machine 1 are shown in front elevational view. As is known, in modem OE rotor spinning machines, often far more than one hundred of these open-end spinning units are arranged in alignment with each other along each side of the spinning machine.
These open-end spinning units 2, which are known and described, e.g., in German Patent Publication DE 195 24 837 A1, comprise a suction-loaded rotor housing 21 in which a spinning rotor 22 rotates at a high speed. The rotor housing, which is not shown in FIG. 1, is open to the front and is closed during spinning operation by a swiveling cover element 3. Swiveling cover 3 also comprises, among other things, a sliver opening device 4.
Sliver opening device 4 operates to separate a sliver 9 being fed to the spinning unit into spinnable individual fibers. For such purpose, the sliver opening device 4 comprises, as is customary, an opening cylinder 6 rotating in an opening-cylinder housing 5, a delivery roller 7 and a sliver feed trough with a sliver compressor 8 facing to the front of the machine. The opening-cylinder housings 5 of these sliver opening devices also have impurity-discharge opening 10 for removal of impurities which are liberated during the opening of sliver.
As is also apparent from FIG. 2, the spinning machine includes a mechanical impurity-removal device 11 comprising an endless impurity-removal belt 12 guided in a conduit assembly 13 extending along the length of the machine below the impurity-discharge openings 10. The conduit assembly 13 comprises, as is customary, an upwardly-open impurity-removal conduit 14 and a return conduit 15 located thereunder within which the endless impurity-removal belt 12 is driven via an electric motor (not shown).
A cleaning carriage 16 rests frictionally on the upper run of the endless impurity-removal belt 12 extending in the impurity-removal conduit 14 and is entrained by such frictional engagement to travel with the impurity-removal belt 12 during the operation thereof.
The cleaning carriage 16 of the present invention is shown in FIGS. 3, 4 on a larger scale and is comprised preferably of two-components, e.g., a lower metallic support foot 17 for resting on the upper belt surface and an elastic cleaning lip 18 upstanding from the support foot 17 to extend into the area of the impurity-discharge openings 10 of the sliver opening devices 4. Moreover, the support foot 17 comprises a portal-like passage opening 19 which enables the transport and removal of impurities to continue along the impurity-removal belt 12 even if frictional transport of the cleaning carriage 14 with the traveling belt 12 should be temporarily blocked, e.g., by engagement with an outwardly opened swiveling cover of an open-end spinning unit.
The cleaning lip 18 comprises a plurality of cleaning fingers 20, 20', 20", etc., which can differ from each other both as regards their size, shape and/or their material. That is, cleaning fingers 20, 20', 20", etc., are preferably specially adapted to the contours of the components of the sliver opening devices 4 which are subject to contamination. Cleaning fingers 20, 20', 20", etc., wipe during operation along such areas of the open-end spinning units subject to contamination and mechanically loosen any accumulated particles of impurities. The loosened particles of impurities fall onto the impurity-removal belt 12 and are transported by the latter to pneumatic devices for the removal of impurities by suction (not shown) located in the area of the end frames of the machine.
On the whole, the provision by the present invention of the cleaning carriage 16 frictionally supported on and transported by the impurity-removal belt 12 and of the cleaning lip 18 wiping along the areas of sliver opening device 4 which are especially endangered by contamination, achieves a clearly improved removal of impurities, which has a positive effect on the operation of the spinning machine, not the least of which is a reduction of the yarn breaks which occur.
FIGS. 5 and 6 schematically show a perspective view of the mechanical impurity-removal device 11 of the open-end spinning machine 1.
As shown, the spinning machine has an endless impurity-removal belt 12 extending along each longitudinal side of the machine below the aligned open-end spinning units of the respective machine sides (not shown in FIGS. 5,6). Impurity-removal belts 12 are driven via reversible electric motors 22 and can travel in either forward direction V or reverse direction R. A cleaning carriage 16 as above-described is arranged to rest on each of impurity-removal belts 12 and is entrained by the rotating impurity-removal belt via frictional engagement. Each of the impurity-removal belts 12 has a cleaning and suction removal device 21 at one end in the area of its respective drive 22 and has a starting device 23 adjacent the opposite belt end.
As is indicated in FIGS. 5 and 6, these starting devices 23 comprise a receiving element 24 for the cleaning carriage and a thrust-piston transmission unit 25 which can extend and retract the receiving element 24 toward and away from the impurity-removal belt 12 between an active position I (FIG. 6) lowered closely adjacent the belt 12 for receiving (i.e. picking up) the cleaning carriage 16 from the belt 12 and transferring (i.e. returning) the cleaning carriage 16 to the belt 12 and an inactive position II raised from the belt 12. In the active receiving and transferring position I, a horizontal shank of the receiving element 24 for the cleaning carriage is positioned closely above the impurity-removal belt 12. Cleaning carriage 16 traveling with the impurity-removal belt 12 in direction R moves with its passage opening 19 over this horizontal shank whereupon the carriage 16 can be subsequently raised by its foot 17 into the inactive position II by the thrust-piston transmission unit 25.
It will therefore be readily understood by those persons skilled in the art that the present invention is susceptible of broad utility and application. Many embodiments and adaptations of the present invention other than those herein described, as well as many variations, modifications and equivalent arrangements, will be apparent from or reasonably suggested by the present invention and the foregoing description thereof, without departing from the substance or scope of the present invention. Accordingly, while the present invention has been described herein in detail in relation to its preferred embodiment, it is to be understood that this disclosure is only illustrative and exemplary of the present invention and is made merely for purposes of providing a full and enabling disclosure of the invention. The foregoing disclosure is not intended or to be construed to limit the present invention or otherwise to exclude any such other embodiments, adaptations, variations, modifications and equivalent arrangements, the present invention being limited only by the claims appended hereto and the equivalents thereof. | An open-end spinning machine (1) with a plurality of adjacent open-end spinning units (2) each having a sliver opening device (4) with impurity-discharge openings (10). An impurity-removal device (11) is installed below the impurity-discharge openings (10) and comprises an impurity-removal belt (12) which can be driven in a reciprocating manner. A cleaning carriage (16) is arranged on the impurity-removal belt (12) and is connected by frictional engagement to the impurity-removal belt (12). The cleaning carriage (16) has a cleaning lip (18) which mechanically cleans the areas of the sliver opening devices (4) especially endangered by contamination. The cleaning carriage (12) can be shifted as required relative to the impurity-removal belt (12). | 3 |
[0001] This application claims the benefit of U.S. Provisional Patent Application Ser. No. 61/699,583, filed Sep. 11, 2012, the disclosure of which is hereby incorporated by reference in its entirety.
FIELD OF THE INVENTION
[0002] The present disclosure generally relates to air flow control assemblies for motor vehicles and, more particularly, to air dams and engine compartment underpanels for motor vehicles. In this regard, an important aspect of this disclosure is directed to air dam and engine compartment underpanel assemblies for improving the aerodynamic characteristics of motor vehicles including, in particular, trucks and truck tractors.
BACKGROUND OF THE DISCLOSURE
[0003] It is known that the aerodynamic characteristics of motor vehicles can be improved by an air dam which typically is mounted to the front of a motor vehicle and extends downwardly into proximity with the roadway.
[0004] For example, U.S. Pat. No. 4 ,291,911 (Gallmeyer) describes an air dam apparatus which is particularly concerned with trucks and truck tractors. That air dam apparatus comprises a pivotally mounted flat doorlike panel which, when deployed into an operative position below the front bumper deflects air from the front to the sides of the vehicle. Correspondingly, U.S. Pat. No. 7,871,121 (Ragsdale) describes a flexible flat plastic panel which extends downwardly from the bumper of a truck, redirecting air flow around the sides of the wheels.
[0005] Neither of these prior art air dams is capable of guiding air streams that impinge on the front of the vehicle in a manner which effectively reduces turbulence in both the engine compartment and interior areas forwardly thereof in the vehicle.
[0006] This design inadequacy and other shortcomings of the prior art are successfully addressed by the novel air flow control assembly described herein.
SUMMARY OF THE INVENTION
[0007] This disclosure is directed to an air flow control assembly for improving the aerodynamic characteristics of a motor vehicle by providing an air dam component at the front of the vehicle, typically mounted to the front bumper, which extends substantially across the entire width of the bumper and includes a rearwardly extending, generally planar surface that is configured to underlie the interior space at the front of the vehicle which is forward of the engine compartment, as well as an engine compartment underpanel component which is coupled to that air dam and underlies the vehicle engine compartment. These components of the assembly cooperate to route air flow when the vehicle is traveling at relatively high speeds so that it passes below the vehicle in a manner which effectively reduces turbulence and drag in both that interior space at the front end of the vehicle and in the engine compartment. As such, this air flow control assembly provides, among other things, enhanced fuel efficiency.
[0008] In accordance with an important aspect of the present disclosure, the engine compartment underpanel component can be coupled to the air dam component mounted forwardly thereof by a plurality of fasteners such as, for example, plastic rivets which, optionally, can be of the type which are releasable and reusable for facilitating removal of the underpanel when service to the engine and other components in the engine compartment is desired and the engine compartment underpanel reattached thereafter.
[0009] Another aspect of this disclosure concerns a tear-away feature for preventing damage to the air dam and/or engine compartment underpanel when either or both of them are contacted by a road obstacle. This feature is achieved by the use of fasteners which are designed to shear when a road obstacle is contacted by the air dam and/or engine compartment underpanel resulting in a force of predetermined magnitude is imparted to either of these components without significant, if any, damage thereto.
[0010] It is to be understood that the foregoing general description and the following detailed description are exemplary and are provided for purposes of explanation only. Other features, benefits and objects of the air flow control assembly of this disclosure will be apparent to those skilled in this art from these descriptions. Accordingly, the invention is to be limited only by the scope of the appended claims.
DESCRIPTION OF THE DRAWINGS
[0011] In describing the features of the disclosed embodiment, reference is made to the accompanying drawing figures wherein like parts have like reference numerals and wherein:
[0012] FIG. 1 is a front lower perspective view of the air dam and engine compartment underpanel of the present disclosure;
[0013] FIG. 2 is a rear upper perspective view of the air flow control assembly shown in FIG. 1 ;
[0014] FIG. 3 is an exploded front perspective view separately showing the bumper, air dam and engine compartment underpanel, as well as the individual fasteners used to interconnect the same;
[0015] FIG. 4 is a top plan view of the air dam component of the subject air flow control assembly;
[0016] FIG. 5 is a front elevational view of the air dam shown in FIG. 4 ;
[0017] FIG. 6 is an upper rear perspective view of the air dam shown in FIG. 4 ;
[0018] FIG. 7 is a side elevational view of the air dam shown in FIG. 4 ;
[0019] FIG. 8 is a top plan view of the engine compartment underpanel of the air flow control assembly of this disclosure;
[0020] FIG. 9 is a rear elevational view of the engine compartment underpanel shown in FIG. 8 ;
[0021] FIG. 10 is an upper rear perspective view of the engine compartment underpanel shown in FIG. 8 ;
[0022] FIG. 11 is a side elevational view of the engine compartment underpanel shown in FIG. 8 ;
[0023] FIG. 12 is a side elevational schematic view of an installed air flow control assembly of this disclosure;
[0024] FIG. 13 is a bottom plan schematic view of an installed air flow control assembly of this disclosure.
DETAILED DESCRIPTION
[0025] Referring to the drawings, the reference numeral 20 generally designates an air flow control assembly of the present invention which includes an air dam component 21 and an engine compartment underpanel component 22 , which assembly, in the illustrated embodiment, is coupled to a bumper 23 . For example in the illustrated embodiment, bumper 23 includes a pair of tow hook holes 24 , 25 and engine ventilation apertures 26 , 27 and 28 . It will be appreciated that the present invention is not limited to any particular bumper design and construction.
[0026] Air dam component 21 and engine compartment underpanel component 23 can be composed of a variety of materials including plastics, metal, fiberglass and composites, as well as other like materials known to those skilled in the art. It can be formed by injection molding, thermal forming, stamping or other manufacturing methods also known to those skilled in the art.
[0027] As best shown in FIGS. 1-7 , the air dam component 21 includes a front facing downwardly extending trim portion 29 which, at its lower end, extends into a curved portion 31 that, in turn, extends into a U-shaped rearwardly extending generally continuous planar surface 32 which is configured to underlie the interior space at the front end of the vehicle. Air dam component 21 can be secured to the bumper 23 by an inwardly extending peripheral mounting flange 33 at its upper edge which is configured to be attached to a mating inwardly extending mounting flange 23 a on the lower portion of the bumper 23 by means of a plurality of fasteners 34 which are received in apertures 33 a of air dam mounting flange 33 and correspondingly sized and spaced apertures 23 b of bumper mounting flange 23 a.
[0028] In the illustrated embodiment, the back portion of U-shaped planar portion 32 includes a raised mounting flange 35 which is configured to receive the forwardmost portion 36 of engine compartment underpanel component 22 . This permits the underpanel component to be received in flush relationship to the bottom surface of U-shaped planar portion 32 of air dam 21 . A plurality of fasteners 34 similar to those used in coupling the air dam 21 to the bumper 23 can be used to attach engine compartment underpanel component 22 to mounting flange 35 which extends through apertures 37 in mounting flange 35 and like-sized and spaced-apart apertures 37 in the forward end 36 of engine compartment underpanel component 22 .
[0029] As shown in FIGS. 1 , 2 and 8 - 11 , engine compartment underpanel 22 can be provided with a generally flat perimeter portion 22 a that extends rearwardly terminating in a downwardly curled lip 38 . A generally rectangular center portion 39 surrounds perimeter portion 22 a and is downwardly tapered from the forward end to the rearward end. A plurality of longitudinal raised ribs 41 can be provided to add rigidity to the engine compartment underpanel component 22 .
[0030] FIGS. 12 and 13 schematically illustrate the orientation of the air flow control assembly 20 of the present disclosure in a truck 42 having a hood 43 that encloses an engine compartment 44 , a front axle 45 and the front bumper 23 to which the trim portion 29 of air dam component 21 is coupled. Desirably, a top filler panel 46 on the topsurface of bumper 23 adjacent wheel well 47 can be provided to limit the flow of air into the wheel well. As shown in FIGS. 12 and 13 , the back edge curl 38 of engine compartment underpanel component 22 preferably terminates slightly forwardly front axle 45 so as to avoid contact with the axle 45 when the vehicle is traveling along a roadway and the front end of the truck moves vertically as a result of contact by the tires 46 with irregularities in the roadway.
[0031] Perimeter portion 22 a of engine compartment underpanel component 22 , as shown in FIG. 13 , includes inwardly tapered sides 22 b which can accommodate angular movement of the tires 48 during right and left turns. In this regard, it will be appreciated that a common design for engine compartment underpanel 22 can be used with a variety of air dam component designs that are individually styled to accommodate the varied multiple truck platforms of different manufacturers.
[0032] The road clearance between the air flow control assembly 20 of this disclosure designated by the fetters “RC” in FIG. 12 should be as low as needed for the desired aerodynamic performance with sufficient clearance above the road to minimize possible damage to the air dam component and/or the engine compartment underpanel component by impact with obstacles. In this regard, there should be a minimum clearance of at least approximately six inches between the lowermost portion of the air dam component 21 and engine compartment underpanel component 22 with the ground. Generally, however, it is believed that a road clearance of approximately eight to eleven inches will be suitable for most installations.
[0033] An important feature of this disclosure, concerns the ready removal of the engine compartment underpanel component 22 when access to the engine compartment is desired. This is facilitated by the use of fasteners such as, for example, plastic rivets which can be of a type which are releasable and reusable for facilitating removal of the underpanel when service to the engine and other components in the engine compartment is desired. These same rivets or replacements thereof can then be used for reattachment of that underpanel when such servicing of the engine compartment is completed.
[0034] If desired, the fasteners 34 can be of a type which are designed to shear when a road obstacle is contacted by either the air dam component or engine compartment underpanel component contact a road obstacle, resulting in a force of predetermined magnitude being imparted to the particular component involved and enabling that component to separate from the assembly without significant, if any, damage to the particular assembly component involved.
[0035] While the invention of this disclosure has been described in accordance with a preferred embodiment, it will be appreciated by those skilled in the art that modifications and/or changes may be made to the foregoing description without departing from the spirit and scope of this invention. Accordingly, the invention of this disclosure is not limited by this disclosure but rather by the scope of the appended claims. | An air flow control assembly for a motor vehicle is disclosed that includes an air dam component at the front of the vehicle, typically mounted to the front bumper, which extends substantially across the width of the bumper. It includes a rearwardly extending generally planar surface that is configured to underlie the interior space at the front of the vehicle as well as an engine compartment underpanel which is coupled to that air dam and underlies the vehicle engine compartment. | 1 |
BACKGROUND OF THE INVENTION
The present invention relates generally to oscillators for, in response to an input signal, generating a periodically varying electrical output within a frequency range such as a millimeter wave and a submillimeter wave.
A Gunn diode oscillator having a waveguide construction is a known solid-state oscillator for generating an output existing within the millimeter or submillimeter band. However, such a diode oscillator requires a larged-sized resonator in comparison with wavelengths and is difficult to manufacture with the required accuracy. In order to avoid this problem a Fabry-Perot type resonator has been proposed whereby it is possible to realize a large-sized resonator in comparison with wavelengths. However, a solid-state oscillator with the Fabry-Perot type resonator has disadvantages in terms of mechanical strength and heat radiation and hence is not yet in practical use. Thus, a further improvement would be required from the veiwpoint of practical use.
SUMMARY OF THE INVENTION
It is therefore an object of the present invention to provide a high-performance oscillator for generating an oscillation output existing within the millimeter-wave or submillimeter-wave range, which oscillator is capable of increased output concurrently with cost reduction.
With this and other objects which will become apparent as the description proceeds, a millimeter-wave/submillimeter-wave oscillator according to the present invention comprises a mirror and a diffraction grating so as to form a Fabry-Perot type resonator. The mirror, being a concave mirror or a plane mirror, and the diffraction grating are disposed in facing and spaced relation to each other. The diffraction grating has a plurality of channels extending in a direction normal to a surface of the mirror so that the oscillator has a comb-like configuration and the channels act as waveguides. A plurality of oscillation elements are mounted on portions within the channels of the diffraction grating. Preferably, a control circuit applies a phase-locked control signal to one of the plurality of oscillation elements. The control circuit comprises a reference oscillator for generating a reference oscillation signal, a frequency multiplexer for multiplexing the reference oscillation signal, a mixer mixing the output of the frequency multiplexer and the RF (radio frequency) output from the millimeter-wave/submillimeter-wave oscillator, a frequency divider for dividing the output of the mixer, and a phase comparator for comparing the output of the frequency divider in phase with the output of a temperature-compensation crystal oscillator. The output of the phase comparator is supplied to a driver which in turn supplies a control signal corresponding to the phase difference therebetween to the one of the plurality of oscillation elements.
BRIEF DESCRIPTION OF THE DRAWINGS
The object and features of the present invention will become more readily apparent from the following detailed description of the preferred embodiments taken in conjunction with the accompanying drawings in which:
FIG. 1 is a side cross-sectional view showing a millimeter-wave and submillimeter-wave oscillator according to an embodiment of the present invention;
FIG. 2 is a perspective view showing an oscillator according to another embodiment of this invention; and
FIG. 3 is a block diagram illustrating an oscillator according to a further embodiment of this invention.
DETAILED DESCRIPTION OF THE INVENTION
Referring now to FIG. 1, there is illustrated an oscillator according to an embodiment of the present invention. In FIG. 1, illustrated at numeral 12 is a diffraction grating which is made of a conductive material and which is placed in opposed and spaced relation to a concave mirror 11 made of a metal, the distance therebetween being set to be l. The diffraction grating 12 functions as a plane reflection mirror and has a plurality of channels 15, having a depth of t, so as to form a comb-like configuration. On the diffraction grating 12 is provided a solid-state oscillation element 13 such as a Gunn diode and an IMPATT diode (impact avalanche and transit time diode). The soild-state oscillation element 13 is directly mounted on an end portion of the diffraction grating 12 so as to be disposed in one channel 15 thereof. The direct mounting causes the diffraction grating 12 to act as a heat radiator for the solid-state oscillation element 13. The solid-state oscillation element 13 is responsive to a direct-current bias supplied through a terminal 14.
In the above-mentioned arrangement, the diffraction grating 12 is arranged such that the pitch of the channel 15 is smaller than 1/2 of the operation wavelength and the channel 15 is constructed so as to easily enable mounting the solid-state oscillation element 13 thereon. Furthermore, the channel 15 acts as a parallel flat-plate waveguide one end of which is shorted. The depth t of the channel 15 may be determined in accordance with the short-circuit condition. Here, the resonance mode of the resonator made between the concave mirror 11 and the diffraction grating 12 is TEMoo and the resonance frequency is determined on the basis of the distance l between the cancave mirror 11 and the diffraction grating 12. The distance l therebetween may be determined appropriately to be above several times of the oscillation frequency so as to allow sufficiently increasing the length of the resonator and make easy the adjustment of the frequency. Although in this embodiment the cancave mirror 11 is provided in facing relation to the diffraction grating 12, it is also appropriate to use a plane mirror instead of the concave mirror 11.
A second embodiment of the present invention will be described hereinbelow with reference to FIG. 2. Parts corresponding to those in FIG. 1 are marked with the same numerals. Generally, in solid-state oscillators, the output level decreases as the oscillation frequency becomes higher, it thereby becoming difficult to obtain a high output in the case of the frequency being high. The second embodiment is for elimination of this problem inherent in the solid-state oscillators. In FIG. 2, on a diffraction grating 12 are provided a plurality of solid-state oscillation elements 21 to 26 which are arranged two-dimensionally so as to form two element lines spaced from each other by S which is integer times of the wavelength. In this case, when all of the solid-state oscillation elements 21 to 26 oscillate simultaneously under the condition that the oscillation frequencies thereof are substantially equal to each other, the frequencies thereof are coincident with each other in accordance with the injection locked phenomenon so as to increase the output of the oscillator. Here, it is also appropriate that some of the solid-state oscillation elements are arranged one-dimensionally so as to form one element line by elements 21, 24 or 21, 22, 23, for example.
Furthermore, a third embodiment of this invention will be described hereinbelow with reference to FIG. 3. The third embodiment is for improving the stability of the second embodiment. In FIG. 3, illustrated at numeral 31 is an oscillator comprising the FIG. 2 Fabry-Perot type resonator and having a RF output terminal 32 for deriving the output of the oscillator. Designated at numeral 35 is a mixer for mixing the output nfr of a frequency multiplier 34 for multiplexing a reference oscillation signal fr from a reference oscillator 33 and the RF output fo from the RF terminal 32. The mixer 35 is coupled to a frequency divider 36 for dividing the output (fo - nfr) of the mixer 35, which frequency divider 36 is in turn connected to a phase comparator (PD) 38 for phase-comparing the output 1/m(fo - nfr) of the frequency divider 36 and the output fs of a temperature-compensation crystal oscillator (TCXO) 37. The comparison result by the phase comparator 38 is supplied to a low-pass filter (LPF) 39 and a driver 40 which in turn supplies a phase-locked control signal to one of the plurality of oscillation elements of the oscillator 31. That is, the driver 40 drives the one of the plurality of oscillation elements in accordance with the phase difference therebetween so that the phase of the output of the oscillator is coincident with the phase of the temperature-compensation crystal oscillator 37. Here, as described in the second embodiment, when all of the oscillation elements are driven at the same time under the condition that their frequencies are nearly equal to each other, the oscillation outputs of the oscillation elements are synchronized and combined with each other so as to obtain a high output in accordance with the injection locked phenomenon. In this instance, the injection locked phenomenon provides a characteristic that the most stable signal leads the other signals, and therefore, the entire oscillator 31 becomes stable by stabilizing the frequency of anyone of the plurality of oscillation elements (21 to 26 in FIG. 2).
It should be understood that the foregoing relates to only preferred embodiments of the present invention, and that it is intended to cover all changes and modifications of the embodiments of the invention herein used for the purposes of the disclosure, which do not constitute departures from the spirit and scope of the invention. For example, although in the third embodiment the frequency stabilizing circuit is based upon the phase locked system, it is also appropriate that it is based upon the automatic frequency control (AFC) system. In this case, a control signal is obtained by detecting the output of the mixer by a frequency discriminator. | There is disclosed herein a millimeter-wave/submillimeter-wave oscillator comprising a mirror and a diffraction grating so as to form a Fabry-Perot type resonator. The mirror, being a concave mirror or a plane mirror, and the diffraction grating are disposed in facing and spaced relation to each other. The diffraction grating has a plurality of channels extending in a direction normal to a surface of the mirror so that the oscillator has a comb-like configuration. A plurality of oscillation elements are mounted on portions within the channels of the diffraction grating. | 7 |
RELATED APPLICATIONS
[0001] This application is a continuation-in-part application of and claims priority to U.S. patent application Ser. No. 10/771,924, filed Feb. 4, 2004, the disclosure of which is incorporated herein in its entirety.
FIELD OF THE INVENTION
[0002] The present invention relates to three-dimensional deep molded structures preferably comprising of a non-woven substrate formed of small diameter fibers and/or filaments.
BACKGROUND ART
[0003] Three-dimensional molded non-woven structures are used in a variety of applications. Most notably, automotive parts account for a great majority of such applications including headliners, door liners, carpets, and the like. Most of these structures however, are molded to conform to the shape of the object they surround or support. The degree to which the fibers in the structure are extended is somewhat limited. Furthermore, these structures are molded to a given shape and recovery from extension or compression is not a concern. Many non-wovens that are used in these applications are composed of fibers that have the ability to be drawn further during the molding process to accommodate the shapes required without being ruptured. For example, spunbonded structures composed of fibers that are not fully drawn during the fabric manufacturing process make ideal candidates for such molding applications. Most other structures however, do not readily lend themselves to molding and often rupture during the molding process.
[0004] Another area of molding relates to honeycomb-like structures that are intended as compression supports in various structures including automotive seats, sports shoes and the like. These, however, use woven and knitted structures manufactured by intersecting or interlooping heavy monofilament fibers to achieve the desired properties.
[0005] Representative related art in the technology of the invention includes the following patent references: U.S. Pat. No. 2,029,376; U.S. Pat. No. 2,627,644; U.S. Pat. No.3,219,514; U.S. Pat. No.3,691,004; U.S. Pat. No. 4,104,430; U.S. Pat. No. 4,128,684; U.S. Pat. No. 4,212,692; U.S. Pat. No.4,252,590; U.S. Pat. No.4,584,228; U.S. Pat. No. 5,731,062; U.S. Pat. No. 5,833,321; U.S. Pat. No. 5,851,930; U.S. Pat. No. 5,882,322; U.S. Pat. No.5,896,680; U.S. Pat. No.5,972,477; U.S. Pat. No.6,007,898; and U.S. Pat. No.6,631,221. The teachings of these prior art references are incorporated by reference herein.
[0006] The present invention is intended to overcome many of the well-known deficiencies of prior art deep molded structures and to meet a long-felt need for a new and improved material that possesses unique properties.
SUMMARY OF THE INVENTION
[0007] Applicants have discovered deep molded three-dimensional structures fabricated from flat planar non-woven substrates of various types in a variety of shapes. The present invention comprises a deep molded structure that is made from non-wovens comprising filaments or staple fibers of any size to create the non-woven structure. Additionally, the present invention could comprise a deep molded structure that is made from knitted or woven materials comprising filament or staple fibers smaller than 100 microns in diameter. The fibers in all structures can be homo-component or multi-component as in sheath-core, side-by-side, striped, tipped trilobal, segmented-pie, and others. Preferably, the substrate is selected from the group consisting of needle punch non-woven fabrics; hydroentangled non-woven fabrics; chemically (resin) bonded staple non-woven fabrics; composite structures containing a non-woven; and meltblown non-woven fabrics.
[0008] The structure can be high in porosity or can be quite dense. The key to the invention for a wide range of products is to ensure that during the heating process, the fibers approach their onset of melting and are only partially melted. This invention also anticipates structures formed from complete melting of the fibrous structure which will result in a structure that does not have much resilience and will form a rigid structure used as a spacerfabric and the like. The structure relies on the thermoplastic components in the structure for moldability. However, the structure may be composed of both thermoplastic and non-thermoplastic components as well. The drawing characteristics of the constituent fibers are important as is the process for molding the structure. The structures are formed by a combination of heat and pressure such as those commonly used in solid phase pressure forming, vacuum bladder match plate molding, stamping, pressing or calendaring.
[0009] It is an object of the present invention to provide a non-woven planar material comprising small diameter filaments or staple fibers to permanently form a multiplicity of raised projections from the plane of the non-woven material.
[0010] It is another object of the present invention to provide a knitted or woven planar material comprising small diameter staple fibers or filaments molded to permanently form a multiplicity of raised projections from the plane of the material.
[0011] It is another object of the present invention to provide a deep molded structure wherein the local structure (from the raised portions to the depressions) retains its textile nature and remains functional.
[0012] It is another object of the present invention to provide a deep molded structure wherein the planar structure to be molded can be selected from a variety of non-wovens but wherein a component in the structure must be thermoplastic.
[0013] It is another object of the present invention to provide additional stiffness to the deep molded structure by laminating or joining another planar substrate to the deep molded structures.
[0014] It is still another object of the present invention to provide additional stiffness to the deep molded structure by nesting two or more deep molded structures face-to-face or face-to-back.
[0015] It is another object of the present invention to provide additional properties to the deep molded structure by adding thermosetting resins, fibrous and non-fibrous coatings, and functionality such as electroactivity, waterproofing, mildew resistance, barrier materials, layer-shedding, and the like.
[0016] Some of the objects of the invention having been stated, other objects will become apparent with reference to the detailed description and the drawings as described hereinbelow.
DESCRIPTION OF THE DRAWINGS
[0017] FIGS. 1A and 1B are schematic views of two representative deep molded structures;
[0018] FIGS. 2A , and 2 B are schematic views of two representative processes making use of (1) flat sheet molding and (2) calendar molding, respectively;
[0019] FIG. 3 is a schematic view of a representative dome shape formed on a substrate;
[0020] FIG. 4 is a graph of draw ratio as a function of dome size;
[0021] FIG. 5 is a top plan view of a sample deep molded structure with holes in the structure due to substrate failure;
[0022] FIG. 6 is a side elevation view of typical dome deformation at high strain levels;
[0023] FIG. 7 is a graph of loading and unloading for spunbonded substrates at three different basis weights;
[0024] FIG. 8 is a bar graph of compression stiffness values for various deep molded structures formed from different non-woven samples; and
[0025] FIGS. 9A and 9B are photographs of a sample deep molded structure after twenty-five (25) launderings.
DETAILED DESCRIPTION OF THE INVENTION
[0026] The invention is a deep molded non-woven structure comprising filaments or staple fibers having a diameter of any suitable size. Applicants also contemplate that the novel structure could be formed from knitted and woven fabrics comprising fibers and/or filaments measuring less than 100 microns in staple fiber or filament diameter. This provides a deep molded structure that retains its textile like hand, but will have significantly different texture and three-dimensionality as well as resilience and compression recovery. The three-dimensional textile structure has improved functionality with respect to heat and moisture management, small particle management, detection and decontamination of hazardous agents, force and impact management, air circulation, personal protection, personal comfort in transportation and confinement.
[0027] Natural and synthetic textile fibers are available in a wide range of cross-sectional shapes including, circular, triangular, multi-lobed, ribbon, hollow, irregular and the like. While measuring fiber diameter is a common means of describing fibers with circular cross-section, it is often necessary to measure fiber dimensions other than the diameter. In the case of trilobal cross-sections, the longest fiber dimension would be along an edge forming the trilobal cross-section or in the case of ribbon fibers, the cross-section would have two distinct measures (width and thickness). The intended invention may use fibers of any cross-sectional shape and have a size less than 100 microns in diameter (e.g., a round cross-section fiber of 80 microns in diameter) or wherein at least one of the principal dimension is less than 100 microns (e.g., a ribbon fiber of 100 microns×10 microns).
[0028] FIGS. 1A, 1B and 2 A, 2 B show typical products and processes that can be used for making these deep molded structures. The manufacturing starts with a specific planar fabric. These fabrics are then stabilized and thermo-formed to create the three-dimensional novel structure of the invention. Multiple layers or composites can be constructed after the thermo-forming stage as a matter of choice. The thermo-forming process can use conventional sheet thermo-forming equipment ( FIG. 2A ) or calendar molding equipment ( FIG. 2B ), and typical processes are shown in FIGS. 2A and 2B .
[0029] In a non-woven substrate, a number of structure variables can be controlled to form the desired structure. In particular, fiber orientation distribution (ODF), fiber crimp and fiber diameter are important controlling elements. The ODF ψ is a function of the angle θ. The integral of the function ψ from an angle θ 1 to θ 2 is equal to the probability that a fiber will have an orientation between the angles θ 1 to θ 2 . The function ψ must additionally satisfy the following conditions:
ψ ( θ + π ) = ψ ( θ )
∫ o π ψ ( θ ) ⅆ θ = 1
To describe the alignment of the fibers, applicants use a ratio known as the Anisotropy Ratio, f p defined as:
f p = 2 〈 cos 2 θ 〉 - 1
〈 cos 2 θ 〉 = ∫ o π ψ ( θ ) cos 2 ( θ ref - θ i ) ⅆ θ ∫ o π ψ ( θ ) ⅆ θ
The anisotropy parameter varies between −1 and 1. A value for f p of 1 indicates a perfect alignment of the fibers parallel to a reference direction and a value of −1 indicates a perfect perpendicular alignment to that direction. f p is zero for a random assembly. The degree of moldability changes with the structure's anisotropy. The best structures for the current inventions are obtained when the non-woven structure is random or when f p =0 or very close to 0. Non-woven substrates suitable for molding generally have a value for f p between −1/2 to ½.
[0030] Note that an increase in fiber crimp will also result in improved moldability. This occurs because an increase in crimp increases the degree to which the structure may be drawn. Fiber diameter is important in determining and controlling the structure because it affects stiffness and porosity properties.
[0031] The present invention most suitably uses filaments, and/or fibers having a diameter less than 100 microns, and preferably about 1-20 microns, and fiber lengths of 5 to 50 millimeters to form the non-woven, woven or knitted substrate thereof. Applicants surprisingly discovered that use of a non-woven substrate formed from such small diameter fibers results in highly resilient three-dimensional structure without adversely affecting the surface properties of the base material. Additionally, these structures can recover well from repeated compression and retain their shape and three-dimensionality. The present invention also contemplates using filaments, and/or fibers having a diameter greater than 100 microns to form a significantly more rigid non-woven. Applicants surprisingly discovered that such rigid non-woven structures are also resilient and have significant recovery from compression.
[0032] The same has also been found to be the case with wovens and knits formed in accordance with the invention from the small diameter fibers and/or filaments.
[0033] Thermo-forming of non-woven substrates is accomplished through a combination of two material phenomena: (1) rheological and (2) mechanical deformation. Rheological deformation implies that a certain amount a molecular movement is induced though the application of heat to the substrate thus softening the fiber to the point of laminar movement. To maintain fibrous characteristics without considerable change to molecular orientation and crystallinity, the forming temperature must be maintained to be above the glass transition and below the melting temperature (e.g., thermoplastic fibers or polymers have a melting temperature between 70-450° C.). Fibers used in thermo-forming non-woven substrates can include (co-poyetherester elastomer, poly (ethylene terephthalate), poly (trimethylene terephthlate), nylon 6, nylon 6,6, polypropylene, polyethylene, polyesters, polyamides, thermoplastic co-polyetherester elastomers, polyolefines, polyacryonitriles, polyacrylates and thermoplastic liquid crystalline polymers); they can be homo-component, bi-component or multi-component; and they can be tipped trilobal, side by side or sheath/core wherein one component melts at a lower temperature. In thermo-forming involving deep draws, fourfundamental modes of mechanical deformation are observed. These are in-plane tension, transverse compression, in-plane shear and out-of-plane bending. The complexity in mechanical deformation will vary with the complexity of the molds used during the thermo-forming process.
[0034] The present invention differs from other molded structures in that the total drawing of the substrate is significant both locally and in the bulk. Applicants use the term “drawability” to express the largest possible draw ratio or limiting draw ratio obtained before failure occurs. For the present invention, the draw ratio is defined as the surface area of the formed product to that of the substrate. Specifically, the surface area at which failure occurs could be used to determine the limiting draw ratio of the substrate with the following equation:
DR = A SF A I
Where the initial surface area (A I ) is the pre-molding area and the final surface area (ASF) is the increase in surface area achieved post molding. To demonstrate the extent to which the substrate is drawn, applicants use the frusto-conical dome geometry shown in FIG. 3 . In determining the Draw Ratio, several assumptions are made. It is assumed that a perfect grid of “domes” of right circular cones normal to the substrate plane describe the geometric shape produced utilizing a male/female mold geometry.
[0035] Applicants have discovered that fibers and/or filaments used to form the substrate normally achieve a better result during the molding process if the fibers and/or filaments are partially oriented fibers and/or filaments. This has been shown to achieve substantially improved fiber and/or filament orientation after molding.
[0036] Referring to FIG. 3 , within a unit cell, the final surface area (A F ) is comprised of the lateral surface area (L) of the frustum, the area of the top base (A t ), and the difference of the initial surface area (A I ) the area of the bottom base (A b ), and is given by:
A SF =[a ( L )+ a ( A t )]+[(A I )− a ( A b )]
Where a, is the total number of domes in a give area; in the unit cell a=1 . The lateral surface area (see FIG. 3 ) is given by L=π(r+R)s where s=√{square root over (([R−r] 2 +h 2 ))}. The area of top base (A t ) is given by A t =πr 2 and the area of the bottom base ( b ) is given by A b =πR 2 . Thus, the final surface area is given by A SF=[a(π(r+R)s)+a(πr 2 )]+[(A I )−a(πR 2 )] where A I =initial surface area.
[0037] Consider a three-dimensional structure as described herein with an initial length and width of 101.6 mm. Utilizing a 9.525 mm (⅜″) male pin diameter in conjunction with a 15.875 mm (⅝″) female hole. The following parameters apply:
Length (L I ), mm 101.6 Width (W I ), mm 101.6 # of “Domes” 16 Radius @ Dome Base, mm 7.9375 Radius @ Dome Top, mm 4.7625 Dome Height (h), mm 12
Consequently,
DR = A SF A I = 12639.849 mm 2 10322.56 mm 2 = 1.222
[0038] For a given substrate, the final draw ratio is a function of dome size. FIG. 4 shows that the final draw ratio can be as much as 3 for various pin diameters. These draw ratios are significantly higher than the strain to failure of the substrates. The properties of the test structure used to create the data shown in FIG. 4 are set forth in Table 1 below.
TABLE 1 Fiber Fiber Fiber Weight Thickness Cross Diameter Sample Type g/m 2 (mm) Section (μ) Spunbond PP 160 0.46 R 40-50
[0039] Applicants contemplate that the projections or depressions within the substrate will have a height between 0.1 mm-5 cm and a width between 0.1-100 mm.
[0040] Applicants believe that formability of the substrates described herein for use with the present invention are affected by the structure anisotropy (fiber orientation distribution, ODF, in non-wovens) as well as the drawability of individual fibers or filaments, and in the case of non-wovens the method of bonding. The strain to failure of the substrate tested at ambient is not an indicator. Applicants' invention allows the use of substrates with as little as 5.0% strain to failure and strains higher than 100%. Common anisotropic structures with strain to failures lower than 5.0% cannot be deep molded and holes are formed at moderate dome heights as shown in FIG. 5 . The properties of the test structure shown in FIG. 5 are set forth in Table 2 below.
TABLE 2 Fiber Fiber Fiber Weight Thickness Cross Diameter Sample Type g/m 2 (mm) Section (μ) Hydroentangled PET 100 1.0 R 20
[0041] Generally, applicants have discovered that the draw ratio will increase as a function of product thickness increases and pin diameter decreases.
[0042] For a single layer structure, the structure's stiffness and strength is a function of the properties of the constituent fibers in the structure as well as the weight per unit area (basis weight) of the samples. This is especially true for spunbonded non-woven structures.
[0043] Maintaining the formed shape of the molded structure is of equal importance. There are no standard test methods for determining the compressive properties of formed deep molded structures. Applicants have tested a method that utilizes a constant rate of extension (CRE) tensile testing machine in compression mode with the following conditions:
Platen Separation: 10 mm Crosshead Speed: 1 mm/min to 40% strain Specimen thickness: measured under .005 kgf Sample Size: 10 cm 2
[0044] At a strain of approximately 40%, the dome projection changes from a more cylindrical shape to a more conical shape as shown in FIG. 6 . The ability to recover to the original shape from this type of deformation was determined by cyclic loading. FIG. 7 shows typical loading unloading behavior of spunbonded samples at three different basis weights (e.g., 320 gsm; 160 gsm; and 90 gsm). Note that the energy absorption and stiffness of the deep molded structure increase rapidly with basis weight. It is also evident that no permanent deformation is evident under compression loading. The properties of the test structures used to create the data shown in FIG. 7 are set forth in Table 3 below.
TABLE 3 Fiber Fiber Fiber Weight Thickness Cross Diameter Sample Type g/m 2 (mm) Section (μ) Spunbond PP 90 0.38 R 40-50 Spunbond PP 160 0.46 R 40-50 Spunbond PP 320 0.75 R 40-50
[0045] FIG. 8 shows the compressive stiffness of eight deep molded structures normalized by the weight of the specimens. It is evident that the stiffness increases with the basis weight of the specimens as seen for the PP samples. Note that these structures are composed of partially oriented fiber (POF) and are better suited for deep molding. These structures tend to form deeper and more uniform projections. Additionally, during the molding process the fibers go though solid state crystallization improving their mechanical properties. Note that the PET spunbonded samples out-perform the PP samples with the hydroentangled products providing the softest specimens. These were composed of fully drawn fibers and the molding process is not expected to result in improvements in the fiber properties. The properties of the eight test substrates shown in FIG. 8 are described in Table 4 below.
TABLE 4 Fiber Fiber Fiber Weight Thickness Cross Diameter Sample Type g/m 2 (mm) Section (μ) Spunbond PP 90 0.38 R 40-50 Spunbond PP 160 0.46 R 40-50 Spunbond PP 320 0.75 R 40-50
[0046] FIGS. 9A & 9B show the before and after photographs of a knitted fleece formed of 50/50 blend of cotton and multilament polyester fiber and laundered fifty (50) times. The shape and appearance can be seen to be retained very well. The properties of the test structure are as follows: 50/50 polyester cotton knitted fleece.
[0047] Summarily, the invention discovered by applicants is a three-dimensional deep molded product made from planar non-woven fabrics formed from staple fibers or filaments of any size. Also, knitted and woven fabrics comprising fibers and/or filaments smaller than 100 microns in diameter are contemplated by the invention. Preferably, the filament and fiber diameter are about 1-20 microns. The best non-woven structures are those with a random fiber orientation distribution. While common anisotropic structures can also be molded, the degree to which they can be drawn becomes more limited with increasing anisotropy. Tufted, stitchbonded and flocked fabrics can also be used to make the deep molded product.
[0048] The stiffness of the structure can be controlled by employing larger diameter fibers and/or a higher basis weight. Higher porosities can be achieved by using thicker fibers. However, the overall flexibility of the structure will also reduce making it more difficult to cut. These attributes can be balanced to achieve the highest resilience, highest porosity, and highest flexibility.
[0049] The non-woven web formation processes (e.g., carding, airlay, wetlay, spunbond and meltblown) typically lead to an oriented structure wherein the majority of fibers are parallel to the direction in which the web is being formed and collected (machine direction). The introduction of crimp into the fibers tends to randomize the orientation distribution locally which leads to improved 1 0 moldability.
[0050] 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 three-dimensional flexible deep molded structure is provided having at least one planar flexible textile non-woven substrate that has been processed through thermo-forming or calendaring equipment to form a multiplicity of compressible projections extending from the planar surface which return to their shape after being substantially compressed. The non-woven substrate preferably is a staple fiber based non-woven fabric manufactured from fibers with a diameter of less than 100 microns and a fiber length of 5 to 50 millimeters. The non-woven fabric preferably has a constant anisotrophy ratio f p between −1/2 to +1/2. | 3 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This application claims priority under 35 U.S.C. §119 to United Kingdom Patent Application Serial No. 0712528.9 filed on Jun. 28, 2007, entitled “APPARATUS AND METHOD,” the disclosure of which is hereby incorporated by reference.
RELATED ART
1. Field of the Invention
The present invention relates to an apparatus and method for creating a localized area of high pressure within a conduit and a method for retaining pressure within an annulus. In an exemplary application, the invention is useful for containing well pressure while performing wireline operations.
2. Brief Discussion of Related Art
When tool strings are deployed through an access hole into a live wellbore there is a need to contain pressurized well fluids and prevent their escape through the annulus between the tool string and the access hole of the wellbore. Sealing of the annulus around slickline (i.e. smooth wire) is currently achieved by compressing a cylindrical rubber to seal against the slickline in the annulus. For braided wire and lines with a rough profile, this type of sealing mechanism is not practical as the surface profile of the wire restricts effective sealing. Instead, a highly viscous fluid such as grease is injected into the annular space around the wife. This creates a seal that prevents the escape of well fluids but without restricting movement of the wire. There can be significant changes in viscosity as a result of temperature increases, which could be detrimental to the ability to contain the well pressure. In addition, there are practical disadvantages to purchasing, storing, handling and disposing of the grease. Grease tends to stick to the wire and as a result when the wire is removed from the well and spooled onto a drum, there can be spills on the deck of the platform leading to an unsafe working environment and environmental contamination.
INTRODUCTION TO THE INVENTION
According to a first aspect of the invention, there is provided a method for containing fluid in an area of a wellbore annulus, the method comprising the steps of:
(a) energizing a fluid to create a fluid flow;
(b) at least partially obstructing the fluid flow; and
(c) directing the fluid flow to form in the annulus a localized area of high pressure to contain fluid in an area of the annulus of lower pressure.
Typically, as a result of the obstruction to fluid flow, performance of step (b) causes a back pressure to be generated. The method may include impacting the fluid against a shaped surface to create a back pressure in the annulus, the back pressure being sufficiently high to contain fluid in the wellbore annulus. Thus, the energized fluid may seal the annulus in the localized area of high pressure, such that escape of fluid from regions of ambient pressure is restricted or prevented.
Step (a) can include accelerating the fluid flow. Step (a) can also include increasing the speed of fluid to a speed between 20-600 m/s. Step (a) can further include injecting fluid into a channel and shaping the channel to energize the fluid. Step (a) can even further include providing a body having a channel with a fluid inlet and a fluid outlet and shaping the channel to have a lower sectional area in the region of the outlet compared with the inlet such that the velocity of the fluid is increased in the region of the outlet. In this way, the fluid can be formed into a jet. Preferably, the jet has sufficient velocity to overcome the ambient pressure, (for example, the pressure at the outlet of the channel) so that it reaches the obstruction of step (b).
Step (b) can include impeding or placing an impediment in a path of the energized fluid. Step (b) can also include at least partially confining the fluid in a chamber and/or can include at least partially confining the energized fluid in a predetermined area of the annulus. Thus, the chamber may define an annular space.
Steps (b) and (c) can be performed simultaneously. Step (b) can include positioning a surface in the path of energized fluid flow and step (c) can include angling the surface such that flow is directed to generates localized area of higher pressure in a predetermined region.
Step (c) of the method can include deflecting the fluid flow to generate an area of higher pressure in the annulus. The method may include deflecting the fluid flow toward the area of higher pressure. The method may include deflecting the fluid flow to generate a pressure plug in the area of higher pressure. The pressure plug and/or area of high pressure may separate first and second regions of lower pressure, and may restrict of prevent fluid flow between the first and second regions. In particular, the plug and/or area of high pressure may contain, act as a barrier to, seal against, cap and/or act as a fluid wall for well fluid located downhole, and may prevent flow of fluid from the downhole location to a second region uphole in relation to the first region. The first and second regions, thus, may be regions of the wellbore annulus.
The wellbore annulus may be an annular space defined between a wireline or slickline, and an inner wall of a wellbore of other wellbore equipment, for example, a pressure control head, stuffing box, wellbore tubing or open hole formations.
The method can include a further step (d) of collecting fluid as the localized area of higher pressure dissipates to the ambient pressure. The method can further include recycling the fluid in step (d) by performing step (a) on the collected fluid. The method may include circulating fluid into and out of said area for maintaining the area of high pressure spatially and over a period time. Thus, in providing the high pressure area or pressure plug, fluid is moved through the high pressure region. In particular embodiments, where the area of high pressure and/of pressure plug separates first and second regions of lower pressure, the second region is at a lower pressure than that of the first region, to provide for fluid flow or dissipation of fluid from the high pressure region to the second region of lower pressure. In certain embodiments, the high pressure area or pressure plug may form an interface separating the first and second regions. Energized fluid used to create the high pressure area may be collected from the second region of lower pressure for repeat use. Fluid may flow from the high pressure region to the second region in preference to the first region, to maintain the pressure conditions of the high pressure region, whilst containing fluid, in the first region.
The method can involve containing ah ambient pressure in an annulus of a wellbore by performing the method previously described downstream of the intended containment region.
The method can include selecting the parameters for fluid speed and the obstruction such that the localized area of high pressure acts as a plug of high pressure to contain the ambient pressure. Such parameters may include, speed of fluid, direction of fluid flow, channel dimensions, relative position and orientation of the channel to the annulus, relative position and/or orientation of the channel to the angled surface. The method can include selecting a fluid having a viscosity of less than 10 centipoise (0.1 Pa s).
According to a second aspect of the invention, there is provided apparatus for containing a fluid in a wellbore annulus comprising:
a means for energizing a fluid to form a fluid flow; and
an obstruction adapted to obstruct the flow of energized fluid; and
means for directing the fluid to the wellbore annulus to create in the annulus a localized area of high pressure sufficient to contain fluid in ah area of the wellbore annulus of an ambient pressure.
The obstruction of fluid flow can creates back pressure, by presenting an obstacle to the flow of the fluid. The energized fluid may plug or seal the annulus at said area of high pressure.
The obstruction is formed from a material having an excellent wear resistance.
The fluid can be a low viscosity and/or water-based fluid. The fluid can be water. The water can include additives such as corrosion inhibitors.
The fluid can have a viscosity of around 1-5 centipoise (1-5×10−2 Pa s).
The apparatus may include a channel having a fluid inlet and a fluid outlet wherein the channel has a smaller sectional area in the region of the outlet than that of the inlet to increase fluid velocity in the region of the outlet for jetting the fluid into the localized area of high pressure. More specifically, the means for energizing a fluid can comprise a body having a channel with an inlet for receiving a fluid and an outlet, and wherein at least a portion of the channel converges towards the outlet. The portion of the channel that converges towards the outlet can have a lower sectional area, which increases the velocity of fluid within that portion of the channel. The apparatus and/or body can have a throughbore. The throughbore may be arranged to receive a line and wherein the obstruction can be arranged and/or positioned such that pressure is generated in an annular space between the throughbore and the line. The body and the channel can form asymmetrical concentric nozzle for producing an annular jet of energized fluid.
The obstruction and/or means for directing the fluid may include a deflector insert located in the throughbore. The deflector insert may be removably attached to a main body of the apparatus. The deflector insert and/or inner surface of the throughbore may include an angled and/or shaped surface. The deflector insert and/or inner surface of the throughbore may have an inwardly protruding member, which may in turn include the angled and/or shaped surface placed in the path of energized fluid. Thus, the shaped surface may extend inwardly to partially occlude an annular space which may be formed around a line received in the throughbore.
The obstruction and/or means for directing the fluid may include a nozzle insert located in the throughbore. The nozzle insert may be removably attached to a main body of the apparatus, and together with the main body may define a channel for jetting fluid into the wellbore annulus. The nozzle insert together with the deflector insert may be arranged to help energize, direct and obstruct the fluid to create said high pressure area and/or pressure plug.
The width of the annulus can be approximately 0.05 to 1.0 inch (1.27 to 25.4 mm).
The obstruction can comprise a surface that is angled relative to the direction of fluid flow. The angle of the surface relative to an axis of the conduit can be selected according to the desired application. The angle of the surface relative to an axis of the conduit can be selected to deflect the fluid flow to create an area of localized pressure in the predetermined position. Thus, the apparatus may include a surface in the path of energized fluid flow oriented at an angle relative to the direction of fluid flow for deflecting the fluid toward the annulus to generate the area of high pressure.
The directing means may include a fluid channel. The obstruction and the directing means may together define a geometry which interacts with the energized fluid permitting sufficient pressure build up to generate a pressure plug in the annulus from the energized fluid. The obstruction, together with the means for directing the fluid, may be adapted to create the localized area of high pressure in the annulus. This geometry may facilitate pressure build-up on directing energized fluid to the annulus. The geometry may be based on selected parameters for the fluid flow, such as required fluid flow speeds and/or other parameters.
The surface can be cone-shaped in section. The cone angle can be between 20° and 60° from the axis of the conduit. The cone angle can be defined as the angle of the surface relative top the axis of the conduit. Alternatively, the surface can be lens-shaped and/or concave.
The invention is advantageous for use in a wellbore to contain a pressure within an annulus as it reduces the amount of equipment space required, increases safety margins and reduces contamination of the surrounding environment.
Contact between a high velocity fluid stream and the surface causes a back pressure to be generated. This creates a localized area of high pressure that can be moved to an appropriate position in an annulus of the wellbore by deflecting fluid accordingly. When the pressure generated exceeds the pressure of the wellbore, the area of high pressure is effective in forming a pressure barrier that acts to substantially contain the well pressure.
The annulus can be created by running a line, such as wireline or slickline through a tubing. The line can be selected from the group consisting of: wireline; slickline; and downhole tubing. The annulus may be formed between a wireline and an inner wall of a throughbore for receiving the line.
The inner wall may have a recess, step, angled surface, inwardly protruding member or be otherwise shaped for interacting with a fluid and/or to assist energizing a fluid. The fluid may be jetted into the annulus through the inner wall of the throughbore. Thus, the wall may at least partially act as an obstruction, or a deflector for energized fluid.
The minimum predetermined velocity can be 20 m/s. More preferably, the minimum predetermined velocity can be 40 m/s. Alternatively, the value for the minimum predetermined velocity can be any value up to around 600 m/s, depending on the application and the pressures in the annulus that need to be contained.
Preferably, the fluid has a lower viscosity than a long-chain hydrocarbon, such as grease. Preferably, the fluid has a viscosity around a factor of 100 times less viscous than a long chain hydrocarbon.
The method can include shaping the surface to deflect the fluid to a predetermined region such that the back pressure forms a pressure plug in the annulus. Thus, the method may include shaping a surface for deflecting fluid to a predetermined region in the annulus and thereby facilitate creating the area of higher pressure.
The apparatus may take the form of a pressure control head, a stuffing box and/or any other pressure control apparatus for wellbore tubing.
The second aspect of the invention can include any previously described features or method steps of the first aspect of the invention, where appropriate.
According to a third aspect of the invention there is provided a pressure control head for wellbore tubing. The pressure control head may comprise apparatus according to the second aspect of the invention, and may be adapted to perform the method of the first aspect of the invention.
The pressure control head may include a main body having an axial throughbore for receiving a wireline therethrough, and an insert or cartridge, wherein the main body and the insert together may form a symmetrical concentric nozzle for producing an annular jet of energized fluid to an annular space defined between ah inner surface the pressure control head and the wireline providing a pressure seal against the wireline.
The insert may be removably attached to the main body for facilitating m maintenance. Other components of the apparatus of the second aspect of the invention, for example, the directing means, energizing means and/or the obstruction, may form a part of a removable cartridge or insert.
According to a fourth aspect of the invention there is provided a method for creating a localized area of higher pressure relative to an ambient pressure in a conduit, comprising the steps of:
(a) energizing a fluid;
(b) at least partially obstructing the fluid flow; and
(c) directing the fluid flow such that a localized area of high pressure is formed.
According to a fifth aspect of the invention, there is provided an apparatus for creating a localized pressure in a conduit comprising:
a means for energizing a fluid; and
an obstruction to obstruct the flow of energized fluid and create ah area of localized pressure.
The fluid may have a viscosity of less than 10 centipoise (0.1 Pa s).
According to a sixth aspect of the invention, there is provided a method for containing a pressure within ah annulus of a wellbore including the steps of:
providing a fluid having a predetermined minimum velocity; and
impacting a fluid against a shaped surface such that the impact creates a back pressure sufficient to contain fluids within the annulus of the wellbore.
According to a seventh aspect of the invention, there is provided a method for containing fluid at pressure in a wellbore annulus, the method comprising the steps of directing a flow of fluid to the annulus and obstructing the flow to create in the annulus an area of sufficiently high pressure to restrict escape of fluid from and/or contain fluid within an area of the wellbore annulus of lower pressure.
According to ah eighth aspect of the invention, there is provided a method for containing fluid at pressure in a wellbore annulus, the method comprising the steps of confining fluid in a localized area of the annulus, and pressurizing the fluid in said area sufficiently to restrict escape of fluid from an area of the wellbore annulus of lower pressure.
Any one of the third to eighth aspects of the invention can include any previously described features or method steps of the first and/or second aspects of the invention, where appropriate.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a sectional view of a pressure control head;
FIG. 2 is a detailed sectional view of a nozzle and a deflector of the pressure control head shown in FIG. 1 ;
FIG. 3 is a sectional schematic view of the nozzle and the deflector shown in FIG. 2 ;
FIG. 4 is an alternative sectional view of the nozzle and the deflector of the FIG. 1 apparatus;
FIG. 5 is a sectional view of the nozzle and an alternative deflector; and
FIG. 6 is a sectional view of the nozzle and another alternative deflector.
DETAILED DESCRIPTION
The exemplary embodiments of the present invention are described and illustrated below to encompass an apparatus and method for creating a localized area of high pressure within a conduit and a method for retaining pressure within an annulus. Of course, it will be apparent to those of ordinary skill in the art that the embodiments discussed below are exemplary in nature and may be reconfigured without departing from the scope and spirit of the present invention. However, for clarity and precision, the exemplary embodiments as discussed below may include optional steps, methods, and features that one of ordinary skill should recognize as not being a requisite to fall within the scope of the present invention.
Referencing FIG. 1 , a pressure control head 8 has four main portions: a collar 110 ; a body 10 ; a housing 40 ; and a funnel 50
Referring to FIGS. 1 and 2 , the collar 110 is connected to the body 10 at a coupling 111 . The body 10 is substantially cylindrical and is formed with a centrally disposed throughbore 13 having a flared portion 13 f for accommodating inserts (described hereinafter). An inlet port 22 extends through a sidewall of the body 10 and an outlet port 44 also extends through the sidewall of the body 10 . Both the inlet port 22 and the outlet port 44 are in fluid communication with the throughbore 13 .
As shown in FIG. 2 , the flared throughbore portion 13 f of the body 10 is arranged to receive a deflector insert 20 . The deflector insert 20 engages the body 10 by means of a threaded connection 21 . An outer surface of the deflector insert 20 is provided with an annular groove 25 that accommodates an annular seal 26 to create a fluid tight seal between the exterior of the deflector insert 20 and the throughbore 13 . The deflector insert 20 has a central passageway or throughbore 23 for receiving a wireline. Part of the throughbore 13 is shaped as a frustocone having an impact surface 28 with a cone angle of around 50° relative to its axis of symmetry. At its upper end, the throughbore 23 of the deflector insert 20 opens out into a diverging annular side wall 27 . The impact surface 28 of the deflector insert 20 is formed from a ceramic material that has excellent wear resistance.
The flared throughbore portion 13 f also has an annular step 13 s positioned adjacent the part of the body 10 where the inlet port 22 communicates with the throughbore 13 . A nozzle insert 30 having a central passageway or throughbore 33 for receiving a wireline is positioned within the body 10 so that a portion of the nozzle insert 30 abuts the annular step 13 s . The nozzle insert 30 is provided with a shaped protrusion 38 at one end that extends into the throughbore 23 of the deflector insert 20 . The protrusion 38 of the nozzle insert 30 has an outer annular side wall 35 . Together, the outer side wall 35 of the nozzle insert 30 and the annular inner side wall 27 of the deflector insert 20 forms a concentric annular channel that acts as a convergent nozzle 31 . An inlet of the nozzle 31 is in communication with an annular chamber 37 and hence the inlet port 22 extending through the sidewall of the body 10 . The inlet port 22 is connected to a pump (not shown) to inject fluid through the port 22 , into the chamber and the nozzle 31 . The exterior of the nozzle insert 30 is provided with an annular groove 39 that accommodates ah annular seal 34 to create a fluid tight seal between the flared throughbore portion 13 f and the exterior of the nozzle insert 30 . Together, the annular seals 26 , 34 act to isolate the lower chamber 37 such that fluid entering through the inlet port 22 can only escape via the nozzle 31 .
The housing 40 has a box end coupled to a pin end of the body 10 , by means of a threaded connection 121 . The housing 40 is substantially cylindrical and has a hollow interior 43 that houses an annular piston 120 , a seal cone 70 , a spring 80 and a wiper 60 . The annular piston 120 is substantially cylindrical and one end is slidably disposed in the flared throughbore portion 13 f . A piston head 120 h abuts and end face 10 e of the body 10 . An upper chamber 46 is formed in the flared throughbore portion 13 f between the nozzle insert 30 and the annular piston 120 . The upper chamber 46 is in fluid communication with the outlet port 44 .
The pin end of the body 10 has an annular groove 14 on its exterior and an annular groove 15 on its interior for accommodating annular seals 122 . The exterior of the piston head 120 h is provided with an annular groove 123 that accommodates an annular seal 122 . All the seals 122 fluidly isolate an annular chamber 126 that is in fluid communication with a pump (not shown) via a port 128 extending through a sidewall of the housing 40 .
The spring 80 is retained between the housing 40 and the piston head 120 h , so that the annular piston 120 is resiliently urged to abut the end face 10 e of the body 10 . The seal cone 70 is attached to the piston 120 and has an angled annular face that abuts the wiper 60 . The wiper 60 is typically a polymer disposed within the housing 40 and the wiper 60 is compressible by the action of the seal cone 70 thereon.
The funnel 50 has a pin end and is attached to a box end of the housing 40 via a threaded connection 51 . The funnel 50 is arranged with its divergent end distal from the housing 40 . The funnel 50 is provided with a centralizer 90 for centralizing a wireline running therethrough. The centralizer 90 also acts as a barrier against which the wiper 60 can react under the force of the seal cone 70 acting thereagainst. An outlet port 52 extending through a sidewall of the funnel 50 is provided to recover fluids collected in the funnel 50 .
A wireline 130 is shown in FIGS. 1 to 6 centrally disposed in the throughbores 13 , 23 , 33 of the pressure control head 8 . The throughbores 13 , 23 , 33 of the components making up the pressure control head 8 shown in FIG. 1 form a continuous throughbore that allows a wireline 130 to run unimpeded therethrough. An annular space 112 is created between the wireline 130 and the throughbores 13 , 23 , 33 . The annular space 112 is substantially continuous through the body 10 , the deflector insert 20 and the nozzle insert 30 .
Prior to use, the pressure control head 8 is assembled in the form shown in FIG. 1 . The deflector insert 20 followed by the nozzle insert 30 are screwed into the flared throughbore portion 13 f of the body 10 . The piston 120 is inserted into an upper end of the body 10 such that the end face 10 e of the body abuts the piston head 120 h . The spring 80 is compressed between the piston 120 and the funnel 50 prior to making up the connections. Connections 111 , 121 , 51 , are made up respectively, between the body 10 and the collar 110 , the body 10 and the housing 40 and the housing 40 and the funnel 50 . The pressure control head 8 is then incorporated in a downhole tubing string such that the divergent end of the funnel 50 is located upstream of (closer to surface than) the collar 110 that forms the lowermost part of the assembly closest to the downhole environment. The wireline 130 can then be run downhole through the pressure control head 8 .
In use when the wellbore is at high pressure e.g. 7500 psi (51.7 MPa), the method of the invention as used to contain these downhole pressures and substantially restrict the escape of downhole fluids via leak paths in the annulus 112 between the throughbores 13 , 23 , 33 and the exterior of the braided wireline 130 . According to the present embodiment, the diameter of the wireline 130 is 0.312 inches (7.9 mm).
As the wireline 130 is being run downhole, the pump connected to the inlet port 22 pumps a working fluid into the chamber 37 . The working fluid is water and can be used with some anti-corrosion additives to limit the corrosive potential of the fluid to the wireline 130 , the pressure control head 8 and other downhole components. Continued pumping of fluid into the lower chamber 37 forces fluid through the nozzle 31 . The dimensions of the nozzle 31 and specifically, the fact that the nozzle 31 converges towards its outlet causes the fluid to accelerate, thereby increasing the speed of the fluid until it exits the nozzle 31 at the outlet in a relatively high velocity jet haying a speed of around 500 m/s. The fluid jet impacts against the impact surface 28 , which acts as an obstruction in the path of the jet. The effect of the high velocity fluid impacting against the impact surface 28 is that a large back pressure is generated due to the surface presenting an impediment to the high speed fluid flow. The 50° cone angle of the impact surface 28 deflects the fluid flow towards the wireline 130 . A localized area of high pressure is thereby formed in the annulus 112 surrounding the wireline 130 . This acts as a pressure plug. The schematic diagram shown in FIG. 3 indicates the direction of fluid flow. Arrows 114 indicate the direction in which the downhole pressures are acting. The pressure plug is at a higher pressure than the downhole pressure and therefore contains the downhole fluids at pressure that would otherwise escape in the direction of the arrows 114 .
The fluid exiting the outlet of the nozzle 31 must have sufficient velocity to overcome the pressure acting against the direction of fluid flow (shown by the arrows 114 ) in the annulus 112 . The small containment region between the nozzle 31 outlet, the impact surface 28 and the wireline 130 obstructs the fluid flow and thereby plugs the annulus to prevent the escape of high pressures. The working fluid then dissipates in the annulus 112 and the pressure decreases away from the region of the high pressure plug. Thus, working fluid flows into, through and then out from the region of the high pressure plug toward the chamber 46 . The pressure away from the pressure plug near the chamber 46 is at a lower pressure than that of the wellbore fluids contained downhole. Since the working fluid is continuously pumped and circulated through the nozzle 31 , the effect of the pressure plug is continuously maintained.
Once the working fluid has dissipated if moves up (and/or down) the annulus 112 and the fluid collected in the chamber 46 is recovered through the outlet port 44 . Fluid collected through the port 44 can then be recycled, treated if necessary, and reinjected through the inlet port 22 .
The method of the invention can be used both as the wireline 130 is run downhole and pulled from the wellbore.
In the case where the wireline 130 is being pulled to surface there may be a need to ensure that any excess fluid is removed before the wireline 130 exits the wellbore to prevent drips and spillage at the surface. In order to substantially reduce the amount of fluid carried by the wireline 130 , the wiper 60 can be urged into contact with the wireline 130 to remove excess fluid. This is achieved by injecting a hydraulic fluid through the port 128 into the chamber 126 . Fluid in the chamber 126 acts against the piston head 121 to urge upward movement of the piston 120 and hence the attached seal cone 70 against the bias of the spring 80 to force the wiper 60 into contact with the wireline 130 to remove excess fluids therefrom. The funnel 50 is shaped to collect any remaining drips from the wireline 130 that are then recovered through the port 52 and recycled if required.
The deflector insert 20 is advantageously provided as a separate component that is coupled to the body 10 . The deflector insert 20 and in particular, the impact surface 28 of the frustocone is prone to wear and can be easily removed and replaced because it is separable from the body 10 . This also applies to the nozzle insert 30 if it is damaged or suffers wear.
Ideally, the nozzle 31 should be sized to suit a large range of wireline diameters, thus, eliminating the need for bespoke equipment depending on wireline diameter. However, the fact that the deflector insert 20 and the nozzle insert 30 are separate components that together determine the shape of the nozzle 31 through which the working fluid is directed (and hence the fluid speed) allows the dimensions of the channel to be easily altered for different applications or ranges of wireline 130 size. For example, the nozzle insert 30 can be removable so that it may be replaced by a nozzle insert 30 having a steeper annular sidewall 35 to vary the speed of the fluid exiting the nozzle. Therefore, several different deflector inserts 20 and nozzle inserts 30 can be provided having differently sized throughbores 23 , 33 to facilitate use of the apparatus with different sizes of wireline 130 .
According to other embodiments, the shape of the impact surface 28 and the geometry of the confined area can be modified to obstruct the fluid flow to create the back pressure and deflect the fluids to the desired region around the wireline 130 . As shown in FIG. 4 the cone angle of the impact surface 28 is 50° relative to the axis of the wireline 130 . This is the preferred embodiment. Alternatively, a steeper cone angle may be used, as shown in FIG. 6 , where the cone angle of an impact surface 28 g is 25° from the axis of the wireline 130 . The 50° cone angle provides a more consistent pressure region in the area of the wireline 130 . According to another alternative arrangement, a lens shaped or concave surface 281 can be provided. The lens shaped surface 281 has the advantage that the smooth edges reduce the risk of cavitation caused by the turbulent flow of fluid.
Modifications and improvements can be made without departing from the scope of the present invention. For example, the nozzle 31 is not required to be concentric. Instead, individual nozzle outlets can create individual jets of fluid flow that create the same cumulative effect by forming a pressure plug in the annulus. The working fluid is not limited, to water and can be any suitable fluid that has a viscosity below around 10 centipoise (0.1 Pa s).
Following from the above description and invention summaries, it should be apparent to those of ordinary skill in the art that, while the methods and apparatuses herein described constitute exemplary embodiments of the present invention, the invention contained herein is not limited to this precise embodiment and that changes may be made to such embodiments without departing from the scope of the invention as defined by the claims. Additionally, it is to be understood that the invention is defined by the claims and it is not intended that any limitations or elements describing the exemplary embodiments set forth herein are to be incorporated into the interpretation of any claim element unless such limitation or element is explicitly stated. Likewise, it is to be understood that it is not necessary to meet any of all of the identified advantages or objects of the invention disclosed herein in order to fall within the scope of any claims, since the invention is defined by the claims and since inherent and/or unforeseen advantages of the present invention may exist even though they may riot have been explicitly discussed herein. | A method and apparatus for containing fluid in ah area of a wellbore annulus, in which fluid is energized to create a fluid flow which is at least partially obstructed and is directed to form in the annulus a localized area of high pressure to contain fluid in an area of the annulus of lower pressure. In an embodiment, the method creates a pressure plug in the annulus. | 4 |
FIELD OF THE INVENTION
This invention relates to inexpensive, knock-down furniture and to molded corner and elbow shell connectors for the assembly of such furniture.
BACKGROUND OF THE INVENTION
Furniture made for children is usually modeled after adult furniture but constructed on a smaller scale. Thus, in furniture for children, the framing might not be as heavy or as reinforced, or panels may not be as thick as those used in adult furniture. In general, the materials used for children's furniture are not as strong and are therefore, less expensive. Although furniture for children need not have the strength capacity of ordinary furniture, furniture for children does need to be made safe. Also, children's furniture tends to get dragged around, and some type of floor guard is preferable and/or necessary.
In the instant invention, novel connectors, in the form of a pair of molded, plastic shells are used: to fabricate the furniture; to protect floors by limiting the need for nail or screw fasteners; to cap, or shield normally sharp corners; and to provide socket-like receptors for channeled rails and panels, provided as parts of the furniture piece.
The connectors make easier a task that has traditionally intrigued parents, that of assembling their children's furniture. The furniture is inexpensively provided in knocked-down condition, thereby reducing shipping charges. The connectors also accomplish their intended purpose in an inexpensive and novel manner, and increase the attractiveness of the assembled furniture.
BRIEF DESCRIPTION OF THE INVENTION
The plastic shell connectors that are an integral part of the invention disclosed herein have a number of attractive and useful features. Each connector is shaped to provide a pair of socket-like receptors for receving the ends of two frame or rail members, preferably made of wood. Each rail member is channeled along its length to receive thereinto an elongated edge of a panel member. Each panel member may be attractively painted or decorated.
Each corner connector is formed of two facing, mating shells which are molded to provide pairs of aligned studs which, when the shells are assembled together, provide an attachment member that cooperates with an aperture provided through the panel member. The attachment member will extend through the aperture to provide for assembly and alignment of the panel member onto the corner connector. Other elements on the connectors provide a stop means against which an end of each of the two rail members abut to limit the projection of the rail member into the corner connector.
In order to provide a smooth corner for the assembled shells, the portion of the connector that does not provide sockets for receiving the ends of rail members is shaped to provide an exterior rounded corner. In order to effect assemblage of the two facing shells, the interior of the connector includes spaced, elongated, tapered pins that are aligned with spaced tubular sleeve parts that are each positioned to frictionally receive thereinto one of the elongated tapered pins. Each shell is preferably provided with one pair of tapered pins and one pair of tubular sleeves, and the pins-and-sleeves are so positioned that each pin will enter or telescope into a tubular sleeve provided on the complementary shell. This arrangement provides a group of four combination pins-and-sleeves which when aligned and pressed together, operate to frictionally hold the two shells assembled to each other without the need of separate fasteners.
Each connector is also provided with ribbing that reinforces the shells. The ribbing is located on the walls of the sockets that receive the ends of the rail members, and serves to help align the end of each rail within its socket. When a pair of shells are secured together, the ribs also grip the rail members in order to prevent twisting of the member relative to its socket and to limit axial movement of the rail member along its longitudinal axis. Ribs are also provided internally at the shells' rounded corners to provide for reinforcement of the corner.
BRIEF DESCRIPTION OF THE DRAWINGS
The benefits of the construction herein disclosed will become apparent to one skilled in the art from the following detailed description of a few preferred forms of construction, having reference to the accompanying drawings wherein:
FIG. 1 is a perspective view of a child's combination desk and seat, having spaced front and rear supports for the desk member and seat member, and with the front and rear supports being constructed to utilize the improved corner connectors;
FIG. 2 is an enlarged, fragmentary, perspective view of one of the corner connectors shown in FIG. 1, attaching a central panel to a pair of rail members, whose intersecting axes form an angle of is less than 90°;
FIG. 3 is an exploded, perspective view of one corner connector showing the interior of the connector and shells before the shells have been secured together;
FIG. 4 is a cross-sectional view, in a vertical plane, illustrating internal features of the assembled corner connector shown in FIG. 2;
FIG. 5 is a cross-sectional view of the corner connector shells shown in FIG. 3, as they would be assembled, but with the rail members and the panel member omitted, for purposes of clarity;
FIG. 6 is a perspective view of the corner connector of FIGS. 2 and 4 showing the two shells, or sections, of the corner connector being clamped together, by the jaws of pliers, to effect their assemblage;
FIG. 7 is a perspective view of a second piece of children's furniture, namely a combination child's bookcase and toy chest;
FIG. 8 is an exploded, perspective view of an intermediate, corner connector, illustrated in the construction shown in FIG. 7;
FIG. 9 is an exploded, perspective view of one of the floor engaging, bottom corner connectors illustrated in FIG. 7, showing the interior of the connector and shells, before the shells have been clamped together; and
FIG. 10 is a cross-sectional view, in a vertical plane, of a bottom corner connector of the type used in the construction illustrated in FIG. 7.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 shows a child's desk, generally indicated at 10. The desk component 12 is an inclined element supported by a front desk leg generally indicated at 14. The means of connection of desk component 12 to the upper end of front desk leg 14 may be any means of connection as it is not part of the invention disclosed herein. The lower portion of the front desk leg support 14 is made up of three, channel-shaped or grooved, elongated frame, or rail, members 16, 18 and 20, pairs of which are attached to each other through floor-engaging corner connectors 22 and 24. The three frame members receive, in the channel grooves thereof, a planar panel 26, which preferably is attractively decorated and is made of inexpensive sheet material, such as a heavy cardboard or chip board.
The planar panel 26 is centrally attached, by any appropriate means, such as screws, or other means of attachment, to the front edge of an elongated, planar brace 28. The brace 28 is located in a substantially vertical plane and may, for example, be cut with an arcuate leg cutout 29 from a sheet of wood. A forward portion 28' of planar brace 28 may be secured in any manner to the underside of the desk component 12. A rear portion 28" of brace 28 is attached to a rear upright support panel 30 and to the underside of a molded or formed seat.
The rear panel 30 is also framed by three channel-shaped, or grooved, elongated rail members 32, 34, 36 attached to each other through floor-engaging corner connectors 38 and 40. The rear support panel 30, its associated channel-shaped frame members 32, 34 and 36 and the two rear corner connectors 38 and 40 form a rear support leg generally indicated at 42, which together with rear portion 28", of brace 28 supports the seat component 44 of the desk 10. The heads 43 of three fastener elements, such as screws or pins, provide connectors to brace portion 28" and upright support rails of rear support panel 30. The forwardmost connector 43 passes through the seat and secures into an edge of planar brace 28. The two rearmost connectors 43 pass through the seat for connection into the ends of upright support rails 32 and 36.
FIG. 2 shows in enlarged detail, one of the desk leg's corner connectors 22. Connector 22 is formed of a pair of shell-like parts which are shaped and arranged so that when they are assembled, a pair of sockets will be formed. The sockets are constructed and arranged to receive and hold the ends of a pair of transverse frame members, such as an upright rail 16 and a horizontal rail 18. The other connector 24 of the front desk leg support 14 is a mirror image of connector 22 and is formed to provide a pair of sockets constructed and arranged to receive thereinto the second end of horizontal rail, 18 and the lower end of upright rail 20. Preferably the cross section of rails 16, 18 and 20 is rectangular with an inner rectangular cutout. The cutout is illustrated as groove 48 on rail 16, groove 52 on rail 18, and an unnumbered groove on rail 20 which has a mirror image of groove 48 on rail 16. The panel 26 is formed with edges or tongues 46 and 50 that are inserted snugly into the grooves 48 and 52 of rails 16 and 18, and into the groove of rail 20.
Each corner connector 22 is made up of two complementary, molded identical parts, so that a corner connector 22 includes an outer shell 56 and an inner shell 54. The corner connector 24 is of the same construction as corner connector 22. The shells 54 and 56 are shaped, dimensioned, and constructed to fasten around the lower end of upright rail 16 or 20, and one end of horizontal rail 18. The panel 26 is of a thickness to fit between the edges of a slot 58 that is formed when each set of two shells 54 and 56 of corner connectors 22 and 24 is fastened together.
The external surface of assembled corner connector 22 provides an exterior bottom support surface 60, best seen in FIGS. 2 and 5 which merges with rounded corner 62. The bottom surface 60 with its rounded corner 62 provides for easy movement of the desk 10 along a floor without scratching the floor. The support surface 60 also operates to space the bottom rail 18 from the floor. The support surface 60 provide, a floor contact that is different than that which a rail 18 would ordinarily make. That is, the support edge 60 provides a floor-engaging support located in a plane spaced intermediate the frame assemblage and the floor surface. The rounded, arcuate, corner surface 62 also provides for movement along the floor without snagging with a floor covering.
FIG. 3 shows the details of the interior construction and interconnection means of the pair of shells 54 and 56. Shell 54 is molded to provide, integral therewith, a pair of solid, tapered pins 64 and 66. Tapered pin 64 is so located, and is selected of a size to telescope with a press fit, into an elongated tubular sleeve 68 provided on shell 56 to develop a frictional securement therebetween. Similarly, tapered pin 66 is located to telescope with a press fit, into an elongated, tubular sleeve 70 provided on shell 56. The sleeves 68 and 70 are integrally provided on shell 56. Shell 56 also has a pair of tapered pins 72 and 74 positioned to be inserted with a press fit, respectively into tubular sleeves 76 and 78 that are provided on shell 54.
A stud segment 80 is provided on shell 54. A second stud segment 82 is provided on shell 56. When the shells are secured to each other by the tapered pins 64, 66 and 72, 74 entering their respective tubular sleeves, the complementary stud segments 80 and 82 will be axially aligned to form sections of an elongated stud. The stud will extend into an aperture 120, seen in FIG. 4, that is provided through panel 26. The panel 26 will thereby be engaged to the two adjacent ends of stud segments 80 and 82 which are each respectively part of the two shell segments 54 and 56.
The end of front upright rail 16 is to be held within a rectangular receptor socket defined by the assembled plastic shells 54 and 56. A receptor socket segment 84, provided by the shape of shell 54, along with a similar receptor socket segment 86, provided by the shape of shell 56, will together form the rectangular receptor socket for receiving a terminal end of rail member 16 when shells 54 and 56 are clamped together. The receptor socket segment 84 is bounded by a set of ribs 92 and 94, while ribs 96 and 98 bound the receptor socket segment 86. Similarly, receptor socket segment 88 is bounded by ribs 100 and 102, and receptor socket segment 90 is defined by ribs 104 and 106. All four receptor segments 84, 86, 88, 90 are also respectively provided with an intermediate rib 108, 110, 112, 114, located between the two boundary ribs. When the shells are gripped together, the ribs serve to support and align the rail members within the receptor sockets and to reinforce the walls of the shells. Each shell 54, 56 is also provided with an angle-shaped, corner, reinforcement wall means 116, 118, in the corner 62.
FIG. 4 shows a cross-sectional view of the assembly shown in FIG. 2, taken substantially at line 4--4. The panel 26 is held at its edges 46 and 50 within the grooves 48 and 52 provided on the frame members 16 and 18. The shell 54 grips the rail members 16 and 18 and aligns the panel 26. Ribs 92,94 and 108 support and center rail 16 within socket segment 84. Ribs 100, 102 and 112 support and center rail 18 within socket 88.
The frictional interconnection means by which shell 56 is held to shell 54 is also shown. Sleeve 70 of shell 56 telescopically receives tapered pin 66 of shell 54. Tapered pin 72 of shell 56 telescopes into and is engaged with sleeve 76 of shell 54. Similarly, tapered pin 64 of shell 54 is telescoped into sleeve 68 of shell 56, and tapered pin 74 of shell 56 is telescoped into and engages with sleeve 78 of shell 54.
The size of the terminal end of rail member 16 is selected so that when the rail member is properly received in a receptor socket, defined by assembled segments 84 and 86, a portion of the longitudinal edge of rail 16 will abut the stud 80 and 82, and a portion of the transverse edge, or terminus face, of rail 16 will abut against the sleeve 70, limiting the projection of the frame member into the corner connector 22. A portion of the longitudinal edge of the terminal end of horizontal rail 18, when received within a receptor socket formed by socket segments 88 and 90, will similarly abut the completed stud 80 and 82, and a portion of the transverse edge of said rail 18 will abut the tubular sleeve 78.
The alignment stud segment 80 of shell 54 projects through a portion of the aperture 120 provided on panel 26. In conjunction and alignment with stud segment 82 of shell 56, the stud segment 80 will hold the panel within slot 58, defined by spaced edges of shell segments 54 and 56, and best seen in FIG. 2.
The terminal ends of the rails 16 and 18 will be held within the assembled connectors 22 and 24, through the joint interaction of the alignment pins, and sleeves for receiving the pins, the abutment studs 80 and 82, and the rail member channels 52 and 48. The alignment stud segments 80 and 82 of the plastic corner segments will fasten the panel 26 within the corner connectors 22 and 24. The rails 16, 18 and 20 hold panel 26 within channels 48 and 52 (seen in FIG. 2). The ends of rails 16, 18 and 20 are held within receptor sockets provided on corner connectors 22 and 24. The rails 16, 18 and 20 are prevented from axial movement along their longitudinal axes by the engagement of an edge of rails 16, 18 and 20 with abutment studs 80 and 82, and by the engagement of an end of rails 16, 18 and 20 with tubular stems 78. Thus, the panel 26, rails 16, 18 and 20 and corner connectors are fastened to each other through the alignment pins/abutment studs and the insertion of the panel 26 within the rail channels 48 and 52.
FIG. 5 shows a cross-sectional view of connector 22, taken when shells 54 and 56, of FIG. 3, are assembled. Solid pin 66 of shell 54 has been telescoped into sleeve 70 of shell 56. Pin 72 of shell 56 has been telescoped into sleeve 76 of shell 54. Rib 92 of shell 54 is aligned with rib 96 of shell 56. A ridge 122 is formed which extends around the circumference of the receptor socket 124 that is formed when the shells are fastened together. Ribs 94 and 98 are aligned to form a circumferential ridge 126. Rib 108 is aligned with rib 110. Reinforcement ribs 116 and 118 are aligned to provide a single reinforcement rib. The bottom surface 60 of the connector 22 is shown in FIG. 5. Its thickness causes the floor surface to be located outwardly of the rails, such that the desk 10 will rest on the corner connectors and not on the frame. The corner connectors thus serve as a mediant between the floor surface and the rail member 18.
FIG. 6 shows shell 54 being connected to shell 56. After the panel 26 is inserted within the channels 48 and 52 of rails 16 and 18, the shells 54 and 56 are to be secured to each other around the assembly. The pins 66, 72, 64 and 74 will respectively be telescoped into a frictional holding cooperation with sleeves 70, 76, 68 and 78. The stud segments 80 and 82 will be aligned with each other and will project into and engage the aperture 120 provided on the panel 26.
Slot 58 allows panel 26 to be received within the connector 22 between the segments 54 and 56 thereof. The rails 16 and 18 will be held within the receptor sockets formed by the cooperating receptor segments 84 and 86, for receiving rail member 16, and 88 and 90, for receiving rail member 18. A cloth 128 or other protective material may be placed around the shells 54 and 56 so that the outside surface of connector 22 remains unscratched when the pliers 130 or other clamping tool is used. The pliers 130 or other clamping tool is then applied to clamp the shells 54 and 56 together, thereby holding the rails 16 and 18 to each other and to the panel 26.
FIGS. 7-10 show another piece of furniture, a child's bookcase and toy chest 132, assembled with planar panels inserted within rail members, and fastened with the novel connectors of the type described above. Side panel 134 has been inserted within the channels provided on rails 136, 138, 140, 142, 144 and 146. Each of corner connectors 148, 150, 152, 154, 156 and 158 captures two of the rails and fastens the panel 134 to them. Thus, connector 148 captures the ends of rails 136 and 146; connector 150 captures the ends of rails 136 and 138, etc. Similarly, side panel 160 has been inserted within the channels provided on rails 162, 164, 166, 168 and hidden rails corresponding with rails 136 and 146, but not seen in FIG. 7. Each of corner connectors 170, 172, 174, 176 and 178 captures two rails and fastens panel 160 to them.
A front panel 180 is inserted within channels, or grooves, that are provided on the pair of rails 182 and 184. Each of corner connectors 150, 152, 176 and 178 is provided with an alignment hole (seen at 318 in FIG. 9), through which an end screw is to be put, in order to screw into and fasten one terminal end of each of the rails 182 and 184 to the respective corner connectors. Similarly, edges of rear panel 186 are received within channels provided on rear rail members (e.g. rail 188), which also are attached with end screws to alignment holes provided on corner connectors 158, 170 and 148 and an unseen connector located at the right, bottom, rear corner of the assemblage. A lower bookshelf 190 is supported by rail 192, that is similarly attached at its ends with end screws, to alignment holes provided on corner connectors 154 and 174. Upper shelves 194 and 198 are inserted between and secured to upper sections of side panels 134 and 160. The ends of said upper shelves are secured to side panels 134 and 160 by screws that project through the side panels 134 and 160 and screw into the ends of rail members 196 and 200 which connect to the lower front edge of the associated shelves. Sliding doors 202 and 204 are inserted within grooves provided on rails 184 and 192.
FIG. 8 is an exploded view of a 225° included angle connector assembly 152, of FIG. 7, fastening panels 134 and 180 to rails 138, 140 and 184. Edge 206 of panel 134 is inserted in channel 208. Edge 210 is inserted in the channel provided on rail 140. Shell 212 is attached to the assembly so that the sleeve 214 will extend through aperture 215. Inclined rail 140 will be held within receptor socket segment 216. The sleeve on shell 230 into which solid pin 218 telescopes (not shown), will extend through aperture 219. Rail 138 will be held within receptor socket segment 220. Alignment hole 222 will line up with aperture 224 of panel 134. Screw 226 will align the panel and rails, 134, 138 and 140 with the shell 212, and will fasten rail 184 to the assembly. Screw 226 will slide through the aperture 224 of panel 134 and through the alignment hole 222 of shell 212, and screw into bore 228 of rail 184. Shell 230 is then clamped to shell 212.
Solid pins carried adjacent the top end of shell 230, but not seen in FIG. 8, telescope into sleeves 214 and 232 of shell 212. Pin 234 on shell 212 telescopes into a sleeve 236 on shell 230. Pin 238 telescopes into a bottom sleeve 240 on shell 230. Pin 218 telescopes into the other bottom sleeve (not shown) of shell 230.
Receptor socket segment 242 will adjoin socket segment 216 on shell 212 to form a receptor socket for holding rail 140. The lower edge of rail 140 will abut the sleeves 214 and 232 provided adjacent the upper end of shell 212. Rib 244 on shell 230 and rib 246 on shell 212 will align and support rail 140. Likewise, receptor socket segments 220 and 248 will form a receptor socket for holding rail 138, and ribbing on said socket segments will provide alignment of said rail. The upper edge of rail 138 will abut the sleeve means 240 only one of which is shown, provided adjacent the bottom of shell 230.
Front panel 180 of FIG. 7 will be received in both channel 250 of rail 184 and slot 252 provided on shell 212. Sliding door panels 202 and 204 will each be received in separate channels 254 and 256 of rail 184.
FIG. 9 shows a 90° included angle corner connector 148 of FIG. 7, before it is fastened together. Shell 258 has solid pins 260 and 262 to be telescoped and press fit into tubular sleeves 264 and 266 of shell 268. Pins 270 and 272 of shell 268 are to be press fit into tubular sleeves 274 and 276 of shell 258. Vertical receptor socket segments 278 and 280 combine to form a receptor socket for holding a vertical rail such as member 146. Ribs 282 and 284 on shell 268 will align with ribs 286 and 288 on shell 258 and ribs 290 and 292 will also align. The ribs will align to hold the vertical rail 146 within the socket formed by segments 278 and 280. Inverted, T-shaped abutments 294 and 296 will limit the projection of the rail 146 into the connector 148.
Horizontal, receptor socket segments 298 and 300 on shells 268 and 258, combine to form a receptor socket for holding a horizontal rail such as member 136, shown in FIG. 7. Ribs 302 and 304 of shell 268 will align with ribs 306 and 308 of shell 258 and ribs 310 and 312 will also align. Inverted, T-shaped abutments 314 and 316 will limit the extent to which the rail 136 enters the horizontal socket of connector 148. An alignment sleeve 318 that is split along its diameter will line up with a bore provided in a cross bar rail, not shown, but opposite rail 182 in FIG. 7, and a screw will be received through the alignment sleeve 318 and screwed into the bore of said rail. Cutouts or openings 320 and 322 on sleeve 318 each provide for sliding accommodation of a corner of the rails 136 and 146 into the connector formed by shells 258 and 268, without interference with the sleeve itself. Alignment stud segment 324 will enter an aperture in a panel such as panel 134, shown in FIG. 7, in order to align and to fasten the panel to the assembly. Slot 326 will receive another panel extending transverse to the panel 134 such as rear panel 186, shown in FIG. 7. Reinforcement angle rib 328 in one corner of shell 268 provides support to the alignment sleeve 318. Corner ribs 330 and 332 provide reinforcement to the bottom surface of the connector segments 268 and 258, upon which the bookcase/toy chest rests.
FIG. 10 shows a cross-sectional view of a connector, such as connector 148, shown in FIG. 7. The view is from the inside of the bookcase/toy chest. Edge 334 of panel 134 is inserted in groove 336 of rail 146 and edge 338 is inserted in groove 340 of rail 136. The shell 258 grips the rails 146 and 136 and aligns the panel 134. Ribs 286, 288 and 292 support rail 146 within socket 280 and provide reinforcement of the shell. Ribs 306, 308 and 312 support rail 136 within socket 300 and provide reinforcement of the shell. The extent to which rail 146 enters socket 280 is limited by abutment 296. Similarly, the extent to which rail 136 enters socket 300 is limited by abutment 316.
Shell 258 is frictionally interconnected with shell 268 to form fastener 148. The interconnection means between the shells consists of pins 270 and 272 of shell 268 frictionally telescoping into sleeves 274 and 276 of shell 258; and sleeves 264 and 266 of shell 268 receiving in a telescoping, friction fit pins 260 and 262 of shell 258. Shell 258 will hold and align panel 134 when alignment stud 324 extends through an alignment aperture 342 that is provided on and through panel 134. The panel will be held within a slot 344, created when shell 268 is fastened to shell 258.
While particular embodiments of this invention have been shown and described, it will be obvious to those skilled in the art that various changes and modifications may be made therein without departing from the spirit and scope of the invention. Therefore, it is intended in the appended claims to cover all such changes and modifications which fall within the true spirit and scope of the invention. | Inexpensive, knock-down, furniture constructions, assembled with mating, molded, plastic shells for corners and elbows are disclosed for use in furniture pieces for use by children. The furniture constructions include panel members of inexpensive sheet material. Each corner connector is formed of two mating shells, that are each molded of plastic and which are shaped to provide internally thereof pairs of telescoping pins and sleeves, which frictionally hold the shells assembled after the pair of shells are pressed together. Each corner connector provides at least two socket means, each for receiving a wooden rail with a channel along its length. The panel members are positioned in and held by the channels of a pair of rails. A pin or sleeve provided on at least one of the corner connectors extends through an aperture provided in each panel member, to effect a holding of the panel member in its proper intended position relative to the plastic mating shells and to the channeled rails. | 5 |
FIELD OF THE DISCLOSURE
The present disclosure is generally directed to a theater entrance of the type that is typically used as the entrance to a motion picture theater.
BACKGROUND OF THE DISCLOSURE
Motion picture theaters have been in existence for over a century and are well known in the art. The design for these theaters has evolved over time, from single screen movie houses showing one film at a time to very large multiplexes having dozens of individual theaters running different films simultaneously. But despite offering such a wide variety of entertainment options, audience attendance at movie theaters has declined.
New developments in digital technology have made home entertainment systems more advanced and accessible and so consumers have a wide variety of options such as DVD rentals, video streaming, etc. Although visiting a motion picture theater was once the only way one could see a film, now nearly every film is available instantaneously via video streaming or downloading from the comfort of one's couch at home. Those who continue to frequent motion picture theaters now do so as much for the whole theater-going experience as to watch the films themselves.
Multiplex owners have observed this trend and motion picture theaters are now being designed with this experience in mind. Special theater designs combine visual, audio, and other sensory features so that the audience is fully immersed. The audience does not merely watch a film; the audience experiences it.
Multiplexes usually include a variety of theater types so that audience members may select which type of experience they prefer. Basic 35 mm films may be suitable for some patrons while others prefer to have the option of seeing their films shown in a higher quality format (e.g. 70 mm film, digital projection, 4K Digital projection, and other developing formats) and in a theater fitted with premium features such as stadium seating, digital sound, or customized theater geometry. However, installing these premium features into a theater comes at a higher price than a basic, staggered row 35 mm projection theater and, therefore, the resulting cost is passed down to the audience members each time they purchase a ticket to one of these high quality performances.
However, the standard layout of most multiplexes and theaters does not allow for any differentiation between basic 35 mm theaters and theaters providing a higher quality, immersive experience. Frequently, the first indication that one theater is different from another occurs only after the audience enters the viewing area and the on-screen advertisements begin. Therefore, audience members may not be getting the whole experience that they desire to justify the higher ticket prices.
Thus, a need exists for a theater entrance designed in a distinctive manner so that the audience is able to distinguish a premium theater from a standard multiplex theater. The theater entrance may possess a variety of distinctive features that indicate to the audience that a different experience lies beyond the entryway from the lobby. It is important that the theater entrance have a distinct, dramatic appearance so that audience members' attention is drawn to the entryway. By creating a new, innovative theater entrance, an audience member's experience and journey begins right when he or she first approaches the theater entrance, whether it be a stand-alone movie house, or within a multiplex.
SUMMARY OF THE DISCLOSURE
The present disclosure relates to a motion picture theater having an entrance that includes an entryway between a lobby and a vestibule. The entryway is flanked by a flat outer wall. A convex image projection wall is in the vestibule that is visible from the lobby, and a curved walkway is located between the vestibule and a viewing area that is further inside the theater. The present disclosure also relates to a theater entrance that may include distinctive border lighting around the edges of the walls of the vestibule, the flat outer wall, as well as the image projection wall.
BRIEF DESCRIPTION OF THE DRAWINGS
In the accompanying drawings that form a part of the specification and are to be read in conjunction therewith, illustrate by way of example and not limitation, with like reference numerals referring to like elements, wherein:
FIG. 1 is a top schematic view of a motion picture theater with an entrance;
FIG. 2 is a front perspective view of the theater entrance shown in FIG. 1 ;
FIG. 3 is another front perspective view of the theater entrance, from a position in the vestibule;
FIG. 4 is a perspective view of the walkway of the theater entrance;
FIG. 5 is a top schematic view of an alternative design of a motion picture theater with an entrance;
FIG. 6 is a front perspective view of the alternative design of FIG. 5 ;
FIG. 7 is another front perspective view of the alternative design of FIG. 5 ;
FIG. 8 is a front view of the alternative design of FIG. 5 ; and
FIG. 9 is a schematic top view of a still further alternative design of a motion picture theater with an entrance.
DETAILED DESCRIPTION
Referring to FIG. 1 , a motion picture theater having a novel entrance design is indicated generally by reference numeral 10 . Theater 10 includes a screen 12 and a viewing area 14 for audience members. The viewing area may include seats, benches, handrails, stairs, or floor space so that the audience may stand or sit in the viewing area. Seating in the viewing area may be arranged in stadium-style, staggered rows, or any other orientation that comfortably allows audience members to view screen 12 .
The theater 10 has an entryway 16 , centrally located in this example, where audience members may enter and exit the theater. The entryway 16 is oriented so that the audience members walk from a lobby 18 and pass through the entryway 16 on their way to the viewing area 14 . The opening of entryway 16 is defined by outer walls 20 A/ 20 B.
Inside entryway 16 is a vestibule 24 where the audience members can gather or pass through on their way to the viewing area 14 . The vestibule 24 has inner walls 22 A/ 22 B, which may be curved.
On one side of vestibule 24 is an image projection wall 26 positioned opposite entryway 16 , so that image projection wall 26 is visible within vestibule 24 as well as outside entryway 16 and in lobby 18 . The image projection wall 26 may be convexly curved similarly to the shape of vestibule 24 so that it remains visible from nearly every position within vestibule 24 .
After passing through the vestibule 24 , audience members can walk along walkway 30 to the viewing area 14 . Walkway 30 may have one or more doorways 32 A/ 32 B located at opposing ends of vestibule 24 that serve to block the sounds originating in the lobby 18 and vestibule 24 from being heard within the viewing area 14 .
FIG. 2 illustrates a perspective view of entryway 16 that may be substantially centered between the two outer walls 20 A and 20 B. Outer walls 20 A and 20 B may be substantially planar so that they provide a distinctive and uniform division between lobby 18 and vestibule 24 .
As shown also in FIG. 3 , to further enhance the distinctiveness of entryway 16 , border lighting 28 may be provided either above and/or below inner walls 22 A/ 22 B and/or image projection wall 26 . Border lighting 28 consists of a light source (e.g., an LED strip) that is concealed in a wall recess located behind the top edge 29 and/or bottom edge 31 of image projection wall 26 . Because the light source is positioned within the wall recess and angled so that light extends along the adjacent wall, the light source itself remains hidden within the recess while providing a smooth and continuous border lighting 28 along the adjacent walls regardless of whether or not the walls are flat or curved. The border lighting 28 can be one solid color, multicolored, and may also have special behaviors such as, but not limited to, blinking, chasing, fading, or color-changing effects.
The image projection wall 26 is directly opposite the entryway 16 as shown in FIG. 2 and extends substantially between the floor 27 to the ceiling 25 of the vestibule 24 . Alternatively, as shown in FIG. 3 , image projection wall 26 may extend less than the full height between the floor and the ceiling of vestibule 24 . In such a case, border lighting 28 may be placed between the ceiling 25 of vestibule 24 and the top edge 29 of image projection wall 26 , or between the floor 27 of vestibule 24 and the bottom edge 31 of image projection wall 26 , or at both the top and bottom edges 29 and 31 of image projection wall 26 . Border lighting 28 may also placed at the top and bottom edges of inner wall 22 B.
As noted above, border lighting 28 may be positioned at the top and the bottom of image projection wall 26 and also on inner wall 22 , and may be placed only at the top or bottom of each wall or, alternatively, not included at all. A plurality of projectors 34 are shown positioned in a recess of ceiling 25 of vestibule 24 . The projectors 34 are positioned so that the image projection wall 26 has a continuous image projected across the entire length and height of image projection wall 26 . Alternatively, a plurality of different images may be projected along different sections of the image projection wall 26 . The projectors 34 are positioned within a recess of ceiling 25 so that they are partially hidden within ceiling 25 of vestibule 24 . Projectors 34 are angled such that audience members can approach the image projection wall 26 without blocking the projectors and disturbing or distorting the projected image on the wall. The technology for creating such an image(s) on image projection wall 26 is commercially available from various companies, such as Christie Digital Systems USA, Inc. of Cypress, Calif. Alternatively, the images on projection wall 26 could be achieved via individual displays or display panels, wherein the panels would be curved to conform with the shape of the vestibule 24 and controlled and synchronized to show a large-sized, continuous image across the whole surface of image projection wall 26 .
FIG. 4 shows walkway 30 between vestibule 24 and viewing area 14 . The walkway 30 is curved and has substantially parallel, curved inner walls 22 C and 22 D with border lighting 28 shown at both the top and bottom edges of inner walls 22 C and 22 D. Alternatively, border lighting may be placed at only one edge of the inner walls 22 C and 22 D or be entirely absent from walkway 30 . Border lighting 28 may be concealed in a wall recess located at the top edge or the bottom edge of inner walls 22 C and 22 D so that the light source itself remains hidden within the recess while providing a smooth and continuous border lighting 28 along the adjacent walls regardless of whether or not the walls are flat or curved. Alternatively, border lighting 28 B can be placed along the top or bottom edges so that the light source is visible. The border lighting 28 and 28 B can be one solid color, multicolored, and may also have special behaviors such as, but not limited to, blinking, chasing, fading, or color-changing effects.
FIG. 5 illustrates a plan view of an alternate design of the theater entrance wherein entryway 16 ′ is positioned at an approximate right angle relative to the position of the entryway 16 of FIG. 1 . Entryway 16 ′ is shown between two outer walls 20 A′ and 20 B′ at one end of vestibule 24 ′ so that it is adjacent to the curved image projection wall 26 ′. The vestibule 24 ′ has a curved inner wall 22 ′ that is opposite image projection wall 26 ′. In this design, there is one doorway 32 ′ that connects vestibule 24 ′ to the curved walkway 30 ′, and doorway 32 ′ is positioned at the far end of vestibule 24 ′, thereby creating a centered, single doorway entrance to walkway 30 ′ and viewing area 14 . Walkway 30 ′ includes substantially parallel curved inner walls 22 C′ and 22 D′ similar to walls 22 C and 22 D of walkway 30 of FIGS. 1 and 4 . Alternatively, a substantially mirror-image layout to the design shown in FIG. 5 , wherein the entryway would be on the opposite side to that shown in FIG. 5 , may be employed, as desired.
FIGS. 6-8 illustrate front views of the alternate design shown in FIG. 5 . In this configuration, outer wall 20 A′ is positioned adjacent image projection wall 26 ′. Image projection wall 26 ′ is shown to extend substantially between the floor 27 ′ and the ceiling 25 ′ of vestibule 24 ′, but it may alternatively extend completely between floor 27 ′ and ceiling 25 ′.
Entryway 16 ′ is positioned between outer walls 20 A′ and 20 B′ adjacent the left edge 33 ′ of image projection wall 26 ′. In this design, border lighting 28 ′ is positioned at the top edge 29 ′ and bottom edge 31 ′ of image projection wall 26 ′, inner wall 22 B′, and along the top and bottom edges of outer walls 20 A′ and 20 B′ (in a similar manner, border lighting 28 in FIGS. 2-4 may be provided at the top and/or bottom edge of outer walls 20 A and/or 20 B). The border lighting 28 ′ is positioned so that it is at the same level on outer walls 20 A′ and 20 B′, inner wall 22 B′, and image projection wall 26 ′ so that it appears continuous from the outer walls into and throughout vestibule 24 ′. However, the border lighting may be positioned at either the top or bottom edges of the walls or may be absent from one or all of the walls 20 A′, 20 B′, 22 B′ and 26 ′.
FIG. 9 illustrates a plan view of an alternate design of the theater entrance in which an entryway 16 ″ is positioned between two flat outer walls 20 A″ and 20 B″. Entryway 16 ″ is positioned so that it is opposite to and at one side of the image projection wall 26 ″. In contrast to the design of FIG. 5 , the design of FIG. 9 employs two doorways 32 A″ and 32 B″ at respective ends of the vestibule 24 ″ that lead to viewing area 14 . This configuration assists in crowd control, i.e., upon exiting the theater, audience members can leave via either of the two doorways 32 A″ and 32 B″ which would aid in preventing overcrowding at one exit. The image projection wall 26 ″ may extend along the entire length of vestibule 24 ″, or it may extend across only a portion of the total vestibule length. Alternatively, a substantially mirror-image layout to the design shown in FIG. 9 , wherein the entryway would be on the opposite side to that shown in FIG. 9 , may be employed, as desired.
Those skilled in the art will appreciate that the conception, upon which this disclosure is based, may readily be utilized as a basis for designing other products. Therefore, the claims are not to be limited to the specific examples depicted herein. For example, the features of one example disclosed above can be used with the features of another example. Thus, the details of these components as set forth in the above-described examples, should not limit the scope of the claims.
Further, the purpose of the Abstract is to enable the U. S. Patent and Trademark Office, and the public generally, and especially the scientists, engineers and practitioners in the art who are not familiar with patent or legal terms or phraseology, to determine quickly from a cursory inspection the nature and essence of the technical disclosure of the application. The Abstract is neither intended to define the claims of the application nor is intended to be limiting on the claims in any way. | The present disclosure is directed to an entrance to a theater of the type normally used to show motion pictures. The motion picture theater entrance has distinctive outer walls separating a vestibule from a lobby. The vestibule has a curved image projection wall located inside said vestibule and is connected to a viewing area by a curved walkway. The entrance also may include border lighting along the upper and or lower edges of its walls. | 4 |
CROSS REFERENCE TO RELATED APPLICATION
[0001] This application is based on and claims the benefit of priority from earlier Japanese Patent Application No. 2011-141332 filed on Jun. 27, 2011 the description of which is incorporated herein by reference.
BACKGROUND
[0002] 1. Technical Field
[0003] The present disclosure relates to power conversion apparatuses, and more particularly to a power conversion apparatus having a power conversion circuit that supplies an on-vehicle auxiliary unit with power converted from power supplied to an on-vehicle main unit.
[0004] 2. Description of the Related Art
[0005] This type of apparatus has been widely used for power conversion in the vehicle systems. For example, Japanese Patent Application Publication No. 2002-345252 discloses an apparatus provided with a plurality of power conversion circuits.
[0006] Assuming a plurality of power conversion circuits are required to supply power to the on-vehicle auxiliary unit, the space where the power conversion circuits are to be arranged is likely to be restricted, and therefore it is preferable to shrink the power conversion circuits. In this instance, when a plurality of power conversion circuits need to be shrunk, the power conversion circuits can be disposed effectively on a single circuit board. However, since heat radiation from each of the power conversion circuits becomes larger, excessive thermal stress may be applied to the single circuit board.
SUMMARY
[0007] An embodiment provides a newly developed power conversion apparatus having a power conversion circuit that supplies power used for an on-vehicle main unit to an on-vehicle auxiliary unit.
[0008] As a first aspect of the embodiment, an apparatus for converting power of a power source used for a main unit mounted on a vehicle includes: a first circuit that converts the power into a first power and supplies the first power to a first auxiliary unit mounted on the vehicle; a second circuit that converts the power into a second power and supplies the second power to a second auxiliary unit mounted on the vehicle; a first board on which the first circuit is mounted; a second board on which the second circuit is mounted; and a connecting member that electrically connects between the first board and the second board to allow the power of the power source to be conducted therebetween.
[0009] According to the first aspect of the embodiment, considering space for disposing the conversion boards is limited, the conversion boards need to be shrunk. However, the first circuit and the second circuit are disposed on separated circuit boards. As a result, an amount of heat radiation from a single conversion board can be reduced so that excessive stress applied to the circuit board can be suppressed.
[0010] As a second aspect of the embodiment, the apparatus includes a casing that accommodates the first board and the second board. The casing includes a first connector that electrically connects between the first circuit and the first auxiliary unit, and a second connector that electrically connects between the second circuit and the second auxiliary unit. The first and second connectors are disposed on the same surface of the casing.
[0011] When the connectors of the first and second circuits are disposed on the same side surface of the casing, comparing to the connectors of the first and second being arranged on each side surface separately, first and second circuits may be arranged to be one-sided to one side surface of the pair of side surfaces facing each other so that location at which heat is generated is one-sided to the one side surface. Therefore, in view of accelerating heat radiation of the first and second circuits, this arrangement would be disadvantageous comparing with the circuit boards being arranged on each of the side surfaces. However, according to the embodiment of the present disclosure, separate circuit boards are arranged in the power conversion apparatus. As a result, degrading heat-radiation characteristics because of the connectors being arranged on the identical side surface, can preferably be compensated for.
[0012] As a third aspect of the embodiment, the apparatus includes a power supply board on which a power supply unit used for supplying the power of the power source to the first and second circuits is disposed; and a casing that accommodates the first board, the second board and the power supply board. The first board, the second board and the power supply board are arranged in a single row, and the power supply board is disposed in an end portion of the casing.
[0013] According to the third embodiment, the power of the power supply board can be sequentially transferred to a circuit board adjacent to the power supply board and the other circuit board which is not adjacent to the power supply board. Therefore, a wiring pattern used for supplying power on the power supply board can readily be accomplished. Moreover, the number of connecting devices mounted on the power supply board can be reduced so that the size of the power supply board which is likely to be large can be shrunk as much as possible.
[0014] As a fourth aspect of the embodiment, the first and second circuits are operated at mutually different switching frequencies.
[0015] The inventors have found that when the switching frequencies of the first and second circuit thereof are different to each other, the power supply unit is shared by the first and second circuits whereby necessary power for the first and second circuits is supplied by the shared power supply unit of which power supply capability (i.e., rated power output) is smaller than sum of the power supply capability of respective power supply units when the power supply units are arranged individually for each of the first and second circuits. Therefore, according to the embodiment, the power supply unit can be shrunk based on the above-described configuration.
[0016] As a fifth aspect of the embodiment, the apparatus includes a casing that accommodates the first board and the second board, and a heat sink is disposed on a surface of the casing to be extended in a direction perpendicular to a direction along which the first and second boards are arranged.
[0017] According to the fifth aspect of the embodiment, the heat-sink is disposed in such a manner. Therefore, compared to the heat-sink extended in a direction along which the first and second boards are arranged, the heat radiation of the first and second boards by the heat sink can be averaged.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] In the accompanying drawings:
[0019] FIG. 1 is a diagram showing a system configuration according to an embodiment;
[0020] FIGS. 2A and 2B are diagrams showing a configuration of the power conversion unit according to the embodiment; and
[0021] FIG. 2C is a cross sectional view taken at line A-A of FIG. 2A .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
First Embodiment
[0022] With reference to the drawings, hereinafter is described the first embodiment in which a power conversion apparatus according to the present disclosure is adapted to a hybrid vehicle.
[0023] FIG. 1 is a diagram showing a system configuration according to the first embodiment.
[0024] A high voltage battery 20 as shown in FIG. 1 is a power source for supplying power to an on-vehicle main unit as a driving motor of the vehicle. The high voltage battery 20 is a secondary battery having a terminal voltage of about 100 volts, such as a lithium-ion battery or a nickel metal hydride battery. The negative terminal voltage of the high voltage battery 200 is isolated from the vehicle body. For example, a pair of capacitors are connected to both terminals of the high voltage battery and the connection point of the pair of capacitors is connected to the vehicle body so that a center value between a potential at the positive terminal and a potential at the negative terminal of the high voltage battery 20 equals the potential of the vehicle body.
[0025] The high voltage battery 20 is electrically connected to a pair of power supply lines Lp and Ln which are connected to the power supply unit PSC. The power supply unit PSC includes a normal mode choke coil 16 and a smoothing capacitor 18 . The normal mode choke coil 16 is connected to each power supply line Lp and Ln and the smoothing capacitor 18 is connected to the power supply lines Lp and Ln in parallel.
[0026] The inverters INV 1 , INV 2 and INV 3 (i.e., conversion circuit) connected in parallel with each other are connected to the power supply unit PSC. The inverter INV 1 is used for applying three phase AC (alternating current) voltage to a heater 10 mounted on the on-vehicle air conditioner. The inverter 2 is used for applying three phase AC voltage to a motor 12 of a blower fan mounted on the on-vehicle 20 . The inverter INV 3 is used for applying three phase AC voltage to a motor 14 mounted on a water pump for cooling coolant in a cylinder block of the on-vehicle internal combustion engine. The above-described heater 10 is an electric heater designed to be driven by a three phase AC inverter similar to the inverters INV 1 , INV 2 and INV 3 . The heater 10 , the motor 12 of the blower fan and the motor 14 connected to respective inverters INV 1 , INV 2 and INV 3 serves as on-vehicle auxiliary units each corresponding to either the first auxiliary unit or the second auxiliary unit. The inverters INV 1 , INV 2 and INV 3 each corresponds to either the first circuit or the second circuit.
[0027] In this configuration, the inverters INV 1 , INV 2 and INV 3 share the power supply unit PSC. This is because capacitance value of the smoothing capacitor connected to the power supply unit PSC when the inverters INV 1 , INV 2 and INV 3 share the power supply unit PSC becomes smaller than the capacitance value of the smoothing capacitor when each inverter has own power supply unit. However, to decrease the capacitance value of the smoothing capacitor, the switching frequencies fs 1 , fs 2 and fs 3 corresponding to the respective inverters INV 1 , INV 2 and INV 3 should be set to be different values each other. Therefore, according to the first embodiment, these switching frequencies fs 1 , fs 2 and fs 3 are set to be different values.
[0028] The above-described inverters INV 1 , INV 2 , INV 3 and the power supply unit PSC are accommodated in a single casing CA which is made of metal. The on-vehicle electrical load, i.e., the motors 12 , 14 and the heater 10 are connected to the casing CA externally whereby the casing CA can be shrunk and arranged at a location where suffering damage if the vehicle collides with something can be avoided.
[0029] The above-described casing CA further includes microprocessors 32 , 34 and 36 which generate control signals of the inverters INV 1 , INV 2 and INV 3 and outputs the control signals to the inverters INV 1 , INV 2 and INV 3 , and the microprocessor 30 . The microprocessor 30 receives a command value used for a control variable of each load (i.e., auxiliary unit) which is inputted externally (from an external device), assigns the command value to the respective microprocessors 32 , 34 and 36 and outputs the command value to the respective microprocessors. Therefore, each of the microprocessor 32 , 34 and 36 controls a phase-voltage corresponding to the respective inverters INV 1 , INV 2 and INV 3 in response to the command value inputted externally. Specifically, each of the microprocessors 32 , 34 and 36 compares the phase-voltage of the inverter with a triangle-wave-shape carrier signal and generates the control signal of the inverters INV 1 , INV 2 and INV 3 based on the result of comparison between the phase-voltage and the carrier signal, so as to control the respective phase-voltage of the inverters. The microprocessor 30 receives the command value via an isolation means such as a photo coupler. The above-described microprocessor 30 and the power supply unit PSC are mounted on a power supply board 40 , the inverter INV 1 and the microprocessor 32 are mounted on a conversion board 42 , the inverter INV 2 and the microprocessor 34 are mounted on a conversion board 44 and, the inverter INV 3 and the microprocessor 36 are mounted on the conversion board 46 . The conversion boards 42 , 44 and 46 each correspond to either the first board or the second board.
[0030] With reference to FIGS. 2A and 2B , a structure of the casing CA according to the first embodiment and how the power supply board 40 , the conversion boards 42 , 44 and 46 are accommodated in the casing CA, are explained as follows.
[0031] As shown in FIG. 2A , in the casing, the power supply board 40 and the conversion boards 42 , 44 and 46 are arranged in a single row having gaps (G 1 , G 2 and G 3 as shown in FIG. 2C ) therebetween. The power supply board 40 and the conversion board 42 are electrically connected via a connecting member 50 . Similarly, the conversion boards 42 and 44 are electrically connected via the connecting member 50 . Further, the conversion boards 44 and 46 are electrically connected via the connecting member 50 as well. The connecting member 50 is a conducting member being embedded into each of the end portions in adjacent two boards.
[0032] Specifically, the connecting member 50 connected between the power supply board 40 and the conversion board 42 includes a pair of power supply path connected to the output terminal of the power supply unit PSC (i.e., positive end and negative end of the smoothing capacitor 18 ) and a signal propagation path in which a command value used for generating the control signals of the inverters INV 1 , INV 2 and INV 3 is transmitted. The connecting member 50 connected between the conversion board 42 and the conversion board 44 includes a pair of power supply path connected to the output terminal of the power supply unit PSC (i.e., positive end and negative end of the smoothing capacitor 18 ) and a signal propagation path in which a command value used for generating the control signals of the INV 2 and INV 3 is transmitted. Further, the connecting member 50 connected between the conversion board 44 and the conversion board 46 includes a pair of power supply path connected to the output terminal of the power supply unit PSC (i.e., positive end and negative end of the smoothing capacitor 18 ) and a signal propagation path in which a command value used for generating the control signal of the INV 3 is transmitted.
[0033] Regarding the above-described casing CA, connectors 60 a, 60 b , 60 c, 60 d and 60 e which are made of resin are arranged on a side surface of the casing CA to be in single row shape. The connector 60 a connects the above-described ECU 22 and the power supply board 40 (interface 30 ), and is disposed facing the power supply board 40 . The connector 60 b connects the above-described pair of power supply line Lp and Ln and the power supply unit PSC of the power supply board 40 , and is disposed facing the power supply board 40 . The connector 60 c connects the heater 10 and the conversion board 42 (inverter INV 1 ), and is disposed facing the conversion board 42 . Moreover, the connector 60 d connects the motor 12 of the blower fan and the conversion board 44 (inverter INV 2 ), and is disposed facing the conversion board 44 . The connector 60 e connects the motor 14 of the water pump and the conversion board 46 (inverter INV 3 ), and is disposed facing the conversion board 46 .
[0034] FIG. 2B is a diagram showing a surface of the casing CA. As shown in FIG. 2B , a heat sink (ribs 62 a and 62 b ) is arranged on the surface of the casing CA (arranged on R 1 and R 2 areas respectively as shown in FIG. 2B ). The heat sink is arranged such that the longitudinal direction of each rib is disposed along a direction where the connectors 60 a, 60 b , 60 c, 60 d and 60 e are extended from the casing CA. The Ribs 62 a and 62 b are used to expand an area being exposed to the atmosphere surrounding the heat sink whereby the heat exchange between the heat sink and the atmosphere can be enhanced.
[0035] As described above, in the first embodiment, the connectors 60 a , 60 b, 60 c, 60 d and 60 e are disposed on a side surface of the casing CA so as to improve a working property when the casing CA is installed to an on-vehicle system. Assuming the connectors are arranged on both side surfaces (a pair of side surfaces facing each other) of the casing CA, it may be necessary to change the type of supporting the casing CA depending on which connectors on the both side surfaces are used for connecting. As a result, the working property may be decreased.
[0036] According to the first embodiment, the power supply board 40 , the conversion boards 42 , 44 and 46 are separated as individual boards. As a first reason, since the circuit board tends to bend to have curvature, when the circuit components to be mounted on the power supply board 40 and the conversion boards 42 , 44 and 46 are mounted on a single circuit board, surface area of the board becomes larger so that the curvature may become significant. Therefore, if the circuit board has curvature, even when a mold material covers the surface of the circuit board to avoid a dielectric breakdown between wiring of the circuit board and the electronic devices, the mold material may be peeled off thereby degrading the insulating performance.
[0037] The second reason is to enhance a capability of heat radiation from the circuit board. Specifically, according to the first embodiment, the connectors 60 a, 60 b, 60 c, 60 d and 60 e are arranged on only one side surface of the casing CA so that the power switching elements (i.e., inverter INV 1 , INV 2 and INV 3 ) need to be disposed on the one side in the casing CA and an amount of heat at the one side in the casing CA increases. Accordingly, the circuit board is divided to enhance the heat radiation when comparing with only one circuit board being used. Further, gaps are disposed between circuit boards, and the connecting member 50 having high heat-radiation characteristics connects between the circuit boards, whereby the effect of the heat radiation can be significant.
[0038] Moreover, the power supply unit PSC used for supplying power to the INV 1 , INV 2 and INV 3 mounted on the respective conversion circuit board 42 , 44 and 46 is mounted to the power supply board 40 , whereby heat radiation from the conversion boards 42 , 44 and 46 can be further enhanced. That is, since the circuit components mounted on the power supply board 40 include a component such as smoothing capacitor 18 of which height is larger than that of the circuit components mounted on the conversion board 42 , 44 and 46 , as shown in FIG. 2B , the length of the rib 62 b (L 1 ) extended from the casing CA is set to be shorter than that of the rib 62 a (L 2 ) at the conversion circuits 42 , 44 and 46 . Therefore, assuming the power supply unit PSC is disposed to each of the conversion boards 42 , 44 and 46 , the length of the rib 62 a extended from the conversion boards 42 , 44 and 46 becomes shorter, thereby degrading heat-radiation characteristics of the conversion boards 42 , 44 and 46 .
[0039] The above-described rib 62 a is formed to be perpendicular to a direction along which the conversion boards 42 , 44 and 46 are arranged (i.e., a direction where the conversion boards are facing each other) so that the capability of heat-radiation in the respective conversion boards 42 , 44 and 46 can be equivalent to each other.
[0040] The power supply board 40 including the above-described power supply unit PSC is disposed in the end portion of the casing CA so that the power supply board 40 can be shrunk. However, if the power supply board 40 is disposed in the central area of the casing CA, the power line which is connected to the positive and negative terminals of the smoothing capacitor 18 needs to be connected to the connecting member 50 disposed at the respective end portions of the power supply board 40 . Therefore, size of the power supply board 40 becomes larger.
Other Embodiment
[0041] The above-described embodiment can be modified as follows. Regarding the connecting member 50 , it is not limited to the conducting member embedded into the end portions where adjacent circuit boards face each other. For example, a bonding wire soldered to a wiring portion in the respective circuit boards can be used to electrically connect the circuit boards.
[0042] Regarding the casing, it is not limited to the circuit boards arranged in a single row, however, the circuit boards can be arranged in double rows. In this case, to avoid interference between wirings, the connectors may preferably be disposed on an opposing pair of surfaces of a hexahedral casing.
[0043] Moreover, the casing is not limited to the hexahedron shape. For example, a casing having ellipse shape can be employed. The casing is not limited to a single casing, however, a plurality of casing can be used such that the a casing accommodating the power supply board 40 , a casing accommodating the conversion board 42 , a casing accommodating the conversion board 44 and a casing accommodating the conversion board 46 can be prepared separately and these casings are connected each other by a connecting member disposed on the respective side surfaces of the plurality of casing. In this case, capability of heat-radiation in the respective circuit boards can be further enhanced.
[0044] Regarding the connector, it is not limited to arrange all of the connectors on one surface of the hexahedron of the casing. For example, the connectors can be arranged on two surfaces that face each other. In this case, a difference between an average distance (average) from the surface facing the inverter to a surface of a pair of surfaces, and an average distance from the surface facing the inverter and the other surface of the pair of surfaces, can be reduced so that locations where the heat is produced can be balanced in the casing.
[0045] The connectors can be made of metal instead of resin whereby the heat-radiation performance at the connector portion can be enhanced.
[0046] Regarding the power supply board, it is not limited to the power supply board disposed at the end portion of the casing.
[0047] As to the power supply board, the power supply board may include not only the microprocessor 30 , but also microprocessors 32 , 34 and 36 .
[0048] Regarding the number of conversion boards, it is not limited to three boards, for example, two boards or four or more conversion boards can be used. Further the number of auxiliary units connected to the respective conversion boards is not limited to three, for example, two auxiliary units or four or more auxiliary units can be used. Moreover, one conversion board does not necessarily include only one conversion circuit, however, one conversion board can include two or more conversion circuits.
[0049] Also, devices used for generating a control signal to control the switching element of the conversion board can be mounted on the conversion board.
[0050] Regarding the heat sink, it is not limited to the rib 62 a and the rib 62 b of which size is smaller than the rib 62 a. However, the rib 62 a and the rib 62 b having the same size can be used, when the smoothing capacitor 18 included in the power supply unit PSC is shrunk so that the dimension of the casing CA is shrunk significantly.
[0051] Regarding the ribs 62 a and 62 b, it is not limited to a rib extending in a direction perpendicular to a direction along which the conversion boards are arranged. However, the ribs 62 a and 62 b can be extended in the direction along which the conversion boards are arranged.
[0052] Regarding the conversion circuit, it is not limited to three phase inverters. For example, a single phase inverter can be used for the heater 10 . When a five phase motor is used for the motor 12 of the blower fan, the inverter used for the motor 12 will be a five phase inverter.
[0053] Further, it is not limited to a DC-AC conversion circuit having a switch element that selectively connects positive/negative terminals of a DC power source and a terminal of an on-vehicle auxiliary unit.
[0054] Moreover, it is not limited to the conversion circuits of which switching frequencies are changed depending on the conversion boards. It is not limited to a hybrid vehicle, that is, for storing energy supplied to an on-vehicle drive motor, only an output unit that outputs an electric energy (i.e., secondary battery, fuel cell) may be provided. Even in this case, the present disclosure has an advantage when the output unit is used for a power source of a plurality of on-vehicle auxiliary units such as a blower fan or a heater. | An apparatus for converting power of a power source used for a main unit mounted on a vehicle includes: a first circuit that converts the power into a first power and supplies the first power to a first auxiliary unit mounted on the vehicle; a second circuit that converts the power into a second power and supplies the second power to a second auxiliary unit mounted on the vehicle; a first board on which the first circuit is mounted; a second board on which the second circuit is mounted; and a connecting member that electrically connects between the first board and the second board to allow the power of the power source to be conducted therebetween. | 8 |
PRIOR RELATED APPLICATION DATA
This application is a continuation of U.S. application Ser. No. 12/478,585, filed Jun. 4, 2009, which claims priority to Indian Patent Application No. 1396/CHE/2008, filed Sep. 6, 2008, the entire content of which is incorporated herein by reference in its entirety.
FIELD
This invention relates to rotary reactors such as rotary kiln for the gasification of solid carbonaceous materials such as biomass and solid wastes and particularly to the gas distributor for introducing gases such as air, oxygen, and steam to the interior of the rotary kiln wherein this gas distributor assures gas solid mixing inside the reactor to promote gas solid reaction.
GENERAL BACKGROUND AND THE STATE OF THE ART
In the last two decades or so, interest in biomass gasification has picked up as means of producing energy from renewable resources to supplement fossil fuels as well as to develop strategy for distributed generation for reasons of meeting energy security needs. This renewed interest has encouraged development of new and improved methods for making biomass gasification efficient and fuel gas generated from these cleaner in terms of its tar content. Biomass typically comprises collectable, plant-derived materials that may be abundant and relevantly inexpensive in comparison to fossil fuels. Additionally, biomass may be potentially convertible to feedstock chemicals or used for electricity generation. Some examples of sources of biomass may be, without limitation, wood, grass, agriculture and farm wastes, manure, waste paper, rice straw or rice husks, corn stores, corn cobs, sorghum stover, poultry litter, sugarcane bagasse, waste resulting from vegetable oil extraction, peanut shells, coconut shells, shredded bark, food waste, urban refuse and municipal solid waste.
The present invention is directed to a reactor vessel in which solid, liquid and gaseous organic wastes such as but not necessarily limited to forestry and agricultural residues, animal wastes, bacterial sludge, sewage sludge, municipal solid waste, food wastes, animal bovine parts, fungal material, industrial solid waste, waste tires, coal washing residue, petroleum coke, oil shale, coal, peat and lignite, waste oil, industrial liquid wastes, residuals from petroleum refining and volatile organic compounds generated by the industrial processes are transformed into gaseous fuels with maximum conversion efficiency while maintaining resultant synthesis fuel gas free of tar and oil. The organic materials of this type commonly referred to as carbonaceous materials include fixed carbon, volatile matter and ash.
Moisture present with all of the carbonaceous is also included in the volatile matter. The primary objective of the transformation is to obtain essentially complete conversion of carbon and volatile matter into synthesis fuel gas, while leaving only ash as solid residue. This transformation of the organic material takes place by combining these organic materials with steam and air or oxygen in a high temperature environment. Gas-solid contact, the temperature and the time allocated for gas-solid contact at a given temperature all play a role in the extent of conversion of the organic material introduced into the reactor vessel. Most of the time, the moisture content of the organic feed material is adequate for the transformation reactions. However, the present invention also includes the benefits of introducing additional moisture to produce uniform quality of the synthesis gas from this apparatus. The present invention does not preclude pre-drying of the organic feed material prior to its introduction into the reactor vessel.
The advantages of converting organic material into synthesis fuel gas over directly combusting the carbonaceous material are quite significant. Direct combustion of carbonaceous materials mentioned above usually results in smoke and discharge of unwarranted polluting compounds to the detriment of human health. Besides, direct combustion results in deposition of tar in the chimneys which poses a fire hazard. In contrast, the synthesis fuel gas, after production and clean-up, contains simple clean burning combustible gases, namely carbon monoxide, hydrogen and some methane along with non-combustible nitrogen, carbon dioxide and water vapor. This synthesis fuel gas is also suitable for fuel use for internal combustion engines.
The ideal device for the transformation of carbonaceous material into synthesis fuel gas would comprise of ability to introduce all types of carbonaceous materials without limitations in reason of its origin, size, and composition and that would also provide ideal mixing between solids present in the device and gas including air and steam that is introduced into the apparatus. There are number of devices that are capable of transforming all sorts of carbonaceous materials into synthetic fuel gas; however, none of them are without limitations.
For example, the bubbling fluidized bed reactors are well known for providing ideal contact between solids and gases; however, these devices lack versatility with respect to handling multiple types and sizes of carbonaceous materials. The operation of fluidized bed device is generally restricted to one particular type and one size of carbonaceous material since any variation in these would upset the delicate balance between fluidization velocity and the size of the carbonaceous material as well as the balance between the composition of the carbonaceous material and amount of reaction gases such as air and steam introduced into the reactor.
Another example of reactor with good contact between solid and gas is the circulating entrained bed reactor. This type of reactor increases contact time between the solids and gases by continuous recirculation of the solids inside the reactor vessel. Again this type of reactor lacks versatility with respect to type and size of the carbonaceous material.
In the small-scale category of the available reactors, common ones are updraft gasifiers, downdraft gasifiers, and cross-draft gasifiers. All of these types of reactors have restrictions with respect to the density and the size of the carbonaceous material they can handle. Besides none of these reactors have ability to provide ideal mixing between solids and gases which is a prerequisite for obtaining maximum conversion of carbonaceous material into synthesis fuel gas. As a result of poor mixing, these reactors lose significant amount of carbon with the solid residue. In comparison to all of the aforementioned devices, the rotary reactor such as kiln is most flexible and versatile in terms of handling vast array of carbonaceous material irrespective, within reasons, of type, composition, and size. The rotary kiln device is also suitable for operating at full load and part load as necessitated by synthesis fuel gas demand or by availability of the carbonaceous material. The primary weakness of the rotary kiln is gas solid mixing without which it is difficult to attain high conversion of carbonaceous fuel into synthesis fuel gas. In a study performed by CPL Industries (Reference 1), it was quite apparent that without allowing provisions for suitable mixing inside the kiln it was not possible to attain high transformations of carbonaceous fuel into synthesis fuel gas. Without adequate mixing between solids and gases, the air and steam has tendency to bypass reaction with solids and instead prefers to react with gases thereby impairing the quality of synthesis fuel gas with respect to its heating value. Moreover the bypassing of air and steam results in lower conversion of carbonaceous material and hence lot of carbon is lost with the solid residue.
The present invention provides an apparatus to introduce air, steam, and other gases which when installed inside of the rotating reactor such as kiln tremendously improves gas solid mixing inside the reactor and thereby assures maximum conversion of carbonaceous material into synthesis fuel gas. With this ability for gas solid mixing and its inherent flexibility with respect to accepting wide array of carbonaceous material irrespective of type, composition, and size; and combined with its ability to operate within large variation of loading of the carbonaceous material, the kiln reactor would become the reactor of choice for distributed power generation for smaller and larger applications.
Some prior attempts to provide improved gas solid mixing in a rotary kiln as well as attempts to improve conversion of carbonaceous material into synthesis fuel gas in rotary kiln by indirect means are mentioned below.
SUMMARY OF THE INVENTION
According to a preferred embodiment of the present invention, there is provided a port assembly secured by the stationary plate of the rotary kiln and positioned for communication with the interior of the rotary kiln. The port assembly comprises of a main conduit for introducing gases such as air, oxygen and steam into the kiln as well as several nozzles extending from the main conduit for distribution of gases into the kiln as well as to promote intimate mixing between gases emerging from these nozzles and solids present in the kiln. The main conduit extends approximately two thirds of the way into the kiln if the kiln is operating as a gasifier. The conduit will extend all the way to the end of the kiln if the kiln is operating as a combustor. A movable gas plug is inserted inside of the main conduit. The position of this gas plug determines the length of the kiln into which reactant gases are introduced. This flexibility is essential because in the case of gasification of the carbonaceous material, it is first necessary to combust portion of the carbonaceous material with air or oxygen to provide energy necessary to carry out the reactions between gases and solids and also to maintain temperature in the reactor that would sustain endothermic reactions between steam and the carbonaceous materials to yield synthesis fuel gas. In contrast, combustion of carbonaceous material is completely consumed by air or oxygen supplied to the kiln and therefore the air is supplied throughout the reactor. In fact, for combustion, additional air beyond that required for complete combustion is introduced into the kiln to absorb the heat and to control run away condition with respect to temperature. The conduit is blocked at the far end of the assembly so that there is sufficient discharge of gases through the nozzles.
The number and spacing of the nozzles depends upon the size of the apparatus and the corresponding gas flow required for the process. The following description is one of many applications of this invention. The person familiar with the art will readily recognize the possibility multiple arrangements of this port assembly as well as multiple applications associated with this port assembly. All of these arrangements and applications are implied and included in this invention.
The port assembly in this invention will work best if minimally three nozzles are associated with each of the designated conduit circumference for nozzle installation. This number would increase depending upon the conduit diameter and the amount of gas flow passing through the main conduit. These circumferential nozzles are repeated along the length of the main conduit. Again minimally three rows of nozzles are preferred, each row being equidistance from the other. This number would increase depending upon the length of the kiln and amount of gas introduced into the kiln.
All nozzles protruding from the main conduit will be installed at an angle that varies from minus 60 degrees to plus 60 degrees from the vertical orientation. Vertical orientation implies that the nozzle is installed perpendicular to the main conduit. This invention incorporates all possible orientation with respect to each of the nozzle installed onto the main conduit. All the nozzles can be mounted uniformly using one particular angle; or mounted non-uniformly facing towards or away from one another with each at the same or different angle.
For the particular application of gasifying carbonaceous material in the rotary kiln, all the nozzles protruding from the main conduit will protrude towards the wall of the kiln terminating 6 to 12 inches from the wall to allow free passage of solids along the wall of the kiln and along the length of the kiln. This dimension, however, is not general and the determination of the termination of these nozzles from the proximity of the kiln wall will largely depend upon the material being processed in the kiln and therefore it will vary from application to application.
In general, the diameter of the nozzles at any given circumference of the port assembly will be identical, although not necessary. However, the diameter of nozzles as they move into the kiln will become successively larger along the main conduit to reduce the pressure drop across them so that the gas flow can pass unhindered through all the nozzles.
In order to reduce the effect of direct impingement of gas jet onto the wall of the kiln, suitable muzzle devices can be installed
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic of rotary kiln gasifier with rotating gas distributor.
FIG. 2 is a cross section of the rotary kin gasifier with rotating gas distributor.
FIG. 3 is a depiction of an example of gas distributor to indicate its structure with respect to nozzle angles and nozzle diameters.
FIG. 4 is example of gas distributor with uniform nozzle spacing and nozzle orientation along the solid and gas flow in the rotary kiln gasifier.
FIG. 5 is example of gas distributor with uniform nozzle spacing and nozzle orientation away from the solid and gas flow in the rotary kiln gasifier.
FIG. 6 is example of gas distributor with nonuniform nozzle spacing and nozzle orientation.
FIG. 7 is a depiction of example of temperature distribution inside the rotary kiln gasifier.
DETAILED DESCRIPTION
FIG. 1 depicts one of many types of rotary kiln apparatus with which the present invention can be practiced. Referring to FIG. 1 , the rotary kiln gasifier 1 is a hollow refractory lined vessel with suitable inlets for feeding carbonaceous material 2 , suitable inlet for feeding reactant gases such as air and steam 3 , suitable outlet for fuel gas 4 , and suitable outlet for ash 5 . The rotary kiln depicted in FIG. 1 can also operate as combustor with equal effectiveness. The gasifier 1 should be large enough to gasify desired capacity of carbonaceous material and to provide adequate residence time for the gasification reactions between carbonaceous materials and the gaseous reactants. The interior of the gasifier 1 is preferably refractory lined 6 or alternatively surrounded by heat transfer devices such as tubes containing flowing liquids to absorb heat. The refractory lined kiln is preferred because the hot refractory retains heat and transfers that heat to the carbonaceous material coming in its contact thereby raising the temperature of the said carbonaceous material and thereby making it easier for gaseous reactant to initiate gasification reactions with the said solids.
Because of the nature of the rotating kiln, when the carbonaceous solid material is introduced into the said kiln, the solid carbonaceous material generally gravitates towards the walls of the said kiln. In contrast the flow of gas introduced at the head of the kiln flows through the middle of the kiln and as a result minimal interaction between the solids and gas is expected in this type of devices. In order to get maximum benefit out of this type of devices it is essential to maximize gas-solid interaction. This is exactly what the rotating gas distributor 7 of the present invention achieves.
The rotating gas distributor 7 is essentially a gas port as a means of introducing and distributing reactant gases such as air, oxygen, and steam into the rotary kiln gasifier or the rotary kiln combustor to attain maximum interaction between the solid carbonaceous material present in the kiln with the reactant gases that are being introduced through the said gas distributor. The gas port 7 is supported at both ends of the kiln by the front and rear hoods of the kiln with flexible sealed insertions 8 and 9 respectively. Although the port comprises of a continuous conduit for providing support, the gas passage through the port is terminated at the appropriate location by means of a solid gas plug 10 inside the kiln depending upon the operation of the kiln as a gasifier or as a combustor. The gas plug 10 is mounted onto the conduit (insert no) so that its location can be manipulated from outside of the rotary kiln. This plug 10 restricts the introduction of oxygen-bearing reactant gases to about two thirds of the way into the kiln, when operating as a gasifier, to facilitate partial oxidation reactions between the solid carbonaceous material and the oxygen in order to provide necessary heat of reaction for endothermic reaction between steam and carbonaceous material which is allowed to be carried out throughout the length of the kiln gasifier 1 . The selection of two thirds of the way into the gasifier for the introduction of oxygen-bearing gases is not to be construed as absolute since this distance will vary according to the properties of the carbonaceous material being processed as well as amount of oxygen introduced into the gasifier. The person knowledgeable in the art of gasification of carbonaceous materials would easily recognize that specific generalization for the extent of insertion of oxygen-bearing gases cannot be made and that the invention covers all possible insertions as are necessary for the efficient utilization of the carbonaceous solid materials. The gas plug 10 is positioned all the way to the end of the kiln, near the exit of the gas, when the kiln is operating as a combustor so that the oxygen bearing gases are supplied to the length of the kiln.
The reactant gases such as air, oxygen, and steam are supplied to the rotating port by means of a fixed conduit communicating with rotating port 7 via a flexible seal connection 12 .
In order to effectively distribute the reactant gases in the vicinity of the solids, the port is fitted with number of nozzles distributed along the length and circumference of the port such as 13 and 14 as depicted in FIG. 1 . These nozzles protrude from the port and terminate some distance from the wall of the kiln gasifier 1 . The plurality of the nozzles will depend upon the size of the kiln gasifier 1 and the capacity with respect to processing carbonaceous material through the gasifier. Typically the nozzles will terminate six to twelve inches from the wall of the rotary kiln gasifier; however, this distance is adjusted according to the size and the capacity of the gasifier.
The gas distributor assembly 7 is fitted externally with sprockets 15 which are connected to reversible variable speed drive so that the gas distributor can be rotated at various speeds. The gas distributor 7 can be operated in a stationary mode or rotated clockwise or counterclockwise. The rotation of the gas distributor 7 in the same direction as the kiln gasifier 1 rotation will tend to confine the solid carbonaceous material inside the kiln pegged to the walls of the gasifier 1 and the heat of reaction for the gasification will be supplied by the heat retained by the refractory via heat conduction and by the heat generated from partial combustion of the said carbonaceous solids. When the gas distributor 7 is rotated in the direction opposite to the motion of the kiln gasifier 1 , the shear forces generated by the gas jets impinging on the walls of the gasifier 1 will tend to strip the particles of the carbonaceous material off the walls of the gasifier 1 and react with them with the help of heat of reaction being supplied by the convection and the radiation from the hot walls of the gasifier 1 as well as from the heat generated from partial combustion of carbonaceous solids. When the gas distributor 7 is operated in a stationary mode, the relative velocity of the kiln gasifier 1 rotation with respect to the gas distributor 7 will dictate the fate of gas solid reactions within the bounds of the gasifier 1 . Each mode of operation is covered by this invention.
FIG. 2 is a cross section of the kiln gasifier 1 . It illustrates the communication between the main gas port 7 and the nozzles depicted by 13 and 14 . It also depicts the allowance of space 18 between the termination of the nozzles 13 and 14 and the refractory wall of the kiln gasifier 1 . This allowance of the space 18 enables the kiln gasifier 1 to maintain conventional profile of solids within the confines of the kiln gasifier 1 .
FIG. 3 illustrates the plausibility of spacing and angles for positioning nozzles onto the main gas port 7 . The number and the inclination of the nozzles will largely depend upon the amount of turbulence required for effective gas solid contact in the vicinity of the walls of the kiln gasifier 1 . The inclinations of each of the nozzle can be different from the other implying that the angles A 1 , A 2 , A 3 and A 4 can be equal or totally different from one another. Similarly circumferential distances along the length of the gas port 7 can be equal or not equal implying that the distances between the nozzles depicted as L 1 , L 2 , L 3 , and L 4 can be equal or totally different from one another. As depicted in FIG. 3 , all directional orientations of the nozzles emanating from the main gas port 7 are covered by the invention.
In order to obtain equitable gas distribution from the port into the nozzles 19 , 20 , 21 , and 22 depicted in FIG. 3 , the diameter of nozzles at successive circumferential location away from the inlet seal 8 of the gasifier 1 will be successively larger to take advantage of pressure drops to minimize the flow disparity from nozzle to nozzle. Therefore for uniform gas flow from all nozzles throughout the length of the gas port 7 , the relationship between diameters d 1 , d 2 , d 3 , and d 4 of the nozzles 19 , 20 , 21 , and 22 in FIG. 3 will be such that d 4 will be greater than d 3 ; d 3 will be greater than d 2 , and d 2 will be greater than d 1 . However if unequal distribution of gas is desired along the path of the kiln gasifier 1 from the standpoint of controlling gas solid reaction, these diameters d 1 , d 2 , d 3 , and d 4 of the nozzles 19 , 20 , 21 , and 22 can be manipulated to obtain the desired results.
FIGS. 4 and 5 are mere recitation of FIG. 3 to illustrate the nature of gas assembly 7 when the nozzles 19 , 20 , 21 , and 22 are uniformly oriented in the direction of the solids flow or against the direction of solids flow inside the kiln gasifier 1 .
Similarly FIG. 6 is a mere recitation of FIG. 3 to illustrate nonuniformity of orientation of the nozzles 19 , 20 , 21 , and 22 .
FIG. 7 is an example of depiction of temperature profile within the kiln gasifier 1 . The kiln gasifier is generally controlled by the temperature of the fuel gas emanating from the fuel gas discharge nozzle 4 . The reactant gases comprising of air, oxygen, and steam entering the kiln gasifier 1 via the gas distributor 7 reacts with carbonaceous solid material entering the reactor via inlet port 2 up to the distance of gas port insertion and to the point blocked by the gas plug 10 . The oxygen in the gas will promote partial combustion reactions whereas the steam present in the gas will promote gasification reactions. The moisture present in the solid carbonaceous material would also contribute towards the gasification reactions. Partial combustion of carbonaceous material produces the mixture of carbon dioxide and carbon monoxide whereas gasification reaction of carbonaceous material with steam produces the mixture of hydrogen, carbon monoxide, and carbon dioxide. Eventually all of these gases including residual water attain water gas shift equilibrium when exiting the gasifier. After the partial combustion ceases due to the lack of introducing oxygen any further, the elevated temperature inside the gasifier 1 will continue to enable residual steam in the gas to react with carbonaceous solids to continue to deplete carbon from the nearly all reacted carbonaceous solids. Since the gasification reaction is endothermic, the gasifier 1 temperature will begin to drop as the gas moves towards the exit nozzle 4 . Thus as depicted in FIG. 7 , it is not unusual for the kiln temperature to progressively increase along the path of the solids within the gasifier 1 until the supply of oxygen is diminished and then decrease progressively. As an example, if the set point temperature at the gasifier 1 exit is controlled at 1800 deg F., the peak temperature in the gasifier could reach as high as 2400 deg F. Again this will depend upon the location of the termination point of the oxidant within the gasifier 1 .
The present invention is also useful when practiced as combustor instead of gasification. In this case the nozzles emanating from the main gas port 7 would be extended all the way into the kiln reactor 1 and the amount of air or oxygen introduced will commensurate with the combustor capacity with respect to the carbonaceous material being combusted. The principles stated with respect to nozzle sizing, spacing, and orientation will be accommodated to attain complete combustion of the carbonaceous material.
For person familiar with the art of gasification and combustion will recognize that for gasification, the amount of air or oxygen introduced into the gasifier 1 is less than fifty percent of the stoichiometric requirement for the complete combustion of the carbonaceous material being gasified whereas in the case of complete combustion, the amount of air introduced into the kiln reactor 1 sometimes exceeds 200 percent of the stoichiometric requirement of the complete combustion of the carbonaceous material depending upon the specified outlet gas temperature in the gas outlet 4 .
The present invention has several advantages.
One advantage is that by allowing intimate contact between gas and carbonaceous solids within the kiln gasifier, it is possible to obtain complete gasification of the carbonaceous material.
Another advantage is that by allowing intimate contact between the gas and the solids in the vicinity of heated refractory lining of the kiln, the gasification reaction occurs much more rapidly since the requisite heat for gasification is provided by the heat retained by the refractory lining as well as by the partial combustion of the carbonaceous material with oxygen present in the gas, and therefore it is possible to reduce the overall length of the kiln gasifier.
Yet another advantage is rotation of the gas distributor which enables added turbulence at the wall of the gasifier thereby increasing the interaction between gas and the solids for attaining optimal reaction and better utilization of carbonaceous material.
Yet another advantage of this invention is the flexible orientation of the nozzles.
When the nozzles are oriented such that they are inclined at negative angle with respect to the main port, it results in added residence time for the reactant gases and hence additional time for the gasification reactions to occur. This flexibility would result in total gasification to occur in shorter time and therefore the length of the kiln can be further reduced.
Whilst the invention has been described in detail in terms of specific embodiment thereof, it will be apparent that various changes and modifications can be made by one skilled in the art without deviating from the spirit and scope thereof.
REFERENCES
1. J. H. Howson and K. Casnello “Risk Reduction Measures for the Development of Biomass Rotary Kiln Gasification,” Report No. ETSU B/U1/00646/REP and DTI/Pub URN 02/754, issued by DTI Sustainable Energy Programmes for CPL Industries, 2002.
2. G. P. Androutsopoulos, K. S. Hatzilyberis, “Electricity Generation And Atmospheric Pollution: The Role Of Solid Fuels Gasification” presented at 7th International Conference on Environmental Science and Technology Ermoupolis, Syros island, Greece, September 2001 [0056] 3. Francesco Fantozzi, Bruno D'Alessandro, and Umberto Desideri, “An IPRP (Integrated Pyrolysis Regenerated Plant) Microscale Demonstrative Unit in Central Italy” Proceedings of ASME Turbo Expo 2007: Power for Land, Sea and Air, May 14-17, 2007, Montreal, Canada | A rotating air distributor for rotary reactors such as rotary kilns for the gasification of biomass and other carbonaceous materials for efficient mixing and maximum conversion of solid biomass and other carbonaceous materials into synthesis fuel gas is disclosed. The invention includes a gas distribution port comprises of one main supply from which several discharge nozzles emerge at different angles and at different locations along the length of the reactor to provide distribution of gas throughout the intended length of the reactor. The discharge of gas from the gas distribution port is adjusted by the variable position of a plug inside the port that can be adjusted during the operation of the kiln to achieve optimum gas-solid interaction along the length of the reactor. The rotating action of the gas distribution port also facilitates and eases the passage of reacted biomass solid and other carbonaceous material residue through the reactor. | 2 |
[0001] This application claims priority from provisional application No. 61/061,403, filed Jun. 13, 2008, the entire contents of which are herewith incorporated by reference. This is a continuation of application Ser. No. 12/483,890 filed Jun. 12, 2009, now U.S. Pat. No. 7,909,307.
BACKGROUND
[0002] Winches can be used to move various objects and scenery, especially in a stage lighting environment. In some applications for a winch, the distances over which force application are carried out can vary.
[0003] For example, when lifting scenery on a stage, the width of the scenery depends on the specific scenery being lifted. This width correspondingly sets the width over which the lifting needs to occur, e.g., when lifting is carried out by the two far sides.
[0004] Also, the supports for the lifting may be separated by varying widths.
SUMMARY
[0005] The present application describes a winch with movable end parts that allow it extend across variable length supports and to carry out lifting across those variable lengths.
BRIEF DESCRIPTION OF THE DRAWINGS
[0006] FIG. 1A-1C show the “tab” winch in multiple extended positions with different distances between the pulling areas;
[0007] FIG. 2 illustrates a “tab” drum used according to an embodiment; and
[0008] FIG. 3 illustrates the way that variable width lifting.
DETAILED DESCRIPTION
[0009] According to an embodiment, a winch is described which can vary in width and hence can vary the locations of its outer extent.
[0010] Another embodiment describes special operations which enable a reduced-thickness winch. This can facilitate the use of this winch in certain applications, such as overhead and in limited space areas.
[0011] The basic diagram of the winch in multiple different configurations is shown in FIGS. 1A-1C .
[0012] The main part of the winch includes a special drum for unwinding cable from two different locations at the same time. The inventors call this a yoyo drum 100 . The yoyo drum 100 has a power plant that causes its rotation. Two extendable arms 110 , 120 are coupled to the yoyo drum 100 and can be extended relative thereto. Each arm 110 , 120 has an idler at its very end. The arm 110 has the idler 111 , and the arm 120 has the idler 121 .
[0013] In operation, the cable pays onto and off of the drum 100 at two different locations simultaneously. One cable goes along arm 110 to idler 111 , and is raised or lowered by the idler. The other cable goes along arm 120 to idler 121 , and is simultaneously and synchronously raised or lowered from both spots.
[0014] FIG. 2 shows a detail of the yoyo drum from its side, illustrating the two tabs in the drum and those tabs can each hold their own supply of cable. The yo-yo drum 100 includes two different tabs, 202 05 . Each tab forms a slot that holds a stack of cable such as 210 . The cable can be stacked in each slot up from one side of the driven element, while simultaneously fed or taken up on the other tab from the driven element.
[0015] The special design allows the yoyo drum to hold cable only within a “tab” in the drum, and hence allows the drum to be very thin, even though it is a double cable supply drum. In the embodiment, the drum can be about the same thickness as the arms that extend and retract, so that the drum can fit within whatever thickness the arms can fit in. In one embodiment the drum is no thicker than the arms. In another embodiment, the drum is no more than 1.5 times the thickness of the arm.
[0016] The embodiment enables reconfiguring between multiple different crossbar sizes. For example, the crossbar elements such as 110 includes two portions 115 , 116 , which slide relative to one another. The portion 116 is smaller in outer cross section than the portion 115 , and hence the portion 116 fits within the portion 115 . Fasteners such as screws and nuts 117 hold the portion 115 relative to the portion 116 .
[0017] Other ways of holding the two arm parts together can also be used. For example, a clamp system could be used to hold the parts relative to each other. A threaded system could be used where one rod is threaded within the other.
[0018] Thus the lengths of the arms can each be independently adjusted to any desired length. Hence, this winch can be reconfigured between any desired set of crossbar lengths.
[0019] FIG. 3 illustrates how the distance 310 between the arms 315 , 316 can be reconfigured. The distance W is based on the distance between holding portions 351 , 352 on the item to be lifted 350 . The movement of the winch cable causes the item 350 to go up and down.
[0020] Although only a few embodiments have been disclosed in detail above, other embodiments are possible and the inventors intend these to be encompassed within this specification. The specification describes specific examples to accomplish a more general goal that may be accomplished in another way. This disclosure is intended to be exemplary, and the claims are intended to cover any modification or alternative which might be predictable to a person having ordinary skill in the art. For example, other sizes, materials and connections can be used. Other structures can be used to receive the magnetic field. In general, an electric field can be used in place of the magnetic field, as the primary coupling mechanism. Other kinds of antennas can be used. Also, the inventors intend that only those claims which use the-words “means for” are intended to be interpreted under 35 USC 112, sixth paragraph. Moreover, no limitations from the specification are intended to be read into any claims, unless those limitations are expressly included in the claims.
[0021] Where a specific numerical value is mentioned herein, it should be considered that the value may be increased or decreased by 20%, while still staying within the teachings of the present application, unless some different range is specifically mentioned. Where a specified logical sense is used, the opposite logical sense is also intended to be encompassed. | A winch with adjustable arms allowing the length to be adjusted. The winch can have a very thin drum to allow it to fit in confined spaces. | 1 |
BACKGROUND TO THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to apparatus for treating sleep apnoea. More specifically, the present invention provides a nasal positive airway pressure device which is reliable and comfortable to wear and, consequently, more acceptable to the patient.
[0003] 2. Summary of the Prior Art
[0004] Obstructive Sleep Apnoea (OSA) is a sleep disorder that affects up to at least 5% of the population in which muscles that normally hold the airway open relax and ultimately collapse, sealing the airway. The sleep pattern of an OSA sufferer is characterised by repeated sequences of snoring, breathing difficulty, lack of breathing, waking with a start and then returning to sleep. Often the sufferer is unaware of this pattern occurring. Sufferers of OSA usually experience daytime drowsiness and irritability due to a lack of good continuous sleep.
[0005] In an effort to treat OSA sufferers, a technique known as Continuous Positive Airway Pressure (CPAP) was devised. A CPAP device consists of a gases supply (or blower) with a conduit connected to supply pressurised gases to a patient, usually through a nasal mask. The pressurised air supplied to the patient effectively assists the muscles to keep the patient's airway open, eliminating the typical OSA sleep pattern.
[0006] The procedure for administering CPAP treatment has been well documented in both the technical and patent literature. Briefly stated, CPAP treatment acts as a pneumatic splint of the airway by the provision of a positive pressure, usually in the range 4 to 20 cm H 2 O. The air is supplied to the airway by a motor driven blower whose outlet passes via an air delivery hose to a nose (or nose and/or mouth) mask sealingly engaged to a patient's face by means of a harness or other headgear. An exhaust port is provided in the delivery tube proximate to the mask. More sophisticated forms of positive airway pressure devices, such as bi-level devices and auto-tritating devices, are described in U.S. Pat. No. 5,148,802 of Respironics, Inc. and U.S. Pat. No. 5,245,995 of Rescare Limited, respectively.
[0007] U.S. Pat. No. 5,477,852 of Airways Ltd, Inc. discloses a nasal positive airway pressure device that has a pair of nasal members each having a cannula tip to be inserted into the nares of the patient. Each cannula is tapered from a substantially circular cross-section outside the patient's nostril to a substantially oval cross-section at the tip inserted into the nostril. An inflatable cuff surrounds each cannula with the interior space of the cuff communicating with the lumen of the cannula through at least one aperture in the sidewall of the cannula. The nasal members are connected to one or more flexible hoses that, in turn, are connected to a source of positive air pressure. In use, positive air pressure is supplied to each cannula tip through the air hoses and nasal members. The positive air pressure inflates the cuffs to hold the nasal members in place and to effect treatment. The nasal device of U.S. Pat. No. 5,477,852 are attached to headgear that is located about a patient's head. This headgear could be considered by many patient's as cumbersome and uncomfortable.
[0008] Conventional nasal masks used for administrating CPAP treatment are also considered uncomfortable and cumbersome, also prior art nasal masks and the like are noisy, due to air leaks. These disadvantages in many cases are a formidable obstacle to patient acceptance of such treatment. Therefore, a substantial number of patients either cannot tolerate treatment or choose to forego treatment. It is believed a substantial number of such patients could benefit from a nasal positive airway pressure apparatus that is more convenient to use and comfortable to wear, thereby resulting in increased treatment compliance.
SUMMARY OF THE INVENTION
[0009] It is an object of the present invention to attempt to provide a nasal positive pressure device which goes some way to overcoming the abovementioned disadvantages in the prior art or which will at least provide the industry with a useful choice.
[0010] In a first aspect the present invention consists in a device for delivering a supply of gases to a patient comprising or including:
[0011] a pair of nasal members, the distal end of each said nasal member defining a cannula,
[0012] a pair of inflatable cuff members, each said cuff member surrounding at least a portion of each of said cannula,
[0013] a pair of inflating tubes each in gaseous communication with the interior of a respective one of said cuff members, said communication provided through an aperture in each of said cuff member in which a respective one of said inflating tubes extends there through,
[0014] a source of pressurised gases connected to said inflating tubes to deliver pressurized air to the interior of said cuff members,
[0015] wherein, in use, when a respective one of said cuff members is inserted within a respective nasal cavity of said patient and when said pressurised gases flow through each of said inflating tubes, each of said cuff members inflate to retain said cuff members within each of said nasal cavity of said patient.
[0016] To those skilled in the art to which the invention relates, many changes in construction and widely differing embodiments and applications of the invention will suggest themselves without departing from the scope of the invention as defined in the appended claims. The disclosures and the descriptions herein are purely illustrative and are not intended to be in any sense limiting.
[0017] The invention consists in the foregoing and also envisages constructions of which the following gives examples.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] One preferred form of the present invention will now be described with reference to the accompanying drawings.
[0019] [0019]FIG. 1 is a block diagram of a humidified continuous positive airway pressure system as might be used in conjunction with the present invention,
[0020] [0020]FIG. 2 is a front view of the nasal plugs and associated tubing of one embodiment of the present invention, where the nasal plugs are made from a foam type material,
[0021] [0021]FIG. 3 is a close-up front view of the two nasal plugs of FIG. 2,
[0022] [0022]FIG. 4 is a cross-sectional view of a nasal plug of FIG. 2 through AA as shown in FIG. 3,
[0023] [0023]FIG. 5 is a front view of one of two nasal plugs of a further embodiment of the present invention, where the nasal plugs are made from a silicon type material,
[0024] [0024]FIG. 6 is a cross-sectional view of the nasal plug through BB as shown in FIG. 5,
[0025] [0025]FIG. 7 is a front view of the nasal plugs and associated tubing of yet another embodiment of the present invention, where the nasal plugs are inflatable cuffs,
[0026] [0026]FIG. 8 is a front view of one the inflatable cuffs of FIG. 7,
[0027] [0027]FIG. 9 is a cross-sectional view of the inflatable cuff, through CC as shown in FIG. 8, when the cuff is in the inflated condition,
[0028] [0028]FIG. 10 is a cross-sectional view of the inflatable cuff, through CC as shown in FIG. 8, when the cuff is in the deflated condition,
[0029] [0029]FIG. 11 is a perspective view of the nasal flap, nasal plugs and associated tubing of still a further embodiment of the present invention, where the nasal flap is in the in use, closed position,
[0030] [0030]FIG. 12 is a front view of the nasal flap, nasal plugs and associated tubing of FIG. 11, where the nasal flap is in the in use, closed position,
[0031] [0031]FIG. 13 is a side view of the nasal flap, nasal plugs and associated tubing of FIG. 11, where the nasal flap is in the in use, closed position,
[0032] [0032]FIG. 14 is a perspective view of the nasal flap, nasal plugs and associated tubing of FIG. 11, where the nasal flap is in the open position,
[0033] [0033]FIG. 15 is a front view of the nasal flap and nasal plugs of FIG. 11, where the nasal flap is in the open position,
[0034] [0034]FIG. 16 is a side view of the nasal flap and nasal plugs of the forth form of the present invention, where the nasal flap is in the open position,
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0035] It will be appreciated that the improvements to nasal plugs as described in the preferred embodiments of the present invention can be used in respiratory care generally or with a ventilator, but will now be described below with reference to their use in a humidified Continuous Positive Airway Pressure (CPAP) system.
[0036] CPAP System
[0037] With reference to FIG. 1 a CPAP system is shown in which a patient 1 is receiving humidified and pressurised gases through the nasal device 2 , such as nasal cannulae, that are connected to a humidified gases transportation pathway or inspiratory conduit 3 . It should be understood that delivery systems could also be VPAP (Variable Positive Airway Pressure) and BiPAP (Bi-level Positive Airway Pressure) or numerous other forms of respiratory therapy. Inspiratory conduit 3 is connected to the outlet 4 of a humidification chamber 5 that contains a volume of water 6 . Inspiratory conduit 3 may contain heating means or heater wires (not shown) that heat the walls of the conduit to reduce condensation of humidified gases within the conduit. Humidification chamber 6 is preferably formed from a plastics material and may have a highly heat conductive base (for example an aluminium base) which is in direct contact with a heater plate 7 of humidifier 8 . Humidifier 8 is provided with control means or electronic controller 9 which may comprise a microprocessor based controller executing computer software commands stored in associated memory.
[0038] Controller 9 receives input from sources such as user input means or dial 10 through which a user of the device may, for example, set a predetermined required value (preset value) of humidity or temperature of the gases supplied to patient 1 . The controller may also receive input from other sources, for example temperature and/or flow velocity sensors 11 and 12 through connector 13 and heater plate temperature sensor 14 . In response to the user set humidity or temperature value input via dial 10 and the other inputs, controller 9 determines when (or to what level) to energise heater plate 7 to heat the water 6 within humidification chamber S. As the volume of water 6 within humidification chamber S is heated, water vapour begins to fill the volume of the chamber above the water's surface and is passed out of the humidification chamber 5 outlet 4 with the flow of gases (for example air) provided from a gases supply means or blower 15 which enters the chamber through inlet 16 . Exhaled gases from the patient are exhausted to the ambient surroundings.
[0039] Blower 15 is provided with variable pressure regulating means or variable speed fan 21 that draws air or other gases through blower inlet 17 . The speed of variable speed fan 21 is controlled by electronic controller 18 (or alternatively the function of controller 18 could carried out by controller 9 ) in response to inputs from controller 9 and a user set predetermined required value (preset value) of pressure or fan speed via dial 19 .
[0040] Nasal Plugs
[0041] In a general form, the nasal device 2 generally consists of Y-shaped connector piece that connects the nasal device to the breathing circuit, transportation passageway or conduit 3 , which is connected to the source of pressurised gas. Each arm of the Y-shaped connector is connected to a nasal tube, which are each connected to nasal members. The nasal members have a tapered end terminating in an aperture (cannula), the tapered end has disposed about it nasal plugs. In use, when a patient inserts each of the nasal plugs into their nasal cavities and positive pressure ventilation therapy is commenced, pressurised gases pass through the conduit 3 , into the Y-shaped connector, through each of the nasal tubes exiting into the patient's nostrils through each nasal cannula, thereby administering positive pressure ventilation therapy to the patient.
[0042] Referring to FIGS. 2 to 4 , there is shown a nasal positive airway pressure device 30 in accordance with a first embodiment of the present invention. Device 30 consists of a Y-shaped connector piece 31 (that is connected to the gases outlet end of the conduit 3 ), and a pair of nasal tubes 32 , 33 each terminating in a nasal member 34 , 35 . The Y-shaped connector 31 and each of the nasal members 34 , 35 are hollow cylinders or tubes that allow for the flow of gases therein. The nasal members terminate in an aperture that is the outlet of pressurised gases from the ventilation system into the patient's nasal cavities. The end of each nasal member 34 , 35 defines a cannula, which is basically a tapered end 36 terminating in an aperture. Fitted about each cannula 36 is a nasal plug 37 , 38 configured and dimensioned to fit within the nasal cavities of a patient. In the first form of the present invention the nasal plugs 37 and 38 are made of a foam type material, preferably a closed-cell foam that has been moulded into the shape of a nostril, that shape being a generally frustoconical.
[0043] The Y-connector 31 and nasal members 34 , 35 are each moulded from a polycarbonate type material, although other substantially rigid materials may be used, such as rigid plastics or metal. Suitable plastics include homopolymers, copolymers, blends and mixtures of polystyrene, ABS, polycarbonate, acrylics, or polyethylene. Suitable metals include stainless steel, titanium, aluminium and alloys thereof One end of each nasal tube 32 , 33 is fitted over the arms 39 , 40 of the Y-connector 31 and the other end of each nasal tube 32 , 33 is adapted to be connected to each nasal member 34 , 35 , for example the nasal member may be fitted within the nasal tubes 32 , 33 . These fittings may be of any convenient manner suitable for coupling without substantial loss of gas pressure, such as by friction fit, snap fit, gluing, welding, threading or the like. The foam nasal plugs 31 , 38 are fixed about the cannulae 36 by appropriate fixing means, for example by gluing, in a manner that preserves gas pressure.
[0044] The nasal tubing 32 , 33 are conduits 44 that is, in the preferred form, molded from an elastomeric material such as a Polyethylene/EVA mixture or silicon rubber. The conduit preferably has a “ribbed” “or corrugated” construction to allow bending, (the ribs are referenced as 45 ). This conduit construction may be accomplished by blowing the molten elastomeric material to form an endless cylinder that is forced outwards against the internal surface of a rotating mould that impresses the ribs onto the conduit. The conduit 44 may also have within it a helically wound heater wire (not shown) that preferably sits against or adjacent to the internal wall of the conduit along its length. The purpose of having a conduit with a heater wire is to reduce the condensation of the gases within the conduit. The nasal tubing 32 , 33 being a “ribbed” conduit provides the advantage of being able to be easily manipulated by the patient for additional patient comfort.
[0045] In use, the patient need only apply pressure to the sides of the foam nasal plugs 37 , 38 thereby depressing the foam deforming the shape of each of the nasal plugs so that each is easily insertable into each nasal cavity. Once each plug is within each cavity the foam will expand to its original form where the external surface of the foam abuts the internal surface of the patient's nasal cavity, thereby filling the area within each nostril. The foam nasal plug provides a seal between the cavity and the cannula, effectively eliminating gases leakage, as the expanding foam provides an outward force upon the inner surface of each of the patient's nasal cavities, which also prevents each plug from falling from the nasal cavity.
[0046] Nasal members 34 , 35 have disposed in them at least one, but preferably a number of, small holes (not shown) that act as vents to exhaust the gases that are exhaled by the patient. The holes and thus the nasal members may be covered with an appropriate type of material that acts as a diffuser.
[0047] In a further form of the nasal device of the present invention, the nasal plugs may be constructed from a silicon type material. With reference to FIGS. 5 and 6, the, nasal device in this form is almost identical to that as shown in FIG. 2, the difference being the nasal plugs are manufactured from a silicon type material that is formed in an inverted U-shape. The nasal plug and nasal member, as shown in FIG. 6, is a cross-section through BB of FIG. 5. The silicon nasal plug 41 is adapted to be connected to the tapered end 42 of the respective nasal member 40 . This connection may be provided by any appropriate means as discussed earlier in relation to the embodiment of the nasal plugs, but more preferably by a type of glue.
[0048] Again, to allow for exhaust and diffusion of exhaled gases from the patient each of the nasal members (of which only one, labelled 40 , is shown in FIGS. 5 and 6 have disposed in them at least one, but preferably a number of, small holes (not shown) that act as vents to exhaust the gases that are exhaled by the patient into the ambient air. The holes and thus the nasal members may be covered with an appropriate type of material that acts as a diffuser.
[0049] The nasal plug 41 may be made from other appropriately flexible materials that will be deformed under a pressure applied by the user of the nasal device. In use, as a patient inserts the U-shaped plugs into his or her nares the arms of each of the U-shaped plugs are compressed, effectively reducing the space 43 between the tapered end 42 and the interior surface of the nasal plug 41 . Once the plugs are completely inside the nares, the arms of each U-shaped plug expand to their natural position, causing the plugs to be retained within the nares by way of friction.
[0050] In both of the abovementioned forms the nasal plugs provide a good seal within the patient's nasal cavities, thereby reducing the effects of gases leakage. As the nasal plugs are deformable, they are easily fitted by the patient and provide greater patient comfort when in use. In addition, the forces of the expanding materials, once inserted, hold the nasal plugs within the nasal cavities in a manner that is more comfortable to the patient than prior treatment devices.
[0051] Inflatable Cuffs
[0052] In accordance with a further embodiment of the present invention, FIGS. 7 to 9 show a nasal device 50 that utilises inflatable cuffs 51 , 52 . The cuffs are attached by appropriate means, for example by moulding or gluing or the like, to the nasal members 53 , 54 . The nasal members 53 , 54 are adapted to be connected to nasal tubes 55 , 56 and the nasal tubes to the Y-connector as described above.
[0053] Each inflatable cuff 51 , 52 surrounds the tapered end 58 (see FIG. 8) and provides a force, when in use, within the nasal cavity, to hold the tapered end 58 in position within the patient's nares in a manner to be explained below. Each tapered end 58 of the nasal members 53 , 54 are preferably substantially oval or elliptical in cross-section at the open end that is distal to nasal members 53 , 54 , and gradually tapers to a substantially circular cross-section outside the patient's nares. The inflatable cuffs 51 , 52 surrounding each tapered end 58 are made of a plastics material, and a small inflation tube 59 , 60 , made from a flexible plastics material communicates with the interior space of each cuff, preferably through the cuff wall. Both inflation tubes 59 , 60 are connected to an inflation device, where when the inflation device provides gases to the tubes ( 59 , 60 ) the cuffs are inflated with the gases. FIG. 9 shows one such inflatable cuff 51 in cross-section when the cuff is inflated in an “in use” form, whereas FIG. 10 shows one such cuff 51 ′ in cross-section when the cuff is the deflated “insertion” form.
[0054] The inflation device that could be used to provide gases to the inflation tubes may be a non-return valve with a fitting at one end, in which a plastic syringe (without the needle) could be placed. The syringe can then be used to force air into each of the cuffs. When the syringe is removed the non-return valve would keep the air in the cuffs. This is similar to the inflation system on an ET tube. To deflate the cuff, the syringe can be inserted into the inflating tubes and valve and draw the gases from the cuff.
[0055] Alternatively, a further inflation device is anticipated which is a small pump mechanism. This would involve having a plastic gases holding compartment with two non-return valves attached on either side of the compartment. One valve would allow air to pass into the compartment from the atmosphere, and once the compartment is compressed, for example, by the patient's fingers, gases are forced through the second non-return valve, into the inflating tubes, inflating the cuffs. To deflate the cuffs, the pump mechanism would be supplied with a bleed valve, that is preferably hand operated.
[0056] In use, when the patient wishes to commence positive pressure ventilation therapy, he or she must place each cuff within his or her nasal cavities and start the inflation device. As air flows through the inflation tubes 59 , 60 the cuffs 51 , 52 will inflate and provide a force against the internal walls of the nasal cavities, preventing the cuffs from falling from the cavities. Again, this embodiment of the nasal plugs of the present invention has the advantage of providing the patient with a comfortable alternative to prior art nasal devices.
[0057] Nasal Snap Flap
[0058] In accordance with a fourth form of the present invention, FIGS. 11 to 16 show a nasal device 60 that utilises an engagement means located about nasal cannulae to engage and secure the cannulae within the nares of a patient. The engagement means is a nasal sealing flap 61 . The flap 61 in its natural bias is tapered, the wide-open end of which is shaped to conform to the facial contours of a patient's nose around the outside of the nose. Thus in a closed form, as shown in FIGS. 11 to 13 , the flap provides a cup-like device that is fitted around the patient's nose and prevent the nasal device 60 from falling from the patients nose. In the open form, that allows for placement and fitting of the nasal device 60 , the flap 61 is intended to be in a bent back position, as shown in FIGS. 14 to 16 , to aid insertion of the nasal cannulae 63 , 64 into the patient's nares.
[0059] The nasal device comprises the nasal sealing flap 61 connected by appropriate means to a nasal member 62 that terminates in at least one nasal cannula, although in the preferred form two cannulae 63 , 64 are provided, one for each of the patient's nares. The flap 61 and cannulae 63 , 64 may be integrally formed or the flap 61 may be attached about the cannulae 63 , 64 (by appropriate means, such as gluing) after the cannulae have been formed. Furthermore, the cannulae 63 , 64 , flap 61 and nasal member 62 may all be integrally formed by injection moulding or the like methods. The cannulae 63 , 64 extend through the proximate end of the flap 61 , so that in use, upon placing the flap about the patient's nose the cannulae extend into the nasal cavities of the patient's nose. The other end of the nasal member 62 is connected, again by appropriate fixing means, such as by friction fit, snap fit, gluing, welding, threading or the like, to a nasal tube 65 .
[0060] The nasal tube 65 is a conduit that is, in the preferred form, moulded from an elastomeric material such as a Polyethylene/EVA mixture or silicon rubber. The conduit preferably has a “ribbed” “or corrugated” construction to allow bending that is constructed as described above with relation to the tubing 32 , 33 of FIG. 2. The nasal tube 65 is preferably connected to the inspiratory conduit 3 and thus to the rest of the ventilation system as detailed with reference to FIG. 1 above. In an alternative form the nasal tube 65 and conduit 3 may be one tube.
[0061] In use, to attach the nasal device to the nose and nares, the patient bends back the flap 61 to the open position, as shown in FIGS. 14 to 16 , and inserts the nasal cannulae 63 , 64 into each nostril. To enable the retaining of the cannulae 63 , 64 within the nares the flap 61 is bent into the closed position, the flap 61 providing a cup-like seal around the patient's nose. The flap is bent back into the open position to enable removal from the patient, by simply pressing on its outer periphery 66 , until it snaps into the bent back position, in which it will stay unaided. The flap 61 may be adjusted into its operational position by pressing on its outer periphery 66 until it snaps forward to press against the outside of the nose.
[0062] It will be appreciated that as well as providing a substantially airtight seal the flap provides enough compressive force on the nose to keep the nasal device and conduit in place without the need for straps. This allows the administering of positive airway pressure ventilation therapy to be considerably less obtrusive than traditional methods.
[0063] In all forms of the nasal device as discussed above, the friction between the plugs or cuff of the device and the interior surface of the patient's nares prevents the plugs or cuffs from falling from the patient's nares. Although it is appreciated that headgear could be used to ensure securement of the nasal device to the patient. Thus, the device may be secured to the head of the user with headgear (not shown) by attaching straps of the headgear at an appropriate point along the length of each nasal tube or at the nasal members. Furthermore, a clip or the like could be used to attach the tubing associated with the nasal device to the patient's clothes. | The present invention relates to apparatus for treating sleep apnoea. More specifically, the present invention provides a nasal positive airway pressure device which is reliable and comfortable to wear and, consequently, more acceptable to the patient. The nasal device has inflatable cuffs worn in a patient's nasal cavities. A pair of inflating tubes are in gaseous communication with the interior of a respective one of the inflatable cuffs and when pressurised gases flow through each of the inflating tubes, each of the cuffs inflate to retain the cuff within each of the nasal cavities of the patient. | 0 |
This application is a Continuation-in-Part of U.S. patent application Ser. No. 10/280,302, filed on Oct. 23, 2002 now U.S. Pat. No. 6,816,834 and entitled SYSTEM AND METHOD FOR SECURE REAL TIME HIGH ACCURACY SPEECH TO TEXT CONVERSION OF GENERAL QUALITY SPEECH.
BACKGROUND INFORMATION
Converting speech to text can be accomplished currently by several methods. Each method has different levels of accuracy, security, speed, tolerance of poor audio quality and price. Court reporters, or stenographers, for example, provide verbatim transcription but at a high price and with a time delay. Computer-based speech recognition is much less accurate, but is less expensive and instantaneous. Transcription of stored messages (such as voice mail) is more difficult for computer-based speech recognition technology to perform accurately due to poor audio quality. No current speech to text method provides the ideal combination of accuracy, security, speed and tolerance when transcribing general-quality speech.
Linking the speech to text conversion process to an existing communications service, such as a telephone system, makes the conversion simpler to achieve. Local telephone companies offer Call Forward on Busy (“CFB”), Call Forward on No Answer (“CFNA”), Call Forwarding (“CF”), Distinctive Ring and other services. FIG. 1 shows a traditional phone system 1 which may offer the services described above. When a user of the traditional phone system 1 places a call, the system has an Automatic Number Identification (“ANI”) service 10 that identifies the number from which the call has been placed. Similarly, the traditional phone system 1 has a Dialed Number Identification Service (“DNIS”) service 20 which identifies the number that the caller dialed. This information is received by the local phone company 30 and the call is directed to the receiving phone which is termed a Plain Old Telephone Service (“POTS”) device 40 .
SUMMARY OF THE INVENTION
A system, comprising an audio shredder receiving an audio segment, the audio segment being a portion of an audio stream, the audio shredder creating an audio shred from the audio segment, an audio mixer receiving the audio shred and randomizing the audio shred with other audio shreds from other audio streams and a plurality of transcribers, wherein one of the transcribers receives the audio shred and transcribes the audio shred into text.
In addition, a method, comprising the steps of receiving an audio stream, filtering the audio stream to separate identifiable words in the audio stream from unidentifiable words, creating a word text file for the identifiable words and storing the word text file in a database, the word text file including word indexing information. Creating audio segments from the audio stream, the audio segments including portions of the audio stream having unidentifiable words, creating audio shreds from the audio segments, the audio shreds including audio shred indexing information to identify each of the audio shreds and storing the audio shred indexing information in the database. Mixing the audio shreds with other audio shreds from other audio streams, delivering the audio shreds to a plurality of transcribers, transcribing each of the audio shreds into a corresponding audio shred text file, the audio shred text file including the audio shred indexing information corresponding to the audio shred from which the audio shred text file was created and reassembling the audio shred text files and the word text files into a conversation text file corresponding to the audio stream.
Furthermore, a system, comprising a service platform for receiving, processing and directing streaming audio and a user device connected to the service platform and configured to receive streaming audio from the service platform and transmit streaming audio to the service platform, the user device further configured to signal the service platform to begin a transcription of the streaming audio transmitted and received by the user device. The service platform including a filter receiving the streaming audio, identifying words within the streaming audio and creating a word text file corresponding to each of the identified words, the filter further creating audio segments from the streaming audio, the audio segments including portions of the audio stream having unidentifiable words, an audio shredder creating a plurality of audio shreds from each of the audio segments, an audio mixer randomizing the audio shreds with other audio shreds from other streaming audio, wherein the service platform delivers the randomized audio shreds to a plurality of transcribers which transcribe the audio shreds into audio shred text files corresponding to the audio shreds, and a reassembler creating a conversation text file corresponding to the streaming audio from the audio shred text files and the word text files.
A system, comprising an audio stream element including information corresponding to an audio stream, the information including a begin time of the audio stream, an end time of the audio stream, a conversation identification of the audio stream and the audio stream file, a word element including information corresponding to a word identified in the audio stream by a speech recognition filter, the information including an identification of the audio stream from which the word was identified, a begin time of the word, an end time of the word, an audio file of the word and text corresponding to the word, an audio segment element including information corresponding to an audio segment of the audio stream, the audio segment being a portion of the audio stream without identifiable words, the information including the identification of the audio stream from which the audio segment originates, the begin time of the audio segment, the end time of the audio segment and the audio file of the audio segment, an audio shred element including information corresponding to an audio shred of the audio segment, the information including an identification of the audio segment from which the audio shred originates, the begin time of the audio shred, the end time of the audio shred and the audio file of the audio shred and a text token element including information corresponding to a textual representation of the audio shred, the information including an identification of the audio shred from which the textual representation originates and the textual representation. The information included in each of the audio stream element, the word element, the audio segment element, the audio shred element and the text token element is processed to generate a text transcription of the audio stream.
A system for the management of a distributed workforce of speech to text transcribers, the testing and monitoring of these transcribers, and financial accounting system to pay these transcribers and set the equilibrium price at which demand for services matches supply.
A system for the capture of spoken conversations or retrieval of stored audio that is then processed by the platform for conversion to text.
BRIEF DESCRIPTION OF DRAWINGS
FIG. 1 depicts a traditional phone system;
FIG. 2 shows an exemplary platform that may be used to implement the present invention;
FIG. 3 shows an exemplary system for the transcription of speech to text according to the present invention;
FIG. 4 shows an exemplary audio stream in the various stages as it is transformed into a transcription according to the present invention;
FIG. 5 shows exemplary data structures which may be used to index the data associated with the audio stream as it is transformed into the transcription according to the present invention;
DETAILED DESCRIPTION
The present invention may be further understood with reference to the following description and the appended drawings, wherein like elements are provided with the same reference numerals. FIG. 2 shows an exemplary platform 100 that may be used to implement the present invention. Those of skill in the art will understand that platform 100 is only exemplary and that the present invention may be implemented on numerous other platforms. The platform 100 components in FIG. 2 are shown between the two lines denoting that the platform 100 components may be located within the same facility. However, those of skill in the art will understand that the platform 100 components may be distributed to any physical location. In addition, it may also be considered that the components located at the customer premises locations 140 - 148 may also form part of the platform 100 .
The platform 100 includes a series of general purpose servers 101 - 107 which perform specific functions to deliver resources to the users of the platform 100 . The resources include database services provided by database server 101 , applications provided by application server 102 , network services provided by network server 103 , media services provided by media server 104 , data storage provided by network attached storage 105 , conferences services provided by conference bridges 106 and call relay services provided by relay/proxy server 107 . For example, the application server 102 may contain all the call control applications for the platform 100 to manage phone calls. The application server 102 may request resources from the other servers and/or hand off calls to the other servers based on the resource needed to handle the call. Those of skill in the art will understand that these resources and the providing servers are only exemplary, additional servers and/or resources may be added to the platform 100 as needed.
The servers 101 - 107 are connected to each other and to the remaining components of the platform 100 via an Ethernet 110 (or any other data pipeline) which provides fast and reliable communication between platform components. Other services provided by the platform 100 may include electronic mail (“email”) services via email server 113 , corporate and client web services via corporate web server 111 and client web server 112 . The platform 100 may also include an automatic speech recognition (“ASR”) engine 115 , customer relationship management (“CRM”) applications 116 , enterprise resource planning (“ERP”) applications 117 , voice markup language (“Voice XML”) engine 118 and a biometric engine 119 . All of the above resources, services and applications are used to provide services to subscribers via the PSTN 123 or direct network connections 133 . Those of skill in the art are familiar with the types of services and functions provided by these resources.
Servers comprising the operational support systems (OSS) 121 are used to monitor the health and security of the platform 100 . Such systems include performance monitoring, record keeping and provisioning. Those of skill in the art will understand that these systems are only exemplary, additional OSS resources may be added to the platform 100 as needed.
Servers comprising the accounting systems 122 keep track of commissions earned by the transcribers and deduct fees from subscribers' accounts. The accounting system 122 may bill subscribers, and pay commissions to transcribers, at a per-word or per-line rate, by metering minutes-of-use or at a flat-rate subscription. The accounting system 122 may also vary the commissions and fees according to the supply and demand of specific services. The accounting systems 122 may continually calculate an equilibrium price at which demand for transcription services matches the supply of those services. The accounting systems 122 also provides a mechanism for dispute resolution where a subscriber may claim a credit for inaccurately transcribed words, the transcriber would be charged back his commission for this error, but the transcriber may dispute the chargeback if the word were inaudible. The accounting systems 122 may also increase a transcriber's commission based on several factors, such as specific skills, availability, accuracy, productivity and/or tenure.
Servers comprising the quality assurance systems 124 continually monitor the accuracy and speed of transcribers. This quality assurance system 124 may also be used to test new transcribers for speed and accuracy as well as report the transcriber's accuracy and speed in real time and assign a skill level to the transcriber.
Servers comprising the workforce management systems 126 are used to schedule, monitor, authenticate, and distribute work tasks to transcribers. The workforce management systems 126 keep track of the transcribers' presence in order to add or remove individuals from the work process conducted by platform 100 . As transcribers join or leave the workforce, their skills are automatically added or removed from the available resources of platform 100 . The workforce management systems 126 communicate with the accounting systems 122 to dynamically adjust commissions paid to transcribers in order to provide more or less incentive for transcribers to join or leave the system depending on demand. In cases where demand exceeds supply, the workforce management systems 126 may contact off-duty transcribers by email, telephone call, pager or other means, to invite them to join the workforce. The workforce management systems 126 keep track of each transcriber's skills and foreign language ability in order to invite that transcriber to join when demand for those abilities exceeds supply. The workforce management systems 126 are used by the application server 102 to distribute work to the various transcribers. The workforce management systems 126 employ heuristic learning to identify which group of transcribers is most accurate and/or efficient at transcribing audio from a particular class of speakers (as further defined below).
The platform 100 may also include a PSTN-IP gateway 120 which receives phone calls directed for the users 140 - 148 from the public switched telephone network (“PSTN”) 123 . Gateway 120 can also be used to place outbound telephone calls to the PSTN. These outbound telephone calls can be placed by the users 140 - 148 or under direction of the Application Server 102 . The phone calls directed from and to the PSTN 123 may be in the form of analog signals which are converted to digital signals by the PSTN-IP Gateway 120 . The conversion of analog signals to digital signals (e.g., data packets) is well known in the art. In the area of telephony, the concept of transmitting voice data in the form of data packets may be referred to as Voice over Internet Protocol (“VoIP”). Throughout this description, the platform for processing and transmitting these data packets may be referred to as VoIP platforms, but those of skill in the art will understand that the Internet Protocol is only one example of a protocol which may be used to transmit data over a network and the present invention may be implemented using any protocol for data packet or voice transmission.
Data packets are distributed across the platform 100 via the Ethernet 110 (or similar data network). The resources of the platform 100 perform the necessary processing on the data packets and the phone call (in the form of data packets) can be directed via aggregation router or gateway 130 to the correct user 140 - 148 . The type of processing performed by the platform 100 resources depends on the services provided by the platform 100 and the services for which each user 140 - 148 has contracted. Examples of features and services will be described in greater detail below.
The connection from the user 140 - 148 locations and the platform location may be via any fast and reliable communication link 133 , for example, a DS 0 circuit, T 1 circuit, a frame relay network, metropolitan Ethernet, DSL, cable, an asynchronous transfer mode (“ATM”) network, etc. The individual links to users 140 - 148 (e.g., T 1 links) may be combined into a single digital link (e.g., a DS 3 link) between the aggregation router/gateway 130 and the communication link 133 . The data being sent across the single digital link may need to be converted to or from VoIP or multiplexed or de-multiplexed based on the direction of the network traffic and the type of link used; and, these functions may be carried out by the aggregation router/gateway 130 . The phone call may then be transferred to an internal network at the user's location, e.g., the network 150 of user 148 or private branch exchange (“PBX”) 160 of user 140 , which may distribute the phone call to various devices within the user location, e.g., PBX extension telephone 164 , IP phone 152 , personal computer 154 , network facsimile 156 and network attached storage 158 .
For example, a third party may be attempting to make a voice phone call from a POTS device (not shown) to the user 148 . The third party will dial a phone number that is related to the user 148 . As will be described in greater detail below, each user 140 - 148 may have one or more traditional phone numbers that may be used to contact the user. The phone call placed by the third party will be routed via the PSTN 123 to the PSTN-IP Gateway 120 of the platform 100 . The analog phone call will be converted to a digital signal by the PSTN-IP Gateway 120 and the digital signal will be processed by the various platform 100 resources. The signal will be routed through aggregation router 130 to the communication link 133 and directed to the network 150 of the user 148 . Since this communication is a voice communication, the network 150 may then direct the data packets for the phone call to the IP phone 152 which converts the digital signal into an audio signal for the user to converse with the third party caller. As will be described in greater detail below, users 140 - 148 may select the location (or device) to which voice and/or data communications are to be directed, including simultaneously directing communications to multiple devices that are either directly or indirectly connected the platform 100 . This entire exemplary communication takes place in the same real time manner as a normal POTS line to POTS line phone call. The fact that the signal is converted to data packets is transparent to both the user of the IP phone 152 and the third party caller.
Conversely, users 140 - 148 may initiate the telephone call to a third party's POTS device (not shown). The telephone call would traverse platform 100 in a similar manner described in the example above.
Platform 100 may be used to provide services to telephone calls that originate and terminate on the PSTN 123 . In this scenario, the telephone call is not originally destined to enter platform 100 . However, through various techniques, a telephone call between two parties outside of platform 100 may be redirected through platform 100 so that services may be delivered. These techniques are described below.
One method of redirecting a telephone call may employ call forwarding (CF, CFB, CFNA) and distinctive ring services available from many local telephone companies. The subscriber's telephone service is provisioned with call forwarding and distinctive ring services. Calls to that subscriber's telephone number may then be redirected to the platform 100 using call forwarding. The platform 100 receives the incoming telephone call and automatically identifies the subscriber either through information provided by the telephone company (such as the ANI and DNIS) or based on information internal to the platform 100 (e.g., the platform 100 has a telephone number dedicated to that subscriber). Simultaneously with this identification, the platform 100 places an outbound telephone call to the subscriber's distinctive ring number. The distinctive ring number does not have call forwarding provisioned and rings the subscriber's POTS device in the usual manner. Alternatively upon receiving the forwarded telephone call, platform 100 may disable the subscriber's call forwarding service (by using a separate service provided by the subscriber's telephone company) and then place a call to the subscriber's telephone number which will ring in the usual way. Using either of these methods, the caller and the subscriber may have a telephone conversation with platform 100 providing services, such as speech to text conversion services that will be described further below.
Lawful intercept as defined by the Communications Assistance to Law Enforcement Act (CALEA) is another source of telephone calls that originate and terminate outside of platform 100 that may be redirected to flow through platform 100 where services such as speech to text conversion may be delivered. The law enforcement agency (LEA) may use platform 100 to convert the telephone conversation to text in the manner that is described below. Biometric information may be used to identify which party is speaking in a two-way or multi-way conversation, as will be described below.
Use of the platform 100 for lawful intercept and surveillance provides a middle ground between court orders authorizing Level 1 (where call progress data is provided to the LEA but not call content) and Level 2 (where call progress data and call content are both provided to the LEA) surveillance. The middle ground provided by platform 100 enables the LEA to monitor not just DTMF digits dialed but also search for keywords or phrases mentioned in the two-way or multi-way conversation without the LEA actually listening to the conversation. As will be described below, the speech to text conversion provided by platform 100 allows the conversation to be searched for keywords or phrases without divulging the conversation's substance.
Platform 100 may be used to provide voice mail services to subscribers. Incoming telephone calls may be destined for either users 140 - 148 or external POTS devices (not shown). For external POTS devices, CFB or CFNA services may be used to redirect telephone calls into platform 100 . In either situation, platform 100 answers the telephone call, plays the appropriate greeting and records the voice message. This voice message may be kept in audio form or converted to text in the manner described below.
Platform 100 may be used to retrieve audio-based information (such as voice mail) stored in an external system such as an individual's home answering machine, wireline or wireless service provider's voice mail system, a company's internal phone system's voice mail, financial account information accessed by telephone, or any other system that uses interactive voice response (IVR). IVR is a technology that will be familiar to those with skill in the art. The person with authority to access this voice mail (or general IVR) system would provide to platform 100 the necessary login and authentication information and necessary permission for platform 100 to retrieve his personal information. To fetch external audio-based information, platform 100 places an outbound telephone call through the PSTN 123 to the third party's telephone access number. This telephone access number may be for a company's voice mail system, wireline or wireless telephone number or an individual's home telephone number. When the voice mail system associated with this telephone number answers the telephone call, platform 100 sends DTMF tones (or other audible commands) in order to authenticate and log into this third party's voice mail (or general IVR) system. Platform 100 may use speech recognition technology provided by ASR engine 115 to identify and decode audio prompts. For example, the audio prompt may be “Press one to access your voice mail.” Platform 100 would have a predefined list of such common prompts and use this information to navigate through the menus of this third party voice mail (or general IVR) system. When this third party's voice mail (or general IVR) system plays the relevant audio information (such as the voice message), platform 100 may record that message. This technique of navigating the third party's system by recognizing and decoding the prompts and issuing DTMF commands may also be used to extract envelope information about the voice mail stored in the third party's system. Such envelope information may consist of date and time the message was delivered, the caller's phone number (or Caller ID), message length, urgency indicators, call back telephone numbers and other information. Once the audio information has been retrieved from the third party voice mail (or general IVR) system, platform 100 may issue DTMF commands to erase or archive the messages. Platform 100 may then present the retrieved messages and envelope information, either in audio form or converted to text, to the subscriber via email, web page or some other data transmission means. Those with skill in the art will understand that the above method may be implemented using VoiceXML technology (among other methods).
The third party IVR system described above may be one that is widely used by many service providers, or it may be a system whose characteristics (such as the menu structure) are not common but are already known by platform 100 . In the former case, platform 100 may identify the system's vendor by using speech to text conversion described below and/or ASR engine 115 and biometric engine 119 to analyze the system's greeting messages and prompts and match those acoustical elements and sentence structures to a list of known vendors' system characteristics. Once the vendor is determined, the menu structure of the third party's system may be identified. Alternatively, in the latter case, platform 100 may keep track of the DTMF navigation codes that were previously used to retrieve information for a specific user. Through either means, platform 100 may improve the efficiency of message retrieval by navigating the menu structure by issuing DTMF commands without first listening to and decoding the entire message prompt. For example, if a user wishes to retrieve voice messages from the voice mail system provided by his wireless telephone company, platform 100 may use ASR engine 115 and biometric engine 119 to identify the wireless company's voice mail system. Alternatively, platform 100 may retrieve from a database the previously successful DTMF codes used for this user's system. Knowing this, platform 100 identifies the system's menu navigation structure. Now, instead of listening and decoding a lengthy message prompt, platform 100 knows which DTMF signal to send and may preempt the message prompt. Through such a method, message retrieval may be accelerated.
Voice mail may also be retrieved from an external source by platform 100 by using a direct interface connection. For example, a PBX with voice mail server may have a proprietary interface, Foreign Exchange Subscriber (or Foreign Exchange System) (FXS) ports and/or Foreign Exchange Office (FXO) ports. Platform 100 may be configured to connect directly to an external PBX, such as PBX 160 depicted in customer premises 140 using such interfaces. In this configuration, platform 100 may have complete information about voice mail stored on voice mail server 162 and extract both the message and envelope information directly. The message and/or envelope information may be converted to text for delivery to the subscriber by email or other digital means. The conversion to text is described below.
Platform 100 may have its own dedicated local access telephone numbers that may be used by individuals to access services provided by platform 100 . One of these services may be dictation. The user may call a telephone number that converts the user's speech to text in the speech to text conversion manner described below.
Platform 100 may be used as a conferencing bridge that connects multiple parties using the conference bridge 106 . For these conference calls, platform 100 may also provide speech to text conversion where each conference participant is identified through biometric techniques. This speech to text conversion and biometric identification process is described below.
Platform 100 services may also be obtained in batch mode where audio files are delivered by email or uploaded through FTP or other means to platform 100 . For example, one or more audio files may be sent by email to platform 100 for processing. Platform 100 converts the audio files to text files and returns the result(s) to the sender by email or other means.
Data transmissions from the public internet 128 (or any other communications network) may be routed to the platform 100 through firewall and router 125 which protects the platform 100 from unwanted access. These data transmissions are already in digital form (e.g., data packets) and are passed via Ethernet 110 (or similar data network) to the components of the platform 100 for processing.
Those of skill in the art will understand that the communication traffic (voice and data) may flow in either direction through the platform 100 . Thus, in addition to the examples described above, a user 140 - 148 may place a voice phone call that gets directed to the PSTN 123 or send an email that gets directed to the public internet 128 . Similarly, users 140 - 148 may communicate directly via the platform 100 .
Those of skill in the art will understand that platform 100 may be a dedicated system or a multi-tenant system. As a dedicated system, platform 100 is used to provide services solely to one company or user. As a multi-tenant platform, a multitude of customers or companies share the resources of platform 100 and each customer or company keeps its records and account information separate from the rest.
Speech to Text Applications: As described above, the VoIP platform allows for the implementation of various features and applications which enhance the phone service of users. A first exemplary feature of speech to text applications, referred to as a transcription service, will be described. The speech may be in any form, for example, a recorded voice mail, a running conversation between two or more parties, a single party dictating, multiple individuals in a room conversing, etc. The text that is generated by these applications may be a text file which a user may store, view and edit or a real time scrolling text that is displayed on, for example, a CRT or LCD screen of a computing device. The exemplary embodiment of the transcription service according to the present invention will be described as being implemented on the exemplary platform 100 described with reference to FIG. 2 . However, those of skill in the art will understand that the exemplary embodiment of the transcription service may be implemented on any platform through which audio data is streamed or where audio files are stored, including non-telephony related platforms.
FIG. 3 shows an exemplary system 300 for the transcription of speech to text. An audio stream 302 is input into an ASR filter 305 . The audio stream may be pre-recorded or occurring in real time. If, for example, a conversation were between a user 148 using the IP phone 152 and a third party caller using the PSTN 123 , the entire conversation would traverse platform 100 . The user 148 may desire to have the conversation transcribed or saved in a text form. As the conversation is streaming through the platform 100 , it may be acted upon by one or more of the various servers which provide the transcription service. It should be noted that the exemplary transcription service according to the present invention does not need to record or keep a record of the audio information.
Continuing with the above example of the user 148 on the IP phone 152 having a phone conversation with a third party caller, the user 148 may decide that the conversation should be transcribed and the user 148 may initiate the transcription service offered by the platform 100 . The user may initiate the service in a variety of manners, for example, the IP phone 152 may have a button or key combination that when pressed sends a signal to the platform 100 to initiate transcription. In another example, the PC 154 may display a graphical user interface (“GUI”), e.g., a web page, showing the different features and functions offered by the platform 100 . The GUI may include a feature that allows the user to click on a button to start the transcription service. When the user 148 sends the signal to the platform 100 to begin transcription, the signal may be received by, for example, the application server 102 which may implement the transcription service alone or in combination with the other resource servers. For example, the application server may access the database engine 101 to determine which user sent the transcription request, the ASR engine 115 in order to access the ASR services, the network server 103 to branch the packets associated with the correct conversation, the biometric engine 119 to identify the speakers, the accounting systems 122 to bill for the service, the workforce management systems 126 to send the audio shreds to various transcribers for processing, etc.
Referring back to FIG. 3 , the ASR filter 305 may be, for example, the ASR engine 115 of platform 100 . The ASR filter 305 may convert a portion of the raw audio into text using ASR techniques that are generally known. Since the speech is conversation quality, only a small portion of the conversation will be recognized by the ASR filter 305 . A general technique used by ASR filters is to spot words and those words which are recognized with a high degree of confidence (e.g., 99% or greater) may be sent directly to a storage database 335 . The text of the words that are sent to the database also include indexing information to allow the word to be placed back within the conversation at the correct location when the speech is reassembled. A more detailed description of the data structure for the indexing will be given below.
FIG. 4 shows an exemplary audio stream 302 in the various stages 350 - 390 as it is transformed into text. FIG. 5 shows exemplary data structures 400 - 425 which may be used to index the data associated with the audio stream 302 as it is transformed into the text. In this example, the audio stream 302 in stage 350 is a representation of the speech “the rain in Spain.” The audio stream 302 may have an associated data structure 400 ( FIG. 5 ). The data structure 400 may be any type of data structure, for example, a database record, an array, a table, a linked list, etc. The data structure 400 may be stored in the database 335 ( FIG. 3 ) or any other storage location that may be accessed by the platform providing the transcription service. Those of skill in the art will understand that the data structure 400 and the other data structures described are only exemplary and it may be possible to use different data structures to implement the exemplary embodiment of the present invention.
The data structure 400 for audio stream 302 may be assigned an AudioStreamID (e.g., AudioStream 1 ) and include information such as the speaker ID, the conversation ID, the begin and end time of the audio stream 302 , and the actual audio stream 302 . Audio that is coming from a specific device (e.g., the IP phone 152 ) may be ascribed to a single user that is associated with that device. If the speaker is the third party caller, the speaker ID may be associated with the telephone number of the third party caller. As described above, the platform 100 has the ANI information (in the case of a third party caller) or the DNIS information (in the case of the third party receiving the call) so the speaker ID may be the third party number (e.g., speaker from 555-1000). In the case where there are multiple parties on a speaker or conference phone, a speaker identification system, for example, based on biometrics provided by biometrics engine 119 ( FIG. 2 ), may be used to identify the party speaking (e.g., speaker “A” from conference line 555-8000).
The conversation ID may be used to identify the audio stream with the particular conversation from which it came. For example, the audio stream 302 “the rain in Spain” may be only a small portion of a conversation which contains hundreds or thousands of words. For the transcription to be accurate, the transcription of every audio stream in the conversation needs to be indexed to the conversation. Thus, every audio stream from the conversation will index back to the conversation ID. The begin time and end time of the data structure are also used to index to the correct conversation because not only do all the words from the conversation need to be identified with the conversation, but the words need to be assembled in the correct temporal order to have an accurate transcription. The time information may be indexed to absolute time (e.g., day/time) as kept by the platform or as some relative time (e.g., time as measured from the start of the conversation). The exemplary embodiment of the transcription service will use (or process) the actual audio stream 302 to create the transcription of the audio. The audio segment ID, word ID and TextStream ID of the data structure 400 will be described in detail below.
Referring back to FIG. 3 , the exemplary audio stream 302 may be input into the ASR filter 305 . In this example, the ASR filter 305 recognizes one word of the audio stream 302 , i.e., “in” 363 as shown in stage 360 of FIG. 4 . A text representation of the word “in” and indexing information for the word may then be stored in the database 335 for when the speech is later reassembled. The data structure 415 for the stored word is shown in FIG. 5 . The data structure 415 may be assigned a WordID and include the AudioStreamID from which the word was identified (e.g., AudioStream 1 ), the beginning and end time of the word, and the actual text file for the word, e.g., “in”. Once again, this word index will be used at a later time to reassemble the conversation into the transcription. Each word that is identified by the ASR 305 will have a separately stored data structure in database 335 . The data structure 400 for the audio stream 302 may also store (or have a pointer to) the WordID for each word in the audio stream 302 .
The result of the audio stream 302 being input into the ASR filter 305 is that the audio stream is broken into recognized words and ambiguous audio segments. Referring to FIG. 4 , this is shown in stage 360 where the recognized word “in” 363 separates two ambiguous audio segments 361 - 362 . The recognized words (e.g., “in” 363 ) set up word boundaries which separate the ambiguous audio segments as shown in stage 360 . Each of the audio segments 361 - 362 also has an associated data structure 410 . The data structures 410 for the audio segments 361 - 362 are each assigned an AudioSegmentID (e.g., AudioSegment 1 and AudioSegment 2 ) and the data structure includes the AudioStreamID of the audio stream from which the segment is derived, the begin and end time of the audio segment and the actual audio segment. In this example, the begin time of the first audio segment 361 is the begin time of the audio stream 302 from which it is derived and the end time is the begin time of the identified word 363 . For the second audio segment 362 , the begin time is the end time of the identified word 363 and the end time is the end time of the audio stream 302 from which it is derived. The AudioShredID will be described in greater detail below. The data structure 400 for the audio stream 302 may also store (or have a pointer to) the AudioSegment ID for each audio segment in the audio stream 302 . Thus, the initial audio stream has been segmented into identified words and ambiguous audio segments.
Referring back to FIG. 3 , the ambiguous audio segments (e.g., the segments 361 - 362 ) may then be directed to an audio shredder 310 which breaks the ambiguous segments into multiple audio shreds, for example, one to ten second audio segments, and more preferably three to five second audio segments, or shreds. However, the duration of the audio shreds is adjustable and may be set to accommodate the longest possible words, but short enough to eliminate all context from the conversation. A similar ASR engine as used for ASR filter 305 may be used to implement the audio shredder 310 . However, in this case, the ASR engine will not identify specific words, but may identify pauses between words, i.e., word boundaries. In the ideal case, each audio shred will start at the beginning of a word and end at the end of a word. The beginning and end may be the same word or it may be multiple words. There may be instances where multiple words are preferred because it may be easier to transcribe the audio of several words rather than just one.
The audio shreds may overlap, i.e., the same portion of an audio segment may appear in two audio shreds. This may add fault tolerance to the audio shreds. For example, while the audio shredder 310 attempts to break the shreds at word boundaries, it may not always be successful and an audio shred may contain only a portion of a word in the audio stream making the word unrecognizable. However, an overlapping shred may contain the entire word making it possible to correctly reconstruct the conversation. The overlapping shreds may also be used as an accuracy check. For example, the same word may appear in two audio shreds which are sent to two different transcribers. If both transcribers accurately transcribe the word, there is a higher degree of confidence in the accuracy of that word as opposed to a single transcriber transcribing the word. If, on the other hand, the two transcribers disagree, there may be a series of checks and/or processes that can be used to determine which word is correct. Such comparisons may also be used to assess the accuracy of the transcribers.
Referring to FIG. 4 , stage 370 shows that the audio segments 361 - 362 of stage 360 have been shredded into the audio shreds 371 - 373 and the audio shreds 374 - 378 , respectively. Each of the audio shreds is indexed and the index information is stored in the database 335 in, for example, the data structure 420 of FIG. 5 . There is a data structure 420 for each audio shred and each data structure is assigned an AudioShredID, the data structure including the AudioSegmentID of the audio segment from which the shred is derived, e.g., the audio shred 371 will contain the AudioSegmentID of the audio segment 361 . The data structure 420 may also include the beginning and ending time for the audio shred and the actual audio of the shred. Once again, this information for the audio shred may be used later to reassemble the audio stream 302 . The data structure 410 for the audio segments may also store (or have a pointer to) the AudioShredID for each audio shred in the audio segment.
Referring back to FIG. 3 , the audio shreds maybe input into an audio mixer 315 and randomized with audio shreds from other audio streams 312 from multiple conversations. Thus, an audio shred from a real time conversation may be randomized with an audio shred from a different conversation, from a voice mail recording, etc. As described above, the short duration of the audio shreds removes the context from each of the audio shreds. The process of mixing the audio shreds with other random audio shreds assures that the transcribers who hear the audio shreds (discussed below) cannot reassemble any one conversation from memory because the transcribers are only hearing random shreds of multiple audio streams from multiple conversations.
The multiple audio shreds are then transmitted to live agent transcribers 320 who may listen to the audio shreds and type the corresponding audio word into text. The workforce management systems 318 (which correspond to workforce management systems 126 of FIG. 2 ) may determine which transcriber receives the audio shreds based on a number of criteria along with monitoring transcriber status (e.g., available, working, unavailable, etc.) and performance metrics such as accuracy and speed. For example, the platform 100 may have one hundred simultaneous two-way conversations which are being transcribed. The audio mixer 315 is randomizing audio shreds from each of these one hundred conversations. The audio mixer sends these audio shreds to the transcribers 320 in order to have the text associated with the shreds transcribed. There is no need to centrally locate the transcribers 320 . Each of the transcribers 320 may be located in a different location which is remote from the other transcribers and from the platform 100 . The minimal requirements are a data connection to platform 100 and appropriate computing hardware and software for receiving audio shreds. For example, the transcribers 320 may receive the audio shreds over a data connection (e.g., internet dial-up access) in a manner similar to the delivery of electronic mail.
Platform 100 may also use the ASR filter 305 to transcribe an audio stream 302 directly. Since the accuracy of such computer-generated transcription may not be high, platform 100 would still perform the audio shredding tasks described above. However, instead of sending the audio shreds to the agent transcribers 320 for transcription, the agent transcribers 320 would instead proofread the text generated by the ASR filter 305 and compare it with the original audio shred. The audio shred and ASR-generated text would be delivered to the agent simultaneously. The agent transcribers 320 may then accept the computer generated text as accurate or make necessary corrections. This proofreading service may be used to improve the efficiency of the agent transcriber 320 while still keeping the speech to text conversion process, described above, secure.
As mentioned above, transcribers need not be physically located in any one place. The transcribers could comprise a distributed workforce located in various countries around the world where each transcriber works as an independent contractor from home. Transcribers may also belong to groups that work in the same facility, as in a traditional call center business. A multitude of such groups and at-home agents would comprise the distributed workforce, managed by platform 100 , providing speech to text conversion services.
The client application used by the transcribers would include audio and data channels. The audio channel could deliver either streamed, real-time speech or stored, pre-recorded speech. This delivery may be via an Internet connection to a media player, email client or web browser. For example, streamed audio may be played by the PC directly using a third party's media player software and retrieved via a web browser; and, stored audio may be retrieved using a third party's email program. The data channel may be an Internet connection that connects a program running on the transcriber's computer to platform 100 , a web browser connection to platform 100 , or an email connection to platform 100 .
The workforce management systems 318 will monitor which transcribers 320 are available and direct an audio shred to an available transcriber 320 . When the transcriber 320 receives the audio shreds, the transcriber control will indicate that the transcriber is working and the transcriber 320 will not receive additional audio shreds until the transcriber finishes with the current audio shred. In addition, the transcriber control 318 may monitor the number of audio shreds from a single conversation that a particular transcriber receives in order to assure that the individual transcriber may not piece together the conversation. The transcriber 320 may receive the audio shred in the form of data packets that are sent to a PC the transcriber 320 is using. The data packets may include the data structure 420 for the audio shred, including the actual audio for the audio shred. The audio may be played, for example, via a media player on the PC and as the transcriber 320 hears the word or words in the audio shred, the text for these words may be typed into the PC, for example, via a dialog screen. The transcriber 320 may also receive the audio shred through a telephony device. The audio shred may be played through a telephone handset or headset and the transcriber 320 enters the corresponding text using a PC.
As the transcriber is typing in the words, a data structure 425 is created for the text which is entered. This text may be referred to as a token. Thus, the data structure 425 is assigned a TokenID and may include the AudioShredID from which the token was transcribed, the identification of the transcriber (TranscriberID), a confidence level (i.e., the level of confidence of the transcriber 320 that the transcription was accurate), the actual text of the word or words and a word index. There may be cases of ambiguities such as inaudible words where the transcriber 320 cannot accurately enter the text corresponding to the spoken word. In these cases, the transcriber 320 may enter an error code which indicates problems such as an error in the transmission (e.g., static), homonym ambiguities, inaudible speech, etc. The transcriber 320 may adjust the confidence level commensurate with such errors. For example, if there was static in the audio shred, the transcriber may enter a code corresponding to static and a confidence level of zero (0) indicating there is no confidence in the transcription because of the error. The data structure 420 for the audio shreds may also store (or have a pointer to) the TokenID for each token in the audio shred.
Thus, at this point each word in the original audio stream 302 is in text form. Referring to stage 380 of FIG. 4 , the text of the words were either determined by the ASR filter 305 and stored in the form of a word data structure 415 in database 335 or determined as part of a token by the transcribers 320 . These data structures containing the actual text of the words and the associated indexing information are input into the reassembler 325 where the words and tokens are reassembled. As described above, each of the words and tokens are indexed to the audio stream and their location within the audio stream and this indexing information may be used to reassemble the text into a coherent text representation of the audio stream. Those of skill in the art will understand that the indexing information from the words (data structure 415 ), the tokens (data structure 425 ) and the other data structures 400 , 410 and 420 may be combined in order to correctly reassemble the audio stream.
As described above, in some instances the audio shreds will overlap, thus the text from the corresponding tokens will also overlap. The reassembler 325 may eliminate these overlapping words to accurately reflect the conversation. In addition, where the transcriber entered an ambiguity, the reassembler 325 may compare the overlaps to eliminate the ambiguities. The reassembler 325 may also contain a grammar engine which aids in the reassembly of the audio stream. For example, a word or token may contain a homonym, e.g., by and buy. The grammar engine may resolve such ambiguities as the text file is being created.
The output of the reassembler 325 is a text stream having the data structure 405 as shown in FIG.5 . The text stream is assigned a TextStream ID and includes the AudioStreamID of the audio stream from which the text steam is derived and the actual text of the text stream. The stage 390 of FIG. 4 shows the transcription output of the exemplary audio stream 302 . The reassembler 325 not only reassembles the audio streams, but also reassembles the conversations from which the audio streams are derived. Thus, the text stream output may include the entire conversation, not just the single audio stream. The output of the reassembler 325 is sent to a delivery module 330 which delivers the text output in the manner prescribed by the user, e.g., a text file, scrolling text, RSS protocol, a Microsoft Word document, formats specific to courts of law or government bodies, etc.
The workforce management systems 318 may employ heuristic methods to identify a group of transcribers that are most suited to transcribing audio streams 302 from a class of speakers. Selection criteria may include knowledge of specialized terms (such as medical or legal terminology), prior success in accurately transcribing a user's speech or skill with a foreign language, dialect or regional accent. The class of speakers may be defined as those individuals from a specific profession (such as doctors, lawyers, etc.), a specific speaking pattern or accent (such as individuals from the Southern, New England or Mid-West regions of the United States), or foreign language (such as German, Spanish or Italian speakers).
The transcription service described here may be for any foreign language. The user may indicate his language during the setup of the transcription service or the speaker's language may be identified through trial and error techniques. For example, an audio shred may be sent to one or more transcribers. If the audio shred is not understandable to those transcribers, the system may send that audio shred to many different transcribers, each specializing in a different language. The transcribers that return a non-ambiguous result will-thereby identify the speaker's foreign language. In addition, the ASR engine 115 may have grammar libraries for multiple foreign languages and also be used to identify which language a speaker is using. Upon conversion of the foreign language speech into text, the text document may be translated into any other language by standard means. For such translation applications, the speech to text service described here becomes the necessary preprocessor of the speech.
In the preceding specification, the present invention has been described with reference to specific exemplary embodiments thereof. It will, however, be evident that various modifications and changes may be made thereunto without departing from the broadest spirit and scope of the present invention as set forth in the claims that follow. The specification and drawings are accordingly to be regarded in an illustrative rather than restrictive sense. | The system is designed to interface with external devices and services, to transcribe audio that may be stored elsewhere such as a wireless phone'voice mail, or occurring between two or more parties such as a conference call. An audio stream is separated into many audio shreds, each of which has duration of only a few seconds and cannot reveal the context of the conversation. A workforce of geographically distributed transcription agents who transcribe the audio shreds is able to generate transcription in real time, with many agents working in parallel on a single conversation. No one agent (or group of agents) receives a sufficient number of audio shreds to reconstruct the context of any conversation. The use of human transcribers allows the system to overcome limitations typical of computer-based speech recognition and permits accurate transcription of general-quality speech even in acoustically hostile environments. | 6 |
CROSS REFERENCE TO RELATED APPLICATIONS
This is a continuation of U.S. Ser. No. 358,435, filed Mar. 15, 1982, abandoned which is a continuation of U.S. Ser. No. 221,426, filed Dec. 30, 1980, abandoned.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to an improved method of sterilizing articles employed in surgery, treatment, and diagnosis.
2. Description of the Prior Art
It is well known that the dipping of articles into concentrated solutions of hydrogen peroxide (10% to 40%) will sterilize such articles; see, for example, U.S. Pat. Nos. 3,854,874 and 3,904,361. It is also known that hydrogen peroxide vapors will effect such sterilization; see, U.S. Pat. Nos. 4,169,123 and 4,169,124. Reference is particularly made to the latter two patents which compare the bactericidal or sporicidal action of both liquid and gaseous hydrogen peroxide and further note that the sporicidal activity, as recommended by the Food and Drug Administration, of a sterilizing process must assure a probability of less than one organism out of one million surviving the sterilization cycle.
While the dipping of articles to be sterilized in solutions of liquid hydrogen peroxide is effective to reduce bacterial spore concentration to about 10 -6 or better, there are disadvantages to be encountered in this process: (1) dipping objects to be sterilized in a bulk liquid can lead to the contamination of the entire solution and prevent its future use, (2) dipping objects exposes workers and the surrounding environment to the usual hazards of working with fairly large quantities of the sterilant hydrogen peroxide and its attending vapors, and (3) dipped objects may have to be rinsed with sterile distilled water before drying to ensure that any nonvolatile materials present in the sterilization solution will not remain on the object following the required drying step. Inasmuch as hydrogen peroxide is unstable in solution it is necessary to employ stabilizers to control its rate of decomposition. While such deposition of solid stabilizers on the products to be sterilized is avoided in the forementioned U.S. Pat. Nos. 4,169,123 and 4,169,124, the advantage of bringing the articles to be sterilized into positive contact with liquid hydrogen peroxide solutions is not thereby obtained. When, in addition, hydrogen peroxide aerosols are employed (NASA Technical Translation TTF-15, 127, of Fedyayev et al., Virucidal Action of Hydrogen Peroxide Aerosols in Decontamination of Air in an Influenza Nidus, Zhurnal Mikrobiologii, Eipidemologii i Immunobiologii, 9, 137-142 (1972) there is no assurance that the aerosols will not carry with them dispersed particles containing stabilizer components.
In addition, dipping methods introduce the inherent unreliability of individual action in that, for example, articles may not be completely dipped in solution or they may be protected by small air pockets and solution thereby does not contact every surface or penetrate every crevice of the article; or the article may not be immersed for a sufficient period of time in the solution.
The notable sporicidal action of gaseous hydrogen peroxide, as taught in U.S. Pat. Nos. 4,169,123 and 4,169,124 may be explained by the fact that the sterilization chamber preferably is evacuated before introduction of the sterilant. This means that the gaseous sterilant is not impeded by diffusion through air in reaching the articles to be sterilized. Further, intimate contact is possible between the gaseous sterilant and the surface of an article to be sterilized without the interference of air entrapped in interstices adjacent such surface.
Since the sporcidal activity of hydrogen peroxide is chemical in nature, the rate of such (killing) activity is increased by an increase in the concentration of the sterilant at the point of attack. The present invention is directed to accomplishing such an increase in sterilant concentration by creating a liquid hydrogen peroxide condensate in the presence of a vacuum, the liquid being more highly concentrated than the hydrogen peroxide vapor taught in U.S. Pat. Nos. 4,169,123 and 4,169,124. In other words, the present invention may be considered a "dip process" with each "dip" applying a fresh, pure liquid sterilant to an evacuated (air free) surface.
SUMMARY OF THE INVENTION
This invention is directed to improvements in methods for the sterilization of articles in which both the advantages of liquid sterilization and gas sterilization can be obtained. None of the aforementioned disadvantages of liquid dipping sterilization exist in the process of invention and yet the sterilizing impact of the relatively high concentrations of hydrogen peroxide that exist in liquid as compared to gaseous form are brought into liquid-surface contact with the articles to be sterilized. At the same time the substantial advantages of gas sterilization are also obtained especially in the high penetration of the particular articles which results in unusually high sporicidal action, for example as cited in U.S. Pat. No. 4,169,124, whereby sporicidal activity in the order of magnitude of assuring the survival of less than one organism out of one million is obtained.
In the method of invention uniformly vaporized mixed hydrogen peroxide-water vapors are delivered at uniform intervals into a closed sterilizer zone, which has been evacuated prior to the vapor introduction; articles to be sterilized resting in a container in the said zone if necessary are cooled prior to the introduction of the vapor (or are cooled by the evacuation of air from the sterilizing zone) to a temperature below the dew point of the entering vapors, whereby the vapors penetrate all the interstices of the said articles, contact all surfaces thereof, and by condensing deposit a film of liquid on all such cool surfaces; and the liquid film is subsequently evaporated and swept out of the chamber by the introduction of filtered air which will act to strip the liquid film from the sterilized articles, the said articles being preferably warmed to aid in driving off the said liquid film.
Apparatus for carrying out the method of the invention while specially adapted to the method can be of widely varying sophistication and it is contemplated that commercial apparatus will be actuated by set timer switches or the like. After the sterilizer is loaded, a single actuator button can be pressed and conventional sequentially timed apparatus will carry out the entire sterilization cycle.
BRIEF DESCRIPTION OF THE DRAWING
The single FIGURE is a side elevational view of means for carrying out the method of the invention, in which FIGURE the means are shown to be manually operated in order to permit simplification of description of the novel method.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
A sterilizer 10 is shown with its front section containing a door (not shown) removed. Contained within the sterilizer section is an instrument table 11 having means for heating or cooling its base 12 such means being symbolized by the electrical cord 13. Resting on the instrument table 11 is a container 15 in which are placed materials emanating from surgical or medical procedures and which require sterilization in high degree before reuse. The sterilization chamber is provided with a pressure gauge 16 and a fan 17. A supply of filtered air is provided to the chamber 10 by valved line 18 and vacuum may be imposed upon the sterilization chamber 10 by withdrawal of air or vapors through valved line 19. Equipment for vaporization of hydrogen peroxide solutions 20 consists of a supply flask 21, a valved supply line 22, and an evaporator 23 having a source of heat symbolized by electrical line 24. Means are provided for releasing the generated hydrogen peroxide vapor through connecting valved line 26.
In operation of the foregoing apparatus according to the method of the invention an aqueous concentrated solution, (having for example from about 10% to 40% of hydrogen peroxide) is permitted to flow from the storage or supply vessel 21 in small volume increments through the valved supply line 22 into the vaporization chamber 23.
At the same time the sterilization chamber 10 is evacuated by pump means (not shown) through vacuum line 19 the valved lines 18 and 26 being closed during this operation. The increment of hydrogen peroxide solution in the vaporizer 23 is heated by means 24 and vapors so produced are allowed to flow through valved line 26, by opening the valve therein, into the sterilization chamber 10.
Importantly the articles (not shown) in the container 14 in the sterilization chamber are maintained at a temperature below the dew point of the hydrogen peroxide vapors entering the said chamber. This is basically accomplished by maintaining the evacuated ambient low pressure air in the chamber at a temperature only slightly above, if at all, of the articles to be sterilized and/or by circulating cooling medium in the base 12 of instrument table 11. Accordingly hydrogen peroxide vapors will condense on the entire surfaces of the articles within the container 14. The valved line 26 will thereupon be closed and the sterilization chamber will be maintained under stable conditions for a selected period of sterilization time. Thereafter valved line 18 and valved line 19 are opened and filtered aseptic air is caused to flow through the chamber 10 to evaporate from the surface of articles being sterilized the liquid film that had been maintained thereon. These vapors are caused to escape through the open valved line 19. Evaporation of the film of liquid on the articles that have been sterilized is augmented by heat delivered by device 13 and associated heating elements (not shown) in the said base 12. The fan 17, the blades of which are mounted in the upper area of the sterilization chamber free of contact with the sterilization articles can be used either to ensure uniform distribution of inflowing hydrogen peroxide vapors (in which case the operation of the fan blades will be at a low velocity) or it may be used at high velocity to aid in the vaporization of the film of liquid on the articles that have been sterilized.
The temperature of operation within the sterilization chamber and especially of the articles to be sterilized will be basically governed by the dew point of the particular concentration of hydrogen peroxide in the vapors introduced into the chamber. Temperatures generally within the range of about 15° C. to 55° C. effect sterilization of most articles in a period of hours, the temperature primarily being selected so that a film of liquid forms on the articles while nevertheless the inflowing vapors are not so rapidly condensed but what in the gaseous form they can and do penetrate all the interstices of the said articles.
A 30 percent by weight solution of hydrogen peroxide is heated in the vessel 23 to a temperature of about 130° F. thereby producing a vapor containing about 2 to 2.5 percent by weight of hydrogen peroxide. Air in sterilization chamber 10 is evacuated therefrom to an absolute pressure of between 2 and 4 inches of Hg. The aforesaid hydrogen peroxide vapor is then permitted to flow into the chamber the walls of which are maintained at or near 100° F. and into contact with articles to be sterilized at normally about 70° F., these articles having just been placed in the chamber at the usual ambient room temperature or at slightly cooler temperatures. That portion of the 2 to 2.5 percent hydrogen peroxide vapor which comes in contact with the said articles will be cooled to about 70° F., a temperature below the dew point of the vapor, and a condensation of a liquid film will result, the condensate liquid containing about 37 percent by weight of hydrogen peroxide. Vapor is allowed to flow into the sterilization chamber until equilibrium pressure is established, the condensation of liquid on the articles to be sterilized in the meantime raising the surface temperature of the said articles, it may be until they reach an equilibrium temperature with the vapor in the chamber. The sterilization zone is then closed and stable conditions are maintained therein for a period which may vary widely from several minutes to several hours with different materials to be sterilized and different microorganism to be killed, until conventional laboratory monitoring means shows complete kill to be obtained. Microorganisms commonly employed in such test procedures are Bacillus subtilis spores, being highly resistant to sterilization.
Actual temperatures and liquid and vapor concentrations can be varied within the limits of about 100° to 300° F. in the vaporization chamber, 6% to 70% concentration of hydrogen peroxide in the aqueous solution in the vaporizing zone (preferably 30 to 70 percent) and from 50° to 200° F. original temperature in the sterilization zone. | A method is provided of hydrogen peroxide sterilization of medical articles whereby there are obtained the advantages of both vapor penetration, especially for such articles as surgical packs, and direct liquid-sterilant article contact, in which a vapor mixture comprising hydrogen peroxide is brought into contact with the article to be sterilized, the article being at a temperature below the dew point or condensation temperature of the vapor mixture, is caused thus to condense as a liquid film on the article, and is revaporized and hence removed from the so-sterilized article. | 0 |
RELATED APPLICATION
[0001] This application is a continuation of U.S. patent application Ser. No. 10/218,989, filed Aug. 14, 2002, now pending.
FIELD OF THE INVENTION
[0002] The present invention relates to pharmaceutical formulations, and more particularly to formulations containing cannabinoids for administration via a pump action spray.
BACKGROUND OF THE INVENTION
[0003] It has long been known to introduce drugs into the systemic circulation system via a contiguous mucous membrane to increase onset of activity, potency etc.
[0004] For example, U.S. Pat. No. 3,560,625 disclose aerosol formulations for introducing an alkoxybenzamide into the systemic circulatory system. Two different types of aerosol formulations are disclosed:
a) fluorinated hydrocarbon type comprising 2% by weight alkoxybenzamide, 18% ethanol, and 80% propellant; and b) nebuliser type comprising 0.5% by weight alkoxybenzamide, a mixed solvent system comprising 10.3% ethanol and 31.4% propylene glycol and 57.8% deionised water.
[0007] U.S. Pat. No. 3 , 560 , 625 identifies a problem in finding a suitable solvent system to produce an aerosol spray for inhalation of the ortho-ethoxybenzamide, due to the fact that whilst ethanol was undoubtedly the best solvent, a mixture containing more than 18% of ethanol by weight produced an unpleasant oral reaction which more than counterbalanced the efficacy of the oral route.
[0008] When the present applicant set out to produce spray formulations for a botanical drug substance comprising one or more cannabinoids they were aware that the highly lipophylic nature of the cannabinoids could present problems in formulating the active component(s).
[0009] The present applicant first sought to develop a formulation for oromucosal, preferably sublingual, delivery in a pressurised aerosol or spray form, as disclosed in international patent application PCT/GB01/01027. Their initial focus was on propellant driven systems with HFC-123a and HFC-227 but these proved to be unsuitable as solvents for the cannabinoids. The formulations comprised synthetic A9-THC in amounts from 0.164 to 0.7% wt/wt, with ethanol as the primary solvent in amounts up to 20.51% by weight. One particular composition comprised 0.164% synthetic Δ9-THC, 4.992% ethanol, 4.992% propylene glycol and 89.582% p134a (propellant).
[0010] The applicant found that even at ethanol levels of 20% by volume of the total formulation volume they were unable to dissolve sufficient levels of A9-THC in a standard spray dose to meet clinical needs, because of the cannabinoids poor solubility in the propellant. They also found that the ethanol level could not be increased, as the delivery characteristics of the device nozzle altered substantially when the lower volatility solvents were increased above a critical ratio. The HFC-123a and HFC-227 propellant sprays delivered a maximum of 7 mg/ml, whereas initial clinical studies suggested the formulations would be required to contain up to 50 mg cannabinoids/ml.
[0011] Thus, the present applicants focussed on self-emulsifying drug delivery systems, as are discussed in detail in a review article European Journal of Pharmaceutics and Biopharmaceutics 50 (2000) 179-188, which concluded that the poor aqueous solubility of many chemical entities represents a real challenge for the design of appropriate formulations aimed at enhancing oral bioavailability.
[0012] In their co-pending International application PCT/GB02/00620 the applicant discloses a wide range of cannabinoid-containing formulations containing at least one self-emulsifying agent. The inclusion of at least one self-emulsifying agent was thought necessary to get the formulation to adhere to the mucosal surface in order to achieve sufficient absorption of the cannabinoids. One particular formulation comprised 2% by wt glycerol mono-oleate, 5% CBME of G1 cannabis to give THC, 5% CBME of G5 cannabis to give CBD, 44% ethanol BP and 44% propylene glycol.
SUMMARY OF THE INVENTION
[0013] Surprisingly, the applicant has found that they do not absolutely require the presence of a self-emulsifying agent in a liquid formulation to achieve a satisfactory dosage level by oromucosal, and specifically sub-lingual or buccal, application.
[0014] Indeed, contrary to the teachings of U.S. Pat. No. 3,560,625 and the European Journal of Pharmaceutics and Biopharmaceutics 50 (2000) 179-188, they have been able to produce a simple and effective vehicle for delivering a lipophilic medicament in a liquid spray.
[0015] According to a specific aspect of the present invention there is provided a pharmaceutical formulation consisting essentially of one or more cannabinoids, ethanol and propylene glycol.
[0016] Preferably the one or more cannabinoids are present in the form of at least one extract from at least one cannabis plant. The cannabis plant(s) preferably include at least one cannabis chemovar. Most preferably the plant extract will be a botanical drug substance (BDS), as defined herein.
[0017] Optionally, the formulation may additionally contain a flavour, such as, for example, peppermint oil.
[0018] The formulation may also contain, in addition to the cannabinoid(s), a further active agent, which is preferably an opiate, for example morphine. Thus, it is contemplated to provide a formulation consisting essentially of one or more cannabinoids, ethanol, propylene glycol and an opiate, preferably morphine.
[0019] A typical liquid pharmaceutical formulation according to this specific aspect of the invention, given by way of example and not intended to be limiting to the invention, may contain in a 1 ml vol: THC 25-50 mg/ml, preferably 25 mg/ml (based on amount of cannabinoid in a botanical drug substance), CBD 25-50 mg/ml, preferably 25 mg/ml (based on amount of cannabinoid in a botanical drug substance), propylene glycol 0.5 ml/ml, peppermint oil 0.0005 ml/ml, and ethanol (anhydrous) qs to 1 ml.
[0020] Other preferred formulations include a “high THC” formulation comprising in a 1 ml vol: THC 25 mg/ml (based on amount of cannabinoid in a botanical drug substance), propylene glycol 0.5 ml/ml, peppermint oil 0.0005 ml/ml, and ethanol (anhydrous) qs to 1 ml; and a “high CBD” formulation comprising in a 1 ml vol: CBD 25 mg/ml (based on amount of cannabinoid in a botanical drug substance), propylene glycol 0.5 ml/ml, peppermint oil 0.0005 ml/ml, and ethanol (anhydrous) qs to 1 ml.
[0021] In these formulations the cannabinoids are added as botanical drug substances derived from cannabis plants, quoted amounts of cannabinoids correspond to total amount (weight) of cannabinoid present in 1 ml of the final formulation. The skilled reader will appreciate that the total amount of BDS which must be added in order to achieve the desired amount of cannabinoid in the final formulation will be dependent on the concentration of cannabinoid present in the BDS, which will vary between different batches of BDS.
[0022] The finding that such a simple combination of one or more cannabinoids, ethanol and propylene glycol can be used effectively in a pump action spray was unexpected.
[0023] The applicant has found that, where the solvent/co-solvent system is ethanol/propylene glycol and the lipophilic medicament comprises one or more cannabinoids in the form of a botanical drug substance (BDS), the limits in which the solvent/co-solvent will work effectively are quite narrow, as discussed below.
[0024] More broadly speaking, and according to a general aspect of the invention, there is provided a liquid pharmaceutical formulation, for use in administration of a lipophilic medicament via a mucosal surface, comprising at least one lipophilic medicament, a solvent and a co-solvent, wherein the total amount of solvent and co-solvent present in the formulation is greater than 55% wt/wt of the formulation and the formulation is absent of a self-emulsifying agent and/or a fluorinated propellant.
[0025] Preferably the amount of solvent/co-solvent is greater than 80%, more preferably in the order 90-98%.
[0026] Preferably the formulation has a water content of less than 5%.
[0027] Preferably the formulation does not contain any type of propellant.
[0028] The formulation also lacks any self-emulsifying agent. Self-emulsifying agents are defined herein as an agent which will form an emulsion when presented with an alternate phase with a minimum energy requirement. In contrast, an emulsifying agent, as opposed to a self-emulsifying agent, is one requiring additional energy to form an emulsion. Generally a self-emulsifying agent will be a soluble soap, a salt or a sulphated alcohol, especially a non-ionic surfactant or a quaternary compound. Exemplary self-emulsifying agents include, but are not limited to, glyceryl mono oleate (esp. SE grade), glyceryl monostearate (esp. SE grade), macrogols (polyethylene glycols), and polyoxyhydrogenated castor oils e.g. cremophor.
[0029] The formulation may additionally comprise a flavouring. The preferred flavouring is peppermint oil, preferably in an amount by volume of up to 0.1%, typically 0.05% v/v.
[0030] Preferably the solvent is selected from C1-C4 alcohols. The preferred solvent is ethanol.
[0031] Preferably the co-solvent is a solvent which allows a lower amount of the “primary” solvent to be used. In combination with the “primary” solvent it should solubilise the lipophylic medicament sufficiently that a medically useful amount of the lipophylic medicament is solubilised. A medically useful amount will vary with the medicament, but for cannabinoids will be an amount of at least 1.0 mg/0.1 ml of solvent/co-solvent.
[0032] Preferred co-solvents are selected from glycols, sugar alcohols, carbonate esters and chlorinated hydrocarbons.
[0033] The glycols are preferably selected from propylene glycol and glycerol, with propylene glycol being most preferred. The carbonate ester is preferably propylene carbonate.
[0034] The most preferred combination is ethanol as the solvent and propylene glycol as the co-solvent.
[0035] The preparation of liquid formulations for oropharangeal delivery of cannabinoids poses a number of problems. First, it is necessary to deliver at least 1.0 mg, more preferably at least 2.5 mg and even more preferably at least 5 mg of cannabinoids per 0.1 ml of liquid formulation to achieve a therapeutic effect in a unit dose. In this regard a patient may require up to 120 mg cannabinoid/day, on average around 40 mg/day to be taken in a maximum of six doses.
[0036] In the case of a sublingual or buccal delivery, this means delivering this quantity of the active ingredient in an amount of formulation which will not be swallowed by the patient, if the active ingredient is to be absorbed transmucosally.
[0037] Whilst such amounts can be achieved by dissolving the cannabinoid in ethanol as the solvent, high concentrations of ethanol provoke a stinging sensation and are beyond the limit of tolerability.
[0038] There is thus a need to use a co-solvent in order to reduce the amount of ethanol, whilst still enabling sufficient quantities of cannabinoid to be solubilised.
[0039] The applicant has discovered that the choice of co-solvent is limited. Preferred co-solvents should have a solubilizing effect sufficient to allow enough cannabinoid to be solubilised in a unit dose, namely at least 1.0 mg/0.1 ml of formulation, and which allows the amount of solvent present to be reduced to a level which is within the limits of patient tolerability. Particularly suitable co-solvents which fulfil these criteria are propylene glycol and glycerol.
[0040] In a preferred embodiment the total amount of solvent and co-solvent present in the formulation, is greater than about 65% w/w, more preferably greater than about 70% w/w, more preferably greater than about 75% w/w, more preferably greater than about 80% w/w, more preferably greater than about 85% w/w of the formulation. Most preferably the total amount of solvent and co-solvent present in the formulation is in the range from about 80% w/w to about 98% w/w of the formulation.
[0041] In a preferred embodiment the formulations according to the invention are liquid formulation administered via a pump-action spray. Pump-action sprays are characterised in requiring the application of external pressure for actuation, for example external manual, mechanical or electrically initiated pressure. This is in contrast to pressurized systems, e.g. propellant-driven aerosol sprays, where actuation is typically achieved by controlled release of pressure e.g. by controlled opening of a valve.
[0042] Pump-action sprays are found to be particularly beneficial when it comes to delivering cannabinoids. Indeed, previously people have focussed their attention on solvent systems including a propellant.
[0043] Whilst it has been recognised that there are disadvantages with such systems, including the speed of delivery, those skilled in the art have tried to address this by slowing the propellant or by altering the nozzle. The applicants have found that by using a pump spray with their formulations they are able to produce a spray in which the particles have a mean aerodynamic particle size of between 15 and 45 microns, more particularly between 20 and 40 microns and an average of about 33 microns. These contrast with particles having a mean aerodynamic particle size of between 5 and 10 microns when delivered using a pressurised system.
[0044] In fact, comparative tests by the applicant have shown such a pump-action spray system to have advantages in being able to deliver the active components to a larger surface area within the target area. This is illustrated with reference to the accompanying Example 3.
[0045] The variation in particle distribution and sprayed area has been demonstrated by direct experiment. A formulation as described in the accompanying Example 4 was filled into a pump action spray assembly (Valois vial type VP7100 actuated). The same formulation was filled into a pressurised container powered by HFA 134a.
[0046] Both containers were discharged at a distance of 50 mm from a sheet of thin paper held at right angles to the direction of travel of the jet. The pattern of spray produced in both cases by discharge of 100 μl was then visualised against the light. In both cases the pattern of discharge was circular and measurements were as follows:
[0000]
Mean Diameter (mm)
Mean Area (mm 2 )
Pump Action Spray
23
425.5
Pressurised Spray
16
201.1
[0047] The pressurised spray produced pooling of liquid at the centre of the area. The pump action spray gave a more even spray pattern and less “bounce back”. There was also a significantly greater area covered by the pump action spray. The conditions under which this test was carried out are relevant to the in-practice use of the device. A wider area of buccal mucosa can be reached by the pump action spray compared with the pressurised spray.
[0048] For pump spray applications the solvent/co-solvent combination must have a viscosity within the viscosity range defined by the preferred solvent/co-solvent combination. Thus it should be a viscosity ranging between that for an ethanol/propylene glycol combination where the ethanol/propylene glycol are present in the relative proportions by volume of 60/40 and 40/60, more preferably still 55/45 to 45/55 and most preferably about 50/50.
[0049] The viscosity of the resulting formulation when packaged for delivery by pump action through a mechanical pump such as, for example, a VP7 actuator valve (Valois), allows the resulting aerosol to deliver a spray having a mean aerodynamic particle size of from 20-40 microns, more preferably 25-35 and most preferably with an average particle size of from 30-35 microns. This maximises contact with the target mucosal membrane for sublingual/buccal delivery.
[0050] Preferably the formulations according to the general and specific aspects of the invention comprises as the lipophilic medicament one or more cannabinoids.
[0051] Preferably the lipophilic medicament is at least one extract from at least one cannabis plant. The cannabis plant(s) preferably include at least one cannabis chemovar. Most preferably the plant extract will be a botanical drug substance (BDS), as defined herein.
[0052] A “plant extract” is an extract from a plant material as defined in the Guidance for Industry Botanical Drug Products Draft Guidance, August 2000, US Department of Health and Human Services, Food and Drug Administration Center for Drug Evaluation and Research.
[0053] “Plant material” is defined as a plant or plant part (e.g. bark, wood, leaves, stems, roots, flowers, fruits, seeds, berries or parts thereof) as well as exudates.
[0054] The term “ Cannabis plant(s)” encompasses wild type Cannabis sativa and also variants thereof, including cannabis chemovars which naturally contain different amounts of the individual cannabinoids, Cannabis sativa subspecies indica including the variants var. indica and var. kafiristanica, Cannabis indica and also plants which are the result of genetic crosses, self-crosses or hybrids thereof. The term “ Cannabis plant material” is to be interpreted accordingly as encompassing plant material derived from one or more cannabis plants. For the avoidance of doubt it is hereby stated that “cannabis plant material” includes dried cannabis biomass.
[0055] In the context of this application the terms “ cannabis extract” or “extract from a cannabis plant”, which are used interchangeably, encompass “Botanical Drug Substances” derived from cannabis plant material. A Botanical Drug Substance is defined in the Guidance for Industry Botanical Drug Products Draft Guidance, August 2000, US Department of Health and Human Services, Food and Drug Administration Center for Drug Evaluation and Research as: “A drug substance derived from one or more plants, algae, or macroscopic fungi. It is prepared from botanical raw materials by one or more of the following processes: pulverisation, decoction, expression, aqueous extraction, ethanolic extraction, or other similar processes.” A botanical drug substance does not include a highly purified or chemically modified substance derived from natural sources. Thus, in the case of cannabis, “botanical drug substances” derived from cannabis plants do not include highly purified, Pharmacopoeial grade cannabinoids.
[0056] “ Cannabis based medicine extracts (CBMEs)”, such as the CBMEs prepared using processes described in the accompanying examples, are classified as “botanical drug substances”, according to the definition given in the Guidance for Industry Botanical Drug Products Draft Guidance, August 2000, US Department of Health and Human Services, Food and Drug Administration Center for Drug Evaluation and Research.
[0057] “Botanical drug substances” derived from cannabis plants include primary extracts prepared by such processes as, for example, maceration, percolation, extraction with solvents such as C1 to C5 alcohols (e.g. ethanol), Norflurane (HFA134a), HFA227 and liquid carbon dioxide under sub-critical or super-critical conditions. The primary extract may be further purified for example by super-critical or sub-critical solvent extraction, vaporisation or chromatography. When solvents such as those listed above are used, the resultant extract contains non-specific lipid-soluble material. This can be removed by a variety of processes including “winterisation”, which involves chilling to −20° C. followed by filtration to remove waxy ballast, extraction with liquid carbon dioxide and by distillation.
[0058] In the case where the cannabinoids are provided as a BDS, the BDS is preferably obtained by CO 2 extraction, under sub-critical or super-critical conditions, followed by a secondary extraction, e.g. an ethanolic precipitation, to remove a substantial proportion of waxes and other ballast. This is because the ballast includes wax esters and glycerides, unsatutrated fatty acid residues, terpenes, carotenes, and flavenoids which are not very soluble in the chosen solvent/co-solvent, particularly the preferred co-solvent, propylene glycol, and will precipitate out. Most preferably the BDS is produced by a process comprising decarboxylation, extraction with liquid carbon dioxide and then a further extraction to remove significant amounts of ballast. Most preferably the ballast is substantially removed by an ethanolic precipitation.
[0059] Most preferably, cannabis plant material is heated to a defined temperature for a defined period of time in order to decarboxylate cannabinoid acids to free cannabinoids prior to extraction of the BDS.
[0060] Preferred “botanical drug substances” include those which are obtainable by using any of the methods or processes specifically disclosed herein for preparing extracts from cannabis plant material. The extracts are preferably substantially free of waxes and other non-specific lipid soluble material but preferably contain substantially all of the cannabinoids naturally present in the plant, most preferably in substantially the same ratios in which they occur in the intact cannabis plant.
[0061] Botanical drug substances are formulated into “Botanical Drug Products” which are defined in the Guidance for Industry Botanical Drug Products Draft Guidance, August 2000, US Department of Health and Human Services, Food and Drug Administration Center for Drug Evaluation and Research as: “A botanical product that is intended for use as a drug; a drug product that is prepared from a botanical drug substance.”
[0062] “ Cannabis plants” includes wild type Cannabis sativa and variants thereof, including cannabis chemovars which naturally contain different amounts of the individual cannabinoids.
[0063] The term “cannabinoids” also encompasses highly purified, Pharmacopoeial Grade substances, which may be obtained by purification from a natural source or via synthetic means. Thus, the formulations according to the invention may be used for delivery of extracts of cannabis plants and also individual cannabinoids, or synthetic analogues thereof, whether or not derived from cannabis plants, and also combinations of cannabinoids.
[0064] Preferred cannabinoids include, but are not limited to, tetrahydrocannabinoids, their precursors, alkyl (particularly propyl) analogues, cannabidiols, their precursors, alkyl (particularly propyl) analogues, and cannabinol. In a preferred embodiment the formulations may comprise any cannabinoids selected from tetrahydrocannabinol, Δ 9 -tetrahydrocannabinol (THC), Δ 8 -tetrahydrocannabinol, Δ 9 -tetrahydrocannabinol propyl analogue (THCV), cannabidiol (CBD), cannabidiol propyl analogue (CBDV), cannabinol (CBN), cannabichromene, cannabichromene propyl analogue and cannabigerol, or any combination of two or more of these cannabinoids. THCV and CBDV (propyl analogues of THC and
[0065] CBD, respectively) are known cannabinoids which are predominantly expressed in particular Cannabis plant varieties and it has been found that THCV has qualitative advantageous properties compared with THC and CBD respectively. Subjects taking THCV report that the mood enhancement produced by THCV is less disturbing than that produced by THC. It also produces a less severe hangover.
[0066] Most preferably the formulations will contain THC and/or CBD.
[0067] In a preferred embodiment the formulations may contain specific, pre-defined ratios by weight of different cannbinoids, e.g. specific ratios of CBD to THC, or tetrahydrocannabinovarin (THCV) to cannabidivarin (CBDV), or THCV to THC. Certain specific ratios of cannabinoids have been found to be clinically useful in the treatment or management of specific diseases or medical conditions. In particular, certain of such formulations have been found to be particularly useful in the field of pain relief and appetite stimulation.
[0068] It has particularly been observed by the present applicant that combinations of specific cannabinoids are more beneficial than any one of the individual cannabinoids alone. Preferred embodiments are those formulations in which the amount of CBD is in a greater amount by weight than the amount of THC. Such formulations are designated as “reverse-ratio” formulations and are novel and unusual since, in the various varieties of medicinal and recreational Cannabis plant available world-wide, CBD is the minor cannabinoid component compared to THC. In other embodiments THC and CBD or THCV and CBDV are present in approximately equal amounts or THC or THCV are the major component and may be up to 95.5% of the total cannabinoids present.
[0069] Preferred formulations contain THC and CBD in defined ratios by weight. The most preferred formulations contain THC and CBD in a ratio by weight in the range from 0.9:1.1 to 1.1:0.9 THC:CBD, even more preferably the THC:CBD ratio is substantially 1:1. Other preferred formulations contain the following ratios by weight of THC and CBD:—greater than or equal to 19:1 THC:CBD, greater than or equal to 19:1 CBD:THC, 4.5:1 THC:CBD, 1:4 THC:CBD and 1:2.7 THC:CBD. For formulations wherein the THC:CBD ratio is substantially 1:1 it is preferred that the formulation includes about 2.5 g/ml of each of THC and CBD.
[0070] Cannabis has been used medicinally for many years, and in Victorian times was a widely used component of prescription medicines. It was used as a hypnotic sedative for the treatment of “hysteria, delirium, epilepsy, nervous insomnia, migraine, pain and dysmenorrhoea”. The use of cannabis continued until the middle of the twentieth century, and its usefulness as a prescription medicine is now being re-evaluated. The discovery of specific cannabinoid receptors and new methods of administration have made it possible to extend the use of cannabis -based medicines to historic and novel indications.
[0071] The recreational use of cannabis prompted legislation which resulted in the prohibition of its use. Historically, cannabis was regarded by many physicians as unique; having the ability to counteract pain resistant to opioid analgesics, in conditions such as spinal cord injury, and other forms of neuropathic pain including pain and spasm in multiple sclerosis.
[0072] In the United States and Caribbean, cannabis grown for recreational use has been selected so that it contains a high content of tetrahydrocannabinol (THC), at the expense of other cannabinoids. In the Merck Index (1996) other cannabinoids known to occur in cannabis such as cannabidiol and cannabinol were regarded as inactive substances. Although cannabidiol was formerly regarded as an inactive constituent there is emerging evidence that it has pharmacological activity, which is different from that of THC in several respects. The therapeutic effects of cannabis cannot be satisfactorily explained just in terms of one or the other “active” constituents.
[0073] It has been shown that tetrahydrocannabinol (THC) alone produces a lower degree of pain relief than the same quantity of THC given as an extract of cannabis. The pharmacological basis underlying this phenomenon has been investigated. In some cases, THC and cannabidiol (CBD) have pharmacological properties of opposite effect in the same preclinical tests, and the same effect in others. For example, in some clinical studies and from anecdotal reports there is a perception that CBD modifies the psychoactive effects of THC. This spectrum of activity of the two cannabinoids may help to explain some of the therapeutic benefits of cannabis grown in different regions of the world. It also points to useful effects arising from combinations of THC and CBD. These have been investigated by the applicant. Table 1 below shows the difference in pharmacological properties of the two cannabinoids.
[0000]
TABLE 1
Effect
THC
THCV
CBD
CBDV
Reference
CB 1 (Brain receptors)
++
±
Pertwee et al,
1998
CB 2 (Peripheral
+
−
receptors)
CNS Effects
Anticonvulsant †
−−
++
Carlini et al,
1973
Antimetrazol
−
−
GW Data
Anti-electroshock
−
++
GW data
Muscle Relaxant
−−
++
Petro, 1980
Antinociceptive
++
+
GW data
Catalepsy
++
++
GW data
Psychoactive
++
−
GW data
Antipsychotic
−
++
Zuardi et al,
1991
Neuroprotective
+
++
Hampson A J
et al,
antioxidant
activity*
++
−
1998
Antiemetic
+
+
Sedation (reduced
Zuardi et al,
spontaneous activity)
++
1991
Appetite stimulation
++
Appetite suppression
−
++
Anxiolytic
GW data
Cardiovascular Effects
Bradycardia
−
+
Smiley et al,
1976
Tachycardia
+
−
Hypertension §
+
−
Hypotension §
−
+
Adams et al,
1977
Anti-inflammatory
±
±
Brown, 1998
Immunomodulatory/
anti-inflammatory
activity
Raw Paw Oedema Test
−
++
GW data
Cox 1
GW data
Cox 2
GW data
TNFα Antagonism
+
+
++
++
Glaucoma
++
+
* Effect is CB1 receptor independent.
† THC is pro convulsant
§ THC has a biphasic effect on blood pressure; in naïve patients it may produce postural hypotension and it has also been reported to produce hypertension on prolonged usage.
[0074] From these pharmacological characteristics and from direct experiments carried out by the applicant it has been shown, surprisingly, that combinations of THC and CBD in varying proportions are particularly useful in the treatment of certain therapeutic conditions. It has further been found clinically that the toxicity of a mixture of THC and CBD is less than that of THC alone.
[0075] Accordingly, the invention provides pharmaceutical formulations, having all the essential features described above, which comprise cannabinoids as the active agents and which have specific ratios of CBD to THC, which have been found to be clinically useful in the treatment or management of specific diseases or medical conditions.
[0076] In a further aspect the invention also relates to pharmaceutical formulations having all the essential features defined above, and which have specific ratios of tetrahydrocannabinovarin (THCV) or cannabidivarin (CBDV). THCV and CBDV (propyl analogues of THC and CBD, respectively) are known cannabinoids which are predominantly expressed in particular Cannabis plant varieties and it has been found that THCV has qualitative advantageous properties compared with THC and CBD respectively. Subjects taking THCV report that the mood enhancement produced by THCV is less disturbing than that produced by THC. It also produces a less severe hangover.
[0077] The invention still further relates to pharmaceutical formulations, having all the essential features as defined above, which have specific ratios of THCV to THC. Such formulations have been found to be particularly useful in the field of pain relief and appetite stimulation.
[0078] It has particularly been observed by the present applicants that the combinations of the specific cannabinoids are more beneficial than any one of the individual cannabinoids alone. Preferred embodiments are those formulations in which the amount of CBD is in a greater amount by weight than the amount of THC. Such formulations are designated as “reverse-ratio” formulations and are novel and unusual since, in the various varieties of medicinal and recreational Cannabis plant available world-wide, CBD is the minor cannabinoid component compared to THC. In other embodiments THC and CBD or THCV and CBDV are present in approximately equal amounts or THC or THCV are the major component and may be up to 95.5% of the total cannabinoids present.
[0079] Particularly preferred ratios of cannabinoids and the target medical conditions for which they are suitable are shown in Table 2 below. Other preferred ratios of THC:CBD, THCV:CBDV and THC:TCHV and preferred therapeutic uses of such formulations are set out in the accompanying claims.
[0000]
TABLE 2
Target Therapeutic Groups for Different Ratios of Cannabinoid
Product group
Ratio THC:CBD
Target Therapeutic Area
High THC
>95:5
Cancer pain, migraine, appetite
stimulation
Even ratio
50:50
Multiple sclerosis, spinal cord injury, peripheral
neuropathy, other neurogenic pain.
Reverse/Broad ratio CBD
<25:75
Rheumatoid arthritis, Inflammatory bowel
diseases.
High CBD
<5:95
Psychotic disorders (schizophrenia),
Epilepsy & movement disorders
Stroke, head injury,
Disease modification in RA and other
inflammatory conditions
Appetite suppression
[0080] Formulations containing specific, defined ratios of cannabinoids may be formulated from pure cannabinoids in combination with pharmaceutical carriers and excipients which are well-known to those skilled in the art. Pharmaceutical grade “pure” cannabinoids may be purchased from commercial suppliers, for example CBD and THC can be purchased from Sigma-Aldrich Company Ltd, Fancy Road, Poole Dorset, BH12 4QH, or may be chemically synthesised. Alternatively, cannabinoids may be extracted from Cannabis plants using techniques well-known to those skilled in the art.
[0081] In preferred embodiments of the invention the formulations comprise extracts of one or more varieties of whole Cannabis plants, particularly Cannabis sativa, Cannabis indica or plants which are the result of genetic crosses, self-crosses or hybrids thereof. The precise cannabinoid content of any particular cannabis variety may be qualitatively and quantitatively determined using methods well known to those skilled in the art, such as TLC or HPLC. Thus, one may chose a Cannabis variety from which to prepare an extract which will produce the desired ratio of CBD to THC or CBDV to THCV or THCV to THC. Alternatively, extracts from two of more different varieties may be mixed or blended to produce a material with the preferred cannabinoid ratio for formulating into a pharmaceutical formulation.
[0082] The preparation of convenient ratios of THC- and CBD-containing medicines is made possible by the cultivation of specific chemovars of cannabis. These chemovars (plants distinguished by the cannabinoids produced, rather than the morphological characteristics of the plant) can be been bred by a variety of plant breeding techniques which will be familiar to a person skilled in the art. Propagation of the plants by cuttings for production material ensures that the genotype is fixed and that each crop of plants contains the cannabinoids in substantially the same ratio.
[0083] Furthermore, it has been found that by a process of horticultural selection, other chemovars expressing their cannabinoid content as predominantly tetrahydrocannabinovarin (THCV) or cannabidivarin (CBDV) can also be achieved.
[0084] Horticulturally, it is convenient to grow chemovars producing THC, THCV, CBD and CBDV as the predominant cannabinoid from cuttings. This ensures that the genotype in each crop is identical and the qualitative formulation (the proportion of each cannabinoid in the biomass) is the same. From these chemovars, extracts can be prepared by the similar method of extraction. Convenient methods of preparing primary extracts include maceration, percolation, extraction with solvents such as C1 to C5 alcohols (ethanol), Norflurane (HFA134a), HFA227 and liquid carbon dioxide under pressure. The primary extract may be further purified for example by supercritical or subcritical extraction, vaporisation and chromatography. When solvents such as those listed above are used, the resultant extract contains non-specific lipid-soluble material or “ballast”. This can be removed by a variety of processes including chilling to −20° C. followed by filtration to remove waxy ballast, extraction with liquid carbon dioxide and by distillation. Preferred plant cultivation and extract preparation methods are shown in the Examples. The resulting extract is suitable for incorporation into pharmaceutical preparations.
[0085] There are a number of therapeutic conditions which may be treated effectively by cannabis, including, for example, cancer pain, migraine, appetite stimulation, multiple sclerosis, spinal cord injury, peripheral neuropathy, other neurogenic pain, rheumatoid arthritis, inflammatory bowel diseases, psychotic disorders (schizophrenia), epilepsy & movement disorders, stroke, head injury, appetite suppression. The proportion of different cannabinoids in a given formulation determines the specific therapeutic conditions which are best treated (as summarised in Table 2, and stated in the accompanying claims).
[0086] The principles of formulation suitable for administration of cannabis extracts and cannabinoids can also be applied to other medicaments such as alkaloids, bases and acids. The requirements are that, if the medicament is insoluble in saliva, it should be solubilised and/or brought into the appropriate unionised form by addition of buffering salts and pH adjustment.
[0087] Other lipophilic medicaments which may be included in the general formulations of the invention may include, but are not limited to, morphine, pethidine, codeine, methadone, diamorphine, fentanyl, alfentanil, buprenorphine, temazepam, lipophilic analgesics and drugs of abuse. The term “drugs of abuse” encompasses compounds which may produce dependence in a human subject, typically such compounds will be analgesics, usually opiates or synthetic derivatives thereof.
[0088] The formulation is preferably packaged in a glass vial. It is preferably filled to a slight over-pressure in an inert atmosphere e.g. nitrogen to prevent/slow oxidative breakdown of the cannabinoids, and is contained in a form such that ingress of light is prevented, thereby preventing photochemical degradation of the cannabinoids. This is most effectively achieved using an amber vial, since the applicant has determined that it is UV and light in the blue spectrum, typically in the wavelength range 200-500 nm, that is responsible for photodegradation.
[0089] The invention will be further described, by way of example only, with reference to the following experimental data and exemplary formulations, together with the accompanying Figures.
BRIEF DESCRIPTION OF THE DRAWINGS
[0090] FIGS. 1 a and 1 b illustrate mean plasma concentrations of cannabinoids CBD, THC and 11-hydroxy THC following administration of high CBD ( FIG. 1 a ) and high THC ( FIG. 1 b ) cannabis extracts to human subjects.
[0091] FIG. 2 illustrates mean plasma concentrations of cannabinoids CBD, THC and 11-hydroxy THC following administration of a cannabis extract containing a 1:1 ratio of THC:CBD to a human subject.
[0092] FIG. 3 illustrates cross-sectional area of aerosol plume vs % propylene glycol in propylene glycol/ethanol liquid spray formulations.
[0093] FIG. 4 illustrates viscosity as a function of propylene glycol content in propylene glycol/ethanol liquid spray formulations.
[0094] FIG. 5 illustrates cross-sectional area of aerosol plume vs viscosity for propylene glycol/ethanol liquid spray formulations.
[0095] FIGS. 6 and 6 a show results of HPLC analysis of samples drawn from stored, light exposed solutions of THC, before and after charcoal treatment.
[0096] FIGS. 7 and 7 a show results of HPLC analysis of samples drawn from stored, light exposed solutions of CBD, before and after charcoal treatment.
DETAILED DESCRIPTION OF THE INVENTION
Development of Pump-Action Spray Formulations
[0097] Initially the applicant looked at cannabinoid uptake in patients by applying drops sublingually (BDS dissolved in a mixture of a glycerol/propylene glycol and ethanol) THC 5 mg/ml, CBD 5mg/ml and THC/CBD 5 mg/ml plus 5 mg/ml.
[0098] The results are noted in Table 3 below:
[0000]
TABLE 3
Initial absorption: 20 min
T max: approx 2 hours
C max: 6 ng/ml THC, 2 ng/ml CBD
AUC 0-12: approx l6 ng · h/mlTHC, 8 ng · h/mlCBD
following a dose of approx 20 mg of each cannabinoids
Plasma levels after 6 hours were about 1 ng/ml THC
and 0.5 ng/ml CBD
[0099] The proportion of 11 hydroxy tetrahydro cannabinol to THC (AUC 0-12) was about 1.9 indicating a significant amount of oral ingestion may have occurred.
[0100] On moving to a pump action sublingual spray (following problems solubilising cannabinoids with hydroflurocabon propellant systems) the applicant obtained the results noted in Table 4. The solvent system comprised 50:50 ethanol to propylene glycol (v/v ratio) with THC 25 mg/ml; CBD 50 mg/ml and THC/CBD 25 mg/ml plus 50 mg/ml respectively.
[0000]
TABLE 4
Initial absorption: 60 min
T max: approx 3 hours
C max: 6 ng/ml THC, 8 ng/ml CBD
AUC 0-12: approx 16 ng · h/ml THC, 22 ng · h/ml CBD
following a dose of approx 21 mg of THC and 35 mg CBD
Plasma levels after 6 hours were about 1 ng/ml THC
and 1 ng/ml CBD
[0101] The proportion of 11 hydroxy tetrahydro cannabinol to THC (AUC 0-12) was about 1.6. The profile for each cannabinoid was similar irrespective of the formulation (THC, CBD, THC plus CBD).
[0102] After accounting for the different dosages, whilst the extent of absorption was comparable to the drops, the rate of absorption was slower and the proportion metabolised reduced.
[0103] Despite the slower rate of absorption the pump spray mechanism and the ethanol/propylene glycol carrier system provided the opportunity to administer sufficient cannabinoids, in a flexible dose form with accuracy and advantageously with reduced metabolism.
[0104] The data obtained is illustrated in FIGS. 1 a, 1 b and 2 , which show the mean plasma concentrations for the formulations identified with reference to Tables 3 and 4.
[0105] That effective delivery of the cannabinoids can be achieved in a vehicle consisting of ethanol and propylene glycol is illustrated by the plasma levels shown in FIGS. 1 a, 1 b and 2 . These show, respectively, formulations containing the high THC and high CBD formulations in FIGS. 1 a and 1 b. Similarly, the effectiveness of a defined ratio formulation THC:CBD 1:1 is illustrated in FIG. 2 .
[0106] Significantly the ethanol/propylene glycol system was found to only work with a pump action spray within quite narrow limits.
[0107] The findings giving rise to the development of pump spray formulations, as exemplified in formulations 1-4 below, are set out below:
EXAMPLE 1
Significance of Particle Size
[0108] Applicant observed that the propellant aerosols that were developed suffered from “bounce back” and this appeared to be a function of delivery speed and particle size.
[0109] Applicant determined that, in contrast to the propellant driven system, a pump spray could deliver an aerosol plume in which the particle size could be controlled to generate a particle size of between 20 and 40 microns (thus maximising the amount of material hitting the sublingual/buccal mucosa and thus the amount of cannabinoids that can be absorbed). To produce particles of the appropriate size the viscosity of the formulation needed to be carefully controlled. If the formulation was too viscous droplet formation was hindered, a jet formed and the valve blocked; If the formulation was not viscous enough they got excessive nebulisation, a plume of broad cross sectional area formed, and the spray was no longer directed solely onto the sublingual/buccal mucosa. This could result in the formulation pooling and some of the formulation being swallowed. In both cases the result is unsatisfactory.
[0110] In fact, it turned out that for the solvent of preferred choice, ethanol, and the co-solvent of preferred choice, propylene glycol, the working range was fairly narrow as demonstrated below:
[0111] The viscosity of different combinations of ethanol/propylene glycol were studied and their spray performance with a vp7/100 valve (Valois) compared. The results are tabulated in Table 5 below:
[0000]
TABLE 5
Relative viscosity
Propylene glycol/ethanol
(run time in sec)
Spray performance
100/0
442
Jet formed
80/20
160
Jet formed
60/40
80
Some jetting
50/50
62
Good aerosol plume
40/60
44
Good aerosol plume
20/80
26
Good aerosol plume
0/100
16
Good aerosol plume
[0112] From this data it appeared that addition of propylene glycol at greater than 60/40 would not be acceptable. These result, when read alongside U.S. Pat. No. 3,560,625, could have suggested that the said solvent/co-solvent combination would be no good. However, applicant found that patients could tolerate ethanol levels of this order when presented in the given formulations.
[0113] The effect of viscosity on aerosol plume was quantified by spraying the various formulations at a standard distance of 0.5 cm onto disclosing paper. The distance represents the typical distance between the nozzle of the pump action spray unit and the sub lingual cavity in normal use. The paper was photocopied and the image of the plume excised and weighed to give a relative cross sectional area. The relative value was then converted into a real cross sectional area by dividing this value by the weight per cm 2 of the photocopier paper (determined by weighing a known area of paper). The results are given in Table 6 below:
[0000] TABLE 6 Area of cross section Propylene glycol/ethanol of spray plume 100/0 3.5 cm 2 80/20 14.2 cm 2 60/40 17.9 cm 2 50/50 20.7 cm 2 40/60 29.4 cm 2 20/80 54.4 cm 2 0/100 93.8 cm 2
This data is illustrated in FIG. 3 .
[0114] Additionally plots of viscosity of mixtures of ethanol and propylene glycol content FIG. 4 and plume cross section as a function of viscosity FIG. 5 are given.
[0115] The figures emphasise the dramatic and undesirable changes in properties which occur outside the narrow range of ethanol/propylene glycol wt/wt of 60/40 and 40/60, and more particularly still 55/45 to 45/55, most preferably about 50/50.
[0116] Other factors are also significant in ensuring the combination is used in a narrow range. Increasing the ethanol levels beyond 60 vol % gives rise to irritation and at propylene glycol levels approaching 60% and as low as 55%, in the case of BDS, non polar derivatives present in the BDS begin to precipitate out on prolonged ambient storage.
[0117] Other co-solvents which might be used would be expected to have similar limitations. The more viscous the co-solvent the greater the problem of producing a plume forming spray, and the more polar, the greater the risk that precipitation will be exacerbated.
[0118] However, because the combination of ethanol/propylene glycol is able to dissolve up to 50 mg/ml (i.e. therapeutically desirable levels of cannabinoids), is non irritating, pharmaceutically acceptable, and the propylene glycol also acts as a penetration enhancer maximising bioavailability of the cannabinoids it is particularly advantageous.
[0119] The mean particle size of the preferred compositions have been shown to be 33 μm when tested using a Malvern Marsteriser. The droplets, which are considerably greater than 5 μm, therefore minimise the risk of inhalation of aerosol.
EXAMPLE 2
Effect of Water When The Cannabinoids Are Present In A BDS.
[0120] The presence of greater than 5% water in the formulation was shown to cause precipitation of the BDS as illustrated by the investigation described in Table 7 below:
[0000] TABLE 7 Sequential addition of water was made to 5 ml 25 mg/ml THC and 5 ml 25 mg/ml CBD in an ethanol/propylene glycol formulate (50/50). Approx final solvent ratio % Vol of water Final vol Water/propylene added ml vol ml glycol/ethanol observation 0 5 0/50/50 Solution 0.05 5.05 1/49.5/49.5 Ppt forms but re dissolves on mixing 0.21 5.26 5/47.5/47.5 Ppt forms. Solution remains cloudy after mixing
Indeed because of this observation the use of anhydrous ethanol is preferred.
Example formulations (non-limiting) according to the invention are as follows:
[0000]
COMPOSITION 1 (General)
FUNC-
COMPONENT
AMOUNT PER UNIT (1 ml)
TION
Active
Active
THC (BDS)
25-50 mg/ml
CBD (BDS)
25-50 mg/ml
Excipient
Propylene Glycol
0.5 ml/ml
Co solvent
Peppermint oil
0.0005 ml/ml
Flavour
Ethanol (anhydrous)
qs to 1 ml
Solvent
[0000]
COMPOSITION 2 (High THC)
COMPONENT
AMOUNT PER UNIT (1 ml)
FUNCTION
Active
THC (BDS)
25 mg/ml
Active
Excipient
Propylene Glycol
0.5 ml/ml
Co solvent
Peppermint oil
0.0005 ml/ml
Flavour
Ethanol (anhydrous)
qs to 1 ml
Solvent
[0000]
COMPOSITION 3 (High CBD)
COMPONENT
AMOUNT PER UNIT (1 ml)
FUNCTION
Active
CBD (BDS)
25 mg/ml
Active
Excipient
Propylene Glycol
0.5 ml/ml
Co solvent
Peppermint oil
0.0005 ml/ml
Flavour
Ethanol (anhydrous)
qs to 1 ml
Solvent
[0000]
COMPOSITION 4 (THC/CBD substantially 1:1)
COMPONENT
AMOUNT PER UNIT (1 ml)
FUNCTION
Active
THC (BDS)
25 mg/ml
Active
CBD (BDS)
25 mg/ml
Active
Excipient
Propylene Glycol
0.5 ml/ml
Co solvent
Peppermint oil
0.0005 ml/ml
Flavour
Ethanol (anhydrous)
qs to 1 ml
Solvent
EXAMPLE 3
[0121] The following example illustrates the application of liquid spray formulations to the buccal mucosae and the blood levels produced by buccal absorption in comparison with sublingual administration.
[0122] The following liquid formulations suitable for buccal administration contain self-emulsifying agents, and hence do not fall within the scope of the present invention. Nevertheless, the general principles illustrated by use of these compositions applies equally to the delivery formulations according to the invention. Solutions were produced by dissolving (at a temperature not exceeding 50° C.) the following ingredients (quantitative details are expressed as parts by weight):—
[0000]
A
B
C
D
E
Glyceryl monostearate
2
—
2
—
2
(self-emulsifying)
Glyceryl monooleate
—
2
—
2
—
(self-emulsifying)
Cremophor RH40
20
30
30
20
30
CBME-G1 to give THC
5
10
—
—
—
CBME-G5 to give CBD
—
—
5
10
—
CBME-G1 and G5 to
—
—
—
—
10 each
give THC & CBD
α-Tocopherol
0.1
0.1
0.1
0.1
0.1
Ascorbyl palmitate
0.1
0.1
0.1
0.1
0.1
Ethanol BP to produce
100
100
100
100
100
[0123] Cannabis Based Medicine Extract (CBME) is an extract of cannabis which may be prepared by, for example, percolation with liquid carbon dioxide, with the removal of ballast by cooling a concentrated ethanolic solution to a temperature of −20° C. and removing precipitated inert plant constituents by filtration or centrifugation.
[0124] The product formed by mixing these ingredients is dispensed in 6 ml quantities into a glass vial and closed with a pump action spray. In use, the dose is discharged through a break-up button or conventional design. Proprietary devices that are suitable for this purpose are Type VP7 produced by Valois, but similar designs are available from other manufacturers. The vial may be enclosed in secondary packaging to allow the spray to be directed to a particular area of buccal mucosa. Alternatively, a proprietary button with an extension may be used to direct the spray to a preferred area of buccal mucosa.
[0125] Each 1 ml of product contains 50-100 mg of Δ 9 -tetrahydrocannabinol (THC) and/or cannabidiol (CBD). Each actuation of the pump delivers a spray which can be directed to the buccal mucosae. In the above formulations CBMEs of known cannabinoid strength are used. CBME-G1 is an extract from a high THC-yielding strain of cannabis, and CBME-G5 is from a high CBD-yielding variety. It will be clear to a person skilled in the art that purified cannabinoids, and extracts containing the cannabinoids, can be made formulated as described above by quantitative adjustment.
[0126] Although solutions of CBME in ethanol alone can be used as a spray, the quantity of cannabinoid that can be delivered is limited by the aggressive nature of pure ethanol in high concentration as a solvent. This limits the amount that can be applied to the mucosae without producing discomfort to the patient. When a group of patients received THC or CBD in a solution of the type described above, directing the spray either sublingually or against the buccal mucosa, the patients uniformly reported a stinging sensation with the sublingual application, but mild or no discomfort when the same solution was sprayed onto the buccal mucosa. Spraying small quantities of this type of formulation onto the buccal mucosa does not appreciably stimulate the swallowing reflex. This provides greater dwell time for the formulation to be in contact with the buccal surface.
[0127] Formulations were administered to a group of 13 human subjects so that they received 4 mg THC, 4 mg of CBD or placebo (vehicle alone) via a sublingual tablet, sublingual pump-action spray or buccal route.
[0128] Absorption [area under the absorption curve (AUC)] of cannabinoid and primary metabolite were determined in samples of blood taken after dosing. The following Table 8 gives these as normalised mean values.
[0000]
TABLE 8
Route of Administration
PAS sublingual
Sublingual tablet
Oropharyngeal
Analyte in Plasma
AUC
AUC
AUC
THC
2158.1
1648.4
1575
11-OH THC
3097.6
3560.5
2601.1
CBD
912
886.1
858
[0129] These results show that the total amounts of cannabinoid absorbed by sublingual and buccal (oropharyngeal) routes are similar but that there is a substantial (approximately 25%) reduction in the amount of 11-hydroxy (11-OH) metabolite detected after oropharyngeal (buccal) administration. This finding is not inconsistent with reduced swallowing (and subsequent reduced hepatic) metabolism of the buccal formulation.
[0130] It is known that the 11-hydroxy metabolite of THC (11-OH THC) is possibly more psychoactive than the parent compound. It is therefore desirable to minimise the amount of this metabolite during administration, and this is likely to be achieved by using a formulation and method of application which reduces the amount of a buccal or sublingual dose that is swallowed. The pump action spray appears to offer a simple means of reducing the amount of material that is swallowed and metabolised by absorption from the intestinal tract below the level of the oropharynx.
EXAMPLE 4
Growing of Medicinal Cannabis
[0131] Plants are grown as clones from germinated seed, under glass at a temperature of 25° C.±1.5° C. for 3 weeks in 24 hour daylight; this keeps the plants in a vegetative state. Flowering is induced by exposure to 12 hour day length for 8-9 weeks.
[0132] No artificial pesticides, herbicides, insecticides or fumigants are used. Plants are grown organically, with biological control of insect pests.
[0133] The essential steps in production from seed accession to dried Medicinal Cannabis are summarised as follows:
EXAMPLE 5
Determination of Cannabinoid Content In Plants And Extracts
Identity By TLC
a) Materials And Methods
[0000]
Equipment Application device capable of delivering an accurately controlled volume of solution i.e., 1 μl capillary pipette or micro litre syringe.
[0135] TLC development tank with lid
[0136] Hot air blower
[0137] Silica gel G TLC plates (SIL N-HR/UV254), 200 μm layer with fluorescent indicator on polyester support.
[0138] Dipping tank for visualisation reagent.
Mobile phase 80% petroleum ether 60:80/20% Diethyl ether. Visualisation reagent 0.1% w/v aqueous Fast Blue B (100 mg in 100 ml de-ionised water).
An optional method is to scan at UV 254 and 365 nm.
b) Sample Preparation
[0142] i) Herbal raw material
[0143] Approximately 200 mg of finely ground, dried cannabis is weighed into a 10 ml volumetric flask. Make up to volume using methanol:chloroform (9:1) extraction solvent.
[0144] Extract by ultrasound for 15 minutes. Decant supernatant and use directly for chromatography.
[0145] ii) Herbal drug Extract
[0146] Approximately 50 mg of extract is weighed into a 25 ml volumetric flask. Make up to volume using methanol solvent. Shake vigorously to dissolve and then use directly for chromatography.
c) Standards
[0000]
0.1 mg/ml delta-9-THC in methanol.
[0148] 0.1 mg/ml CBD in methanol.
[0149] The standard solutions are stored frozen at −20° C. between uses and are used for up to 12 months after initial preparation.
d) Test Solutions And Method
[0150] Apply to points separated by a minimum of 10 mm.
[0151] i) either 5 μl of herb extract or 1 μl of herbal extract solution as appropriate,
[0152] ii) 10 μl of 0.1 mg/ml delta-9-THC in methanol standard solution,
[0153] 10 μl of 0.1 mg/ml CBD in methanol standard solution.
[0154] Elute the TLC plate through a distance of 8 cm, then remove the plate. Allow solvent to evaporate from the plate and then repeat the elution for a second time (double development).
[0155] The plate is briefly immersed in the Fast Blue B reagent until the characteristic re/orange colour of cannabinoids begins to develop. The plate is removed and allowed to dry under ambient conditions in the dark.
[0156] A permanent record of the result is made either by reproduction of the image by digital scanner(preferred option) or by noting spot positions and colours on a tracing paper.
Assay THC, THCA, CBD, CBDA And CBN By HPLC
a) Materials And Methods
[0000]
Equipment: HP 1100 HPLC with diode array detector and autosampler. The equipment is set up and operated in accordance with in-house standard operating procedures (SOPlab037)
HPLC column Discovery C8 5 μm, 15×0.46 cm plus Kingsorb ODS2 precolumn 5 μm 3×0.46 cm.
Mobile Phase Acetonotrile:methanol:0.25% aqueous acetic acid (16:7:6 by volume)
Column Operating 25° C.
Temperature
Flow Rate 1.0 ml/min
Injection Volume 10 μl
Run time 25 mins
Detection Neutral and acid cannabinoids 220 nm (band width 16 nm)
[0166] Reference wavelength 400 nm/bandwidth 16 nm
[0167] Slit 4 nm
[0168] Acid cannabinoids are routinely monitored at 310 nm (band width 16 nm) for qualitative confirmatory and identification purposes only.
Data capture HP Chemistation with Version A7.01 software
b) Sample Preparation
[0170] Approximately 40 mg of Cannabis Based Medicinal Extract is dissolved in 25 ml methanol and this solution is diluted to 1 to 10 in methanol. This dilution is used for chromatography.
[0171] 0.5 ml of the fill solution, contained within the Pump Action Sublingual Spray unit, is sampled by glass pipette. The solution is diluted into a 25 ml flask and made to the mark with methanol. 200 μl of this solution is diluted with 800 μl of methanol.
[0172] Herb or resin samples are prepared by taking a 100 mg sample and treating this with 5 or 10 ml of Methanol/Chloroform (9/1 w/v). The dispersion is sonicated in a sealed tube for 10 minutes, allowed to cool and an aliquot is centrifuged and suitably diluted with methanol prior to chromatography.
c) Standards
[0000]
External standardisation is used for this method. Dilution of stock standards of THC, CBD and CBN in methanol or ethanol are made to give final working standards of approximately accurately 0.1 mg/ml. The working standards are stored at −20° C. and are used for up to 12 months after initial preparation.
Injection of each standard is made in triplicate prior to the injection of any test solution. At suitable intervals during the processing of test solutions, repeat injections of standards are made. In the absence of reliable CBDA and THCA standards, these compounds are analysed using respectively the CBD and THC standard response factors.
The elution order has been determined as CBD, CBDA, CBN, THC and THCA. Other cannabinoids are detected using this method and may be identified and determined as necessary.
d) Test Solutions
[0000]
Diluted test solutions are made up in methanol and should contain analytes in the linear working range of 0.02-0.2 mg/ml.
e) Chromatography Acceptance Criteria:
[0000]
The following acceptance criteria are applied to the results of each sequence as they have been found to result in adequate resolution of all analytes (including the two most closely eluting analytes CBD and CBDA)
[0178] i) Retention time windows for each analyte:
CBD 5.4-5.9 minutes CBN 7.9-8.7 minutes THC 9.6-10.6 minutes
[0182] ii) Peak shape (symmetry factor according to BP method)
CBD <1.30 CBN <1.25 THC <1.35
[0186] iii) A number of modifications to the standard method have been developed to deal with those samples which contain late eluting impurity peaks e.g., method CBD2A extends the run time to 50 minutes. All solutions should be clarified by centrifugation before being transferred into autosampler vials sealed with teflon faced septum seal and cap.
[0187] iv) The precolumn is critical to the quality of the chromatography and should be changed when the back pressure rises above 71 bar and/or acceptance criteria regarding retention time and resolution, fall outside their specified limits.
f) Data Processing
[0000]
Cannabinoids can be subdivided into neutral and acidic—the qualitative identification can be performed using the DAD dual wavelength mode. Acidic cannabinoids absorb strongly in the region of 220 nm-310 nm. Neutral cannabinoids only absorb strongly in the region of 220 nm.
Routinely, only the data recorded at 220 nm is used for quantitative analysis.
The DAD can also be set up to take UV spectral scans of each peak, which can then be stored in a spectral library and used for identification purposes.
Data processing for quantitation utilises batch processing software on the Hewlett Packard Chemstation.
a) Sample Chromatograms
[0000]
HPLC sample chromatograms for THC and CBD Herbal Drug extracts are provided in the accompanying Figures.
EXAMPLE 6
Preparation of the Herbal Drug Extract
[0193] A flow chart showing the process of manufacture of extract from the High-THC and High-CBD chemovars is given below:
[0194] The resulting extract is referred to as a Cannabis Based Medicine Extract and is also classified as a Botanic Drug Substance, according to the US Food and Drug Administration Guidance for Industry Botanical Drug Products.
EXAMPLE 7
[0195] High THC cannabis was grown under glass at a mean temperature of 21+2° C., RH 50-60%. Herb was harvested and dried at ambient room temperature at a RH of 40-45% in the dark. When dry, the leaf and flower head were stripped from stem and this dried biomass is referred to as “medicinal cannabis”.
[0196] Medicinal cannabis was reduced to a coarse powder (particles passing through a 3 mm mesh) and packed into the chamber of a Supercritical Fluid Extractor. Packing density was 0.3 and liquid carbon dioxide at a pressure of 600 bar was passed through the mass at a temperature of 35° C. Supercritical extraction is carried out for 4 hours and the extract was recovered by stepwise decompression into a collection vessel. The resulting green-brown oily resinous extract is further purified. When dissolved in ethanol BP (2 parts) and subjected to a temperature of −20° C. for 24 hours a deposit (consisting of fat-soluble, waxy material) was thrown out of solution and was removed by filtration. Solvent was removed at low pressure in a rotary evaporator. The resulting extract is a soft extract which contains approximately 60% THC and approximately 6% of other cannabinoids of which 1-2% is cannabidiol and the remainder is minor cannabinoids including cannabinol. Quantitative yield was 9% w/w based on weight of dry medicinal cannabis.
[0197] A high CBD chemovar was similarly treated and yielded an extract containing approximately 60% CBD with up to 4% tetrahydrocannabinol, within a total of other cannabinoids of 6%. Extracts were made using THCV and CBDV chemovars using the general method described above.
[0198] A person skilled in the art will appreciate that other combinations of temperature and pressure (e.g. in the range +10° C. to 35° C. and 60-600 bar) can be used to prepare extracts under supercritical and subcritical conditions.
EXAMPLE 8
The Effects of Light On the Stability of the Alcoholic Solutions of THC, CBD Or THCV
[0199] The following example includes data to support the packaging of liquid dosage forms in amber glass, to provide some protection from the degradative effects of light on cannabinoids.
[0200] Further credence is also given to the selection of the lowest possible storage temperature for the solutions containing cannabinoid active ingredients.
Background And Overview
[0201] Light is known to be an initiator of degradation reactions in many substances, including cannabinoids. This knowledge has been used in the selection of the packaging for liquid formulations, amber glass being widely used in pharmaceutical presentations as a light exclusive barrier.
[0202] Experiments were set up to follow the effects of white light on the stability of methanolic solutions of THC, CBD or THCV. Following preliminary knowledge that light of different wavelengths may have differing effects on compound stability (viz. tretinoin is stable only in red light or darkness), samples were wrapped in coloured acetate films or in light exclusive foil. A concurrent experiment used charcoal treated CBME to study the effects of the removal of plant pigments on the degradation process.
Materials And Methods
[0203] Cannabinoids : 1 mg/ml solutions of CBME were made up in AR methanol. Methanolic solutions of CBME (100 mg/ml) were passed through charcoal columns (Biotage Flash 12AC 7.5 cm cartridges, b/no. 2730125) and were then diluted to 1 mg/ml. Solutions were stored in soda-glass vials, which were tightly screw capped and oversealed with stretch film. Tubes were wrapped in coloured acetate films as follows:
Red, Yellow, Green, and Cyan
[0205] Solutions were also filled into the amber glass U-save vials; these were sealed with a septum and oversealed. One tube of each series of samples was tightly wrapped in aluminium foil in order to completely exclude light. This served as a “dark” control to monitor the contribution of ambient temperature to the degradation behaviour. All of the above tubes were placed in a box fitted with 2×40 watt white Osram fluorescent tubes. The walls of the box were lined with reflective foil and the internal temperature was monitored at frequent intervals.
[0206] A further tube of each series was stored at −20° C. to act as a pseudo to the reference sample; in addition, one tube was exposed directly to light without protection. Samples were withdrawn for chromatographic analysis at intervals up to 112 days following the start of the study. The study was designated AS01201/AX282.
[0207] Samples of the test solutions were withdrawn and diluted as appropriate for HPLC and TLC analysis. HPLC was carried out in accordance with TM GE.004.V1 (SOPam058). TLC was performed on layers on Silica gel (MN Si1G/UV) in accordance with TM GE.002.V 1 (SOPam056).
[0000] Two further TLC systems were utilised in order to separate degradation products:
[0208] a) Si1G/UV, stationary phase, hexane/acetone 8/2 v/v mobile phase
b) RPC18 stationary phase, acetonitrile/methanol/0.25% aqueous acetic acid 16/7/6 by volume
Visualisation of cannabinoids was by Fast Blue B salt.
Results And Discussion
HPLC Quantitative Analysis
[0210] The results from the HPLC analysis of samples drawn from the stored, light exposed solutions, are plotted and presented as FIGS. 6 and 6 a (THC before and after charcoal treatment), and FIGS. 7 and 7 a (CBD before and after charcoal treatment).
[0211] It can be seen from FIGS. 6 and 6 a that there are significant improvements to the stability of THC in all solutions, except those stored in the dark (at ambient temperature) and at −20° C. (and hence which are not under photochemical stress). Even storage in amber glass shows an improvement when un-treated extract is compared with charcoal treated extract. This, however, may reflect in an improvement of the thermal stability of the charcoal treated extract.
[0212] FIGS. 7 and 7 a present similar data for CBD containing extracts, from which it can be seen that this cannabinoid is significantly more sensitive to the effects of light than is THC. In the absence of charcoal, all exposures, except in amber glass, light excluded (foil) and −20° storage, had degraded to non-detectable levels of CBD before 40 days. This improved to figures of between 42 and 62 days following charcoal treatment. Amber glass protected CBD showed an improvement from ˜38% residual compound at 112 days without charcoal clean up, to approximately 64% at the same time after charcoal treatment. There was also an improvement in the stability of CBD in light excluded solution after charcoal treatment. This can only reflect a reduction in either thermo-oxidative degradation, or a residual photochemical degradation initiated by light (and/or air) during CBME and solution preparation.
Thin Layer Chromatography Qualitative Analysis
[0213] The evaluation of the light degraded solutions using thin layer chromatography, used both the existing normal phase system (i.e. Silica stationary phase and hexane/diethyl ether as mobile phase) and two additional systems, capable of resolving more polar or polymeric products formed during the degradation processes.
[0214] Thus, chromatography using the hexane/diethyl ether system, showed that for THC by day 112, there was a reduction in the intensity of the THC and secondary CBD spots with all of the colour filtered lights (data not shown). At the same time, there was an increase in the intensity of Fast Blue B staining material running at, or close to, the origin. Foil protected solution exhibited none of these effects.
Conclusions And Recommendations
[0215] Cannabinoids are known to be degraded by a number of natural challenges, viz. light, heat, oxygen, enzymes etc. It is most likely that in an extract of herbal plant material, which has not been subjected to extensive clean-up procedures, that some of these processes may still be able to continue. Paradoxically, it is also likely that the removal of cannabinoids from the presence of any protection agents within the plant tissue, may render the extract more likely to suffer from particular degradation pathways.
[0216] Packaging into amber glass vials, conducting formulation manufacture in amber filtered light, and the storage of plant extracts and pharmaceutical formulations at temperatures as low as possible compatible with manufacturing and distribution requirements and patient compliance eliminates, or at least reduces, the effect of light on degradation of cannabinoids. These actions dramatically improved the storage stability of both plant extracts and finished products.
[0217] It was interesting to note that CBD appeared to be markedly less stable than THC, when subjected to photochemical stress. This is the opposite of the finding for the relative thermo-oxidative stabilities, in which THC is the less stable. This seems to indicate that, although polymeric degradation products may be the common result of both photochemical and thermo-oxidative degradation, the exact details of the mechanism are not identical for the two processes.
Among the conclusions that can be drawn are the following: 1] The choice of amber glass for the packaging of the dose solutions provides improved stability, but minor improvements can be made by additional light exclusion measures. 2] The drying process and subsequent extraction and formulation of cannabis extracts should indeed be carried out in low intensity, amber filtered light. 3] Consideration should be given to the blanketing of extracts under an inert atmosphere (e.g. Nitrogen). 4] Clean-up of cannabis extracts by simple charcoal filtration after winterisation, may yield substantial improvements to product shelf-life.
[0223] Those skilled in the art will recognize, or be able to ascertain using no more than routine experimentation, many equivalents to the specific embodiments of the invention described herein. Such equivalents are intended to be encompassed by the following claims.
[0224] All references disclosed herein are incorporated by reference in their entirety. | The invention relates to pharmaceutical formulations, and more particularly to formulations containing cannabinoids for administration via a pump action spray. In particular, the invention relates to pharmaceutical formulations, for use in administration of lipophilic medicaments via mucosal surfaces, comprising: at least one lipophilic medicament, a solvent and a co-solvent, wherein the total amount of solvent and co-solvent present in the formulation is greater than 55% wt/wt of the formulation and the formulation is absent of a self emulsifying agent and/or a fluorinated propellant. | 0 |
BACKGROUND OF THE INVENTION
1. FIELD OF THE INVENTION
This invention relates to a semiconductor capacitance element and more particularly to a MIS capacitance element adapted for use in a complementary metal-insulator-semiconductor integrated circuit (MIS IC) for a wristwatch.
2. DESCRIPTION OF THE PRIOR ART
Conventionally, capacitive elements have been formed in the semiconductor integrated circuit utilizing (a) the MIS gate capacitance using directly the MIS structure which includes the metal-oxide-semiconductor (MOS) structure, (b) the junction capacitance using the diffused layer-substrate junction, and (c) the junction capacitance using the diffused layer-well region capacitance. An example of the MIS capacitance element is proposed by W. G. Pfann and C. G. B. Garrett in Proc. IRE 47, p 2011 (1959). A problem in the MIS capacitance element lies in the property of an insulator-semiconductor interface which tends to collect carriers of one polarity to form a channel region thereunder. A modification of the MIS capacitance element to be integrated into a semiconductor integrated circuit is proposed in Japanese Patent Publication No. 44-30537, in which a metal layer is evaporated on part of the oxide layer formed on a p-type silicon body, the structure is heat-treated at a temperature of 300° C. to 500° C. in a gas atmosphere including hydrogen or moisture and then the unnecessary oxide layer is removed from the silicon surface so as to allow an n-type inversion layer to be formed only in the silicon surface below the remaining oxide layer. In the above capacitances, the voltage is applied in the reverse bias direction and hence the width of the inversion layer or depletion layer formed at the semiconductor surface or the junction interface is varied depending on the applied voltage. Thus, the value of capacitance is also changed. Namely, the capacitance has a voltage or field dependency. For this reason, these capacitive elements cannot be used as stable capacitance elements.
The present inventors have studied the possibilities of obtaining capacitive elements free of field-dependence in the semiconductor integrated circuits. In a complementary silicon gated IC device, the well region, the p + -type (or n + -type) diffused layer, the polycrystalline silicon layer and the aluminium layer can be used as the wiring layer. The present inventors have found that the capacitIve element of almost no field dependence can be formed by appropriately selecting one or two from the above-mentioned four wiring materials. Further, particular consideration is paid to the utilization of the gate oxide film from the point of capacitance per unit area.
SUMMARY OF THE INVENTION
Therefore, an object of this invention is to provide a MIS capacitance element free from the field dependence.
Another object of this invention is to provide a MIS capacitance element adapted to be integrated into a complementary MIS IC.
A further object of this invention is to provide a MIS capacitance element suited for use as a load capacitance in a logic gate for setting the time constant of the logic operation large.
According to an aspect of this invention, there is provided a MIS capacitance element to be formed in a semiconductor substrate of a first conductivity type, comprising a well region of a second conductivity type formed in a surface of the semiconductor substrate, a gate insulating film formed on the surface of the well region, and a polycrystalline layer formed on the gate insulating film, the well region and the polycrystalline region serving as the two polar plates of the capacitance element which are to be supplied with a voltage of such a polarity that the well region is forward biased and hence no carrier channel is induced by the voltage application.
In such a MIS capacitance element, since no carrier channel is induced in the well region which serves as one polar plate, the capacitance of the element is not subjected to variation by the change in the applied voltage. When the capacitance has no field dependence, it is easy to design a circuit including such capacitance elements since the time constant is fixed regardless of the applied voltage.
The above and other objects, features and advantages of this 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. 1A is a plan view of a fundamental MIS capacitance structure according to an embodiment of this invention.
FIG. 1B is a sectional view taken along the line IA--IA of FIG. 1A.
FIG. 1C is an alternative plan view taken along the line IA--IA of FIG. 1A.
FIG. 2 is a cross section of a MIS capacitance structure according to another embodiment of this invention.
FIGS. 3A and 3B are sectional and plan views of another embodiment of this invention respectively.
FIG. 4 is a cross-sectional view of a further embodiment of the MIS capacitance element of FIG. 1A.
FIG. 5 is a schematic view of a MIS capacitive element of the present invention integrated into a complementary MIS IC.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Detailed description will be made hereinbelow of the preferred embodiments referring to the accompanying drawings.
FIG. 1A shows a fundamental embodiment of the semiconductor capacitance device according to this invention. In the Figure, numeral 1 denotes a silicon substrate, say of n-type, of a complementary MIS IC chip, 2 a p-type well region formed by ion-implantation of a p-type impurity such as boron, or by the epitaxial growth of p-type silicon layer lightly doped with a p-type impurity formed on a recessed portion which is formed by selective etching. The p-type well 2 is formed by the same steps as those for other p-type wells in which n-channel MIS elements are to be formed. A thin insulator film 3 is formed of the same film for forming the gate region of MIS transistor elements and hence is referred to as the gate insulator film hereinbelow. The gate insulator film 3 may be a thin oxide film having a thickness of about 1200 A, and defined in a predetermined area. The thickness and the area substantially determine the capacitance. A field insulator film 4 for passivating the semiconductor surface may be a thick oxide film, e.g. 1.4 μm thick. A polycrystalline silicon layer 5 is formed and superposed onto the gate insulator film 3 to a thickness of about 0.5 μm, for example by the thermal decomposition of monosilane (SiH 4 ). The polycrystalline layer 5 is doped with n + or p + -type impurity to have electric conductivity, for example a sheet resistivity of 80 to 150 Ω/□. The impurity doping in the polycrystalline layer 5 is accomplished during a source and drain diffusion step. A p + -type diffused region 6 is formed in the peripheral part of the p-type well region 2 for extracting electrode contacts and has a ring-like shape or a strip shape as shown in FIGS. 1B and 1C. J 1 denotes a junction between the n - -type substrate 1 and the p + -type diffused region 6, and J 2 denotes a junction between the p-type well 2 and the p + -type diffused region 6.
An n + -type diffused region 11 is formed in a portion of the p + -type diffused region 6 to form a part of junction J 1 as shown in FIGS. 1B and 1C, and the p + -type diffused region 6 is connected to the n - -type substrate 1 through an aluminum electrode 8 and the n + -type diffused region 11 and hence grounded. The electrode 8 partially contacts the n + -type diffused region 11. A protective insulator film 7 may be formed of phosphorous silicate glass formed by the chemical vapor deposition (CVD) or of a polyimide-iso-indroquinazolinedione (polyimid series region), and has windows on those portions where lead-out electrodes make contact with the p + -type diffused region 6 and with the polycrystalline region 5 respectively. The aluminium electrode 8 makes contact with the p-type well region 2 through the p + -type diffused region 6 and another aluminium electrode 9 makes contact with the polycrystalline layer 5, both through respective through-holes formed in the protective insulator film 7 by photoetching technique. The electrode 8 may be formed in a ring shape or a strip shape similar to the p + -type diffused region 6 as shown in FIGS. 1B and 1C.
In the above structure, a capacitor is formed of the p-type well region 2 and the polycrystalline silicon layer 5 sandwiching the gate insulator film 3. The electrode 9 connected to the polycrystalline silicon layer 5 is applied with a negative potential and the electrode 8 connected to the p-type well region 2 is supplied with a positive potential so that a forward bias voltage is applied between the polycrystalline silicon layer 5 and the p-type well region 2, for example, the polycrystalline silicon layer 5 is supplied with -3 V to -6 V and the p-type well region 2 is maintained at ground potential. Thus, no carrier channel is formed in the well surface.
The area of the polycrystalline layer 5 determines the capacitance with the thickness of the gate insulator film 3.
According to the above embodiments, the objects of this invention as described earlier can be achieved for the following reasons.
(a) The polycrystalline silicon layer and the p-type well region are, even though not perfect, conductors having sheet resistances, e.g. 80 to 150 Ω/□ and 2 to 10 Ω/□, respectively, and hence they constitute a capacitor with the intervening gate insulator film. In the conventional MIS gate capacitors or diffused layer-substrate capacitors, a reverse bias voltage is applied. Thus, they have a field dependence. On the other hand, according to the present invention, a forward bias voltage is applied, so that no inversion layer is formed under the insulating layer. Therefore, there arises no field dependence.
(b) In integrating a capacitor in a MIS device formed on the same IC chip, the gate insulator film for forming a MIS transistor structure can be directly used as the dielectric material isolating the two polar plates. Further, the p-type well region and the polycrystalline silicon gate region are also used directly. Namely, a capacitance element can be formed by heavily doping an impurity of the same conductivity type to that of the well region to form a contact region for the well region, without increasing or requiring particular layer forming processes or mask forming processes. Since the gate insulator film is formed to be very thin, the capacitance formed thereacross becomes large. For example, the capacitance ranges in the order of 2.5 to 3×10 -4 pF/μm 2 which is 2 to 3 times as large as the junction capacitance. Here, the polycrystalline silicon layer 5 may be substituted by a refractory metal layer of molybdenum or tungsten.
It is to be noted that this invention is not limited to the above embodiment but can be modified in various ways, as will be seen from the following.
The substrate is not limited to those of n-type. In a p-type substrate, n-type well regions are formed to make p-channel MIS transistors, etc. Sucn n-type wells may be similarly utilized to form MIS capacitance elements. In such a case, it will be apparent that a positive voltage is applied to the polycrystalline layer 5 for forward biasing the well region 2.
The capacitance may be increased by increasing the area of the polar plate. Namely, FIG. 2 shows a composite MIS capacitor element including a MIS structure and a metal-insulator-metal structure. In this embodiment, a polycrystalline silicon layer 5 extends not only on the gate insulator film 3 but also partially on the field insulator film 4 and an electrode 9 is formed to make contact with the polycrystalline layer 5 at a portion on the field insulator film 4. On the protective Insulator film 7 over the polycrystalline layer 5, an aluminium film 10 is formed in a predetermined shape (square, circular, etc.) so as to cover the polycrystalline silicon layer 5 through the protective insulator film 7 and is connected with the aluminium electrode 8 making contact with the well region 2. The protective insulator film 7 has a larger thickness than the gate insulating layer. Thus, the capacitance is increased in a small amount by the addition of this metal-insulator-metal structure. It will be apparent that the capacitance may further be increased by decreasing the thickness of the insulator layer in this metal-insulator-metal structure.
The gate insulator film may also be formed of a silicon nitride (Si 3 N 4 ) film or of a double layer of silicon oxide 32 and silicon nitride 3b, such as illustrated in FIG. 4.
The present MIS capacitance element is generally usable in complementary MIS ICs where wells of the opposite conductivity to that of the substrate are formed, such as that illustrated in FIG. 5. For example, the electrode connected to the polycrystalline silicon layer may be connected to a fixed operating potential V SS or V DD and the electrode connected to the p-type (or n-type) well is at a varying potential level. Here, the sum of the capacitance between the polycrystalline silicon layer and the p-type well and that between the p-type well and the n-type silicon substrate may be used. In such a case, however, there arises some field dependence since the latter capacitance is an ordinary junction capacitance. The order of the field dependence, as a whole is yet smaller than that of the pure junction capacitance.
FIGS. 3A and 3B show a modification of the MIS capacitor structure of FIG. 1A, in which a p + -type diffused region 36 of bar-like or strip-like configuration is formed to extend along a portion of the outer periphery of a gate insulator film 33. The p + -type diffused region 36 is connected to an n-type substrate 31 through an aluminium electrode 38 and an n + -type diffused region 40. The shape of aluminium electrodes 38 and 39 may be any one other than that in FIG. 3B.
According to the present invention, the gate insulator film may be formed onto the surface of the n - -type substrate. The polycrystalline silicon layer is formed onto the gate insulator film. A capacitor is formed of the n - -type substrate and the polycrystalline silicon layer sandwiching the gate insulator film, not using the p-type well region. In such a case, the polycrystalline silicon layer is supplied with a positive potential and the n - -type substrate is supplied with a negative potential, for example, the polycrystalline silicon layer is supplied with +3 V to +6 V and the n - -type substrate is maintained at ground potential. | A MIS capacitance element formed in a semiconductor substrate of p-(or n-) conductivity type comprises an n- (or p-) type well region formed in one principal surface of the semiconductor substrate and a polycrystalline region formed on the surface of the well region through a gate insulator layer. A polar voltage is applied between the well region and the polycrystalline layer so that the well region is forward biased and no carrier channel region is formed in the surface of the well region. The MIS element is particularly suited for use in a complementary MIS IC and provides almost no voltage or field dependency of the capacitance. | 8 |
TECHNICAL FIELD OF THE INVENTION
This invention relates to apparatus useful in the drilling of wells, such as oil wells, wherein a mud pump is used to circulate drilling mud under pressure through a drill string, down to and around the drill bit and out into the annulus between the drill string and the bore hole of the well into a mud tank or reservoir; the apparatus of the present invention being useful for degassing drilling mud used in the drilling of the well. More particularly, this invention relates to a drilling mud degasser having a gear box and means for the continuous self-lubrication of the gear box.
DESCRIPTION OF THE PRIOR ART
In the drilling of wells, such as oil wells, it is a common practice to penetrate the earth with a drill bit supported on a drill string in the bore of a well being drilled. In order to lubricate the drill bit, protect the well against blowouts, etc., it is conventional practice to circulate drilling mud under pressure through the drill string down to and around the drill bit and up the annulus between the drill string and the bore of the well. Mud flowing through the well is passed through a suitable device such as a shaker, etc., in order to remove drill cuttings, etc., and is then delivered to a mud reservoir, such as a mud tank, for recirculation to the mud pump for pressured injection into the well.
It is conventional practice to use a mud pump, such as a duplex or a triplex mud pump comprising reciprocating pistons mounted in cylinders for pressuring the incoming drilling mud and delivering it to the well bore under pressure. The operation and construction of mud pumps is well known to those of ordinary skill in the art, as illustrated, for example, by the textbook "Mud Pump Handbook" by Samuel L. Collier (Gulf Publishing Co., Houston, Tex., 1983).
It is also known to remove contaminating gases such as air, methane, etc., from the drilling mud in the mud tank before it is delivered to a mud pump.
Thus, devices for the removal of contaminating gases from aqueous fluids such as drilling muds is disclosed, for example, in Burgess U.S. Pat. No. 3,973,930 dated Aug ust 10, 1976 and entitled "Drilling Mud Degasser Apparatus and Method", Burgess U.S. Pat. No. 3,999,965 dated Dec. 28, 1976 and entitled "Liquid Treating Apparatus", Burgess U.S. Pat. No. 4,084,946 dated Apr. 18, 1978 and entitled "Drilling Mud Degasser", Phillips et al. U.S. Pat. No. 4,088,457 dated May 9, 1978 and entitled " Degassification System", Tkach U.S. Pat. No. 4,201,555 dated May 6, 1980 and entitled "Method and Apparatus for Degassification of Liquid by Inducing Vortexing", Day et al. U.S. Pat. No. 4,326,863 dated Apr. 27, 1982 and entitled "Centrifugal Degasser", Egbert U.S. Pat. No. 4,365,977 dated Dec. 28, 1982 and entitled "Drilling Mud Degasser", Underwood U.S. Pat. No. 4,416,672 dated Nov. 22, 1983 and entitled "Degasser", and Burgess U.S. Pat. No. 4,609,385 dated Sept. 2, 1986 and entitled "Multi-Stage Water Deoxygenator". Among the contaminating gases that are removed are air, nitrogen, carbon dioxide, methane, etc.
The present invention is uniquely adapted for use in connection with a drilling mud degassing device of the type shown in the Burgess patents, such as Burgess Pat. No. 4,084,946.
BACKGROUND OF THE INVENTION
The drilling of deep wells such as oil wells, and especially the drilling of offshore oil wells, is a very costly endeavor. For instance, the cost per day of operating an offshore drilling rig in comparatively shallow waters of 100 feet or less typically amounts to about $10,000 per day while the cost of operating a drilling vessel in deep waters exceeding depths of 200 feet can cost $30,000 per day or more.
It is manifest, therefore, that any interruption of the drilling operation will be very costly, and that it is highly desirable to avoid all but the most essential of drilling interruptions.
As indicated above, it is conventional practice to remove contaminating gases such as methane, air, carbon dioxide, etc., from drilling mud before it is pressured and injected into a well bore. If this is not done, there is an everpresent danger that the gas will accumulate in either the drill string or the well bore annulus in an amount sufficient to form a gas pocket.
Therefore, if a drilling mud degasser fails to operate properly, the drilling operation must be suspended until the drilling mud degasser is repaired.
Moreover, since drilling operations normally continue on an essentially continuous basis for 1 to 12 months or more, any part of the drilling mud degasser that does not have a design life of at least six months is apt to be the cause of an undesired and very expensive interruption of drilling operations.
Drilling mud degassers of the type shown in Burgess U.S. Pat. No. 4,084,946 require a motor, usually an electric motor, which operates a vacuum pump at one rate of speed and a centrifuge tube at another second lower rate of speed. In order to run both the centrifuge tube and the vacuum pump off a single drive shaft, it is necessary to utilize an appropriate gear reduction system, such as a planetary gear reduction system between the drive shaft and the centrifuge tube. Gear reduction systems such as planetary gear reduction systems are normally housed in a gear box.
Since appreciable friction is generated in the gear box during operations, it is necessary that the gear box at all times be properly lubricated with a lubricant which can stand the operating pressures employed. It has been the practice to use a grease, such as a high temperature grease able to withstand temperatures of about 250° F. or more generated in the gear box. Moreover, the gear box needs to be greased on a daily basis and if for any reason the lubrication of the gear box is overlooked by workmen or if the gear box becomes overheated, a gear box failure is likely. When the gear box fails, drilling operations must be interrupted while the drilling mud degasser is taken apart to the extent necessary to replace the damaged gear box with a new gear box. Of course, if a spare gear box is not present on the vessel, an even greater delay will be experienced in bringing a gear box to the vessel. Although the down time of the degasser for the replacement of the gear box will normally be about 2 hours, the down time for the drilling rig will normally amount to 12 hours or more.
There is a need, therefore, for a self-lubricating drilling mud degasser which can operate without maintenance for prolonged periods of time such as about 1 to about 6 months.
SUMMARY OF THE INVENTION
In accordance with the present invention, a self-lubricating centrifugal drilling mud degasser is provided for a degasser of the type wherein a motor is provided with a depending drive shaft. A hollow gear box casing is mounted on the drive shaft and provided with a lubricant inlet port formed therein adjacent the top thereof. A reduction gear arrangement is also provided in the gear box comprising a stationary gear ring fixed to the casing below the inlet port; the ring gear being provided with interior teeth and a lubricant outlet port formed in the groove between two adjacent teeth. A plurality of reduction gears in the gear box are operatively interconnected with the drive shaft.
A lubricant reservoir is located adjacent the gear box and an inlet line is provided interconnecting the lower portion of the lubricant reservoir with the gear box inlet port and with a lubricant outlet line interconnecting the top portion of the lubricant reservoir with the gear box outlet port. As a consequence, since the gear box system is sealed, whenever hot lubricant is pumped from the gear box to the lubricant reservoir, an equivalent quantity of lubricant will automatically flow to the gear box. This is accomplished in accordance with the present invention during operation of the reduction gear system because rotation of the reduction gears about the ring gear will cause the reduction gears to mesh with the adjacent teeth defining the groove between which the outlet port is formed and, as a consequence, a pulse of the lubricant will be pumped from the gear box to the lubricant reservoir and an equivalent pulse of lubricant will flow from the lubricant reservoir back to the gear box.
BRIEF DESCRIPTION OF THE DRAWINGS
In the accompanying drawings;
FIG. 1 is a side elevational view illustrating a self-lubricating drilling mud degasser of the present invention;
FIG. 2 is a side elevational view, partly in section, showing the combination of a motor drive shaft, a motor drive shaft extension, a gear box containing a planetary gear reduction system, a driven gear and a lubricant reservoir of the present invention;
FIG. 3 is a fragmentary sectional view taken along the lines 3--3 of FIG. 2 illustrating in greater detail the manner in which the lubricant outlet port is formed in a ring gear in accordance with the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to the drawing, and especially to FIG. 1, there is shown a drilling mud degasser designated generally by the number 10 interconnected with a mud tank 8 by an inlet line 6 and with a mud pump 4 by way of an outlet line 2.
An appropriate motor of any suitable construction, such as a diesel motor, a gasoline motor, an electric motor, etc., but preferably an electric motor 20 is provided with a motor handling bracket 21 and a motor support such as a motor support plate 22.
With reference to FIGS. 1 and 2, a motor drive shaft 26 depends from the motor 20 and is provided with a first interior keyway 26 or any other suitable structure for use in operatively connecting the motor drive shaft 26 with a drive shaft extension 36.
In accordance with this embodiment, a drive shaft coupling 30 is provided which is of a tubular construction having a central opening designed to fit over the depending end of the drive shaft 26 and the upstanding end of the drive shaft extension 36, the drive shaft coupling 30 having a third interior keyway 32 and a fourth interior keyway 34 formed therein.
There is also provided a gear box designated generally by the numeral 40 comprising (with reference to FIGS. 2 and 3) an interiorly toothed ring gear 42 provided with a plurality of interior teeth 44 and, in this embodiment, a plurality of circular fastening shafts 75 milled therein for use in assembly of the gear box 40.
With particular reference to FIG. 3, it will be noted that a lubricant outlet port 46 has been formed in the groove between adjacent teeth 44a and 44b for a purpose to be described.
The gear box casing 40 may be formed in any desired manner. In the embodiment shown herein the ring gear 42, for convenience, comprises a part of the gear box casing 40.
Thus, in accordance with this embodiment, there is provided an upper gear box casing member 48 having a lubricant inlet port 50 formed therein and a lower gear box casing member 52. The upper gear box casing member 48 and the lower gear box casing member 52 are interconnected with ring gear 42 by any suitable means. For example, hex bolts 76 extend through upper gear box casing member fastening shafts 49 which are formed in the upper gear box casing flange 47 and are aligned with the ring gear fastening shafts 75 so that the hex bolts 76 can be extended therethrough and threaded into threads tapped into corresponding openings in the fastening flange 54 of the lower gear box casing member 52. An upper bearing 60 is journaled into the upper gear box casing member 48 and a lower bearing 62 is journaled into the lower gear box casing member 52.
It will be understood that the bearings 60 and 62 may be the same or different and will be bearings of the type known to those skilled in the art for supporting a shaft in a casing, such as ball bearings, needle bearings, roller bearings, etc. For example, the upper bearing 60 may suitably comprise a ball bearing and the lower bearing 62 may comprise one or more sets of roller bearings.
A drive shaft extension 36 is mounted in the upper ball bearing 60 and is provided at the lower end thereof with a toothed planetary drive gear 39 designed to operatively engage a gear comprising an appropriate reduction system. The reduction gear system may comprise, for example, one or more appropriately sized and operatively interconnected helical gears, herringbone gears, worm gears, planetary gears, etc. In the preferred embodiment of the invention, the reduction gear system will comprise a plurality of planetary gears 72 which are mounted in planetary ball bearings 70 carried by a plurality of equally spaced upright planetary gear shafts mounted between laterally spaced planetary gear plates 66.
It will be noted from FIG. 3 that each of the planetary gears 70 is provided with one or more planetary ball bearing lubricant ports 74 which are formed in a groove between adjacent teeth of the planetary gear.
With particular reference to FIG. 2, in accordance with the present invention, a lubricant reservoir 200 is provided with is of any suitable construction being formed, for example, of a lubricant reservoir base plate 202, an upstanding cylindrical lubricant reservoir body 204 and a lubricant reservoir cover plate 206 provided with a lubricant filling plug 208. In accordance with this construction, the upstanding cylindrical lubricant reservoir body 204 is also provided with a lubricant reservoir drain plug 210, a lubricant reservoir inlet plug 212, a lubricant reservoir outlet plug 214 and upper sight port 220 and a lower sight port 222.
With this construction, and with the lubricant reservoir filling plug 208 open, an appropriate lubricant such as a liquid synthetic hydrocarbon lubricant (e.g., Dextron II transmission fluid) can be poured into the reservoir until the fluid level inside the lubricant reservoir 200 is at or above the upper sight port 220. Thereafter, the lubricant reservoir plug may be put back in place in order to seal the reservoir. The lower sight port 222 is provided so that visual inspection will show if the level of a lubricant in the reservoir 200 has fallen to an undesirable level, such as the level below lower sight port 222.
An output shaft 77 is fixed in the planetary gear plate 66 in any suitable fashion (not shown) and supported in the lower ball bearing 62 for a purpose to be described.
A vacuum pump 80 of any suitable construction, such as a "regenerative" vacuum pump of the type formed with a disclike body containing oppositely projecting impeller vanes is operatively connected with the drive shaft 26 above the gear box 40. For example, the vacuum pump 80 is secured to the motor support plate 22 by any suitable means such as a plurality of vacuum motor brackets 81 to which a vacuum motor support stand 83 is fixed by any suitable means such as a plurality of hex bolts 84; the vacuum pump 80 being, in turn, fixed to the vacuum pump support stand 83 by upper hex bolts 86.
The vacuum motor brackets 81 are fixed to the cover plate 102 comprising the top of a vacuum chamber 100 which is further defined by a side wall 104 and a bottom wall 106 to which a cylindrical degassed drilling mud chamber 140 is mounted. The interior of the degassing chamber 100 and the cylindrical degassing drilling mud collection chamber 140 are closed from the atmosphere by a collection chamber base plate 142 and the interior of the degassing chamber 100 is operatively interconnected with the vacuum pump 80 by a vacuum hose 82.
With this construction, and on appropriate operation of the vacuum motor 80, it is possible to maintain a suitable vacuum within the vacuum chamber 100 and the cylindrical degassed drilling mud collection chamber 140, such as a pressure of about 10 inches to about 15 inches of mercury.
The output shaft 77 is journaled into the cover plate 102 of the vacuum chamber 100 and extends into the vacuum chamber 100. A centrifuge tube 110 in the vacuum chamber is provided with centrifuge tube slots 116 in the sidewall thereof adjacent the top thereof and with a centrifuge spider at the top thereof which is fixed to the output shaft 77 by any suitable means such as a spider retaining bolt 114.
An evacuation pump cross brace spider 128 is mounted inside the vacuum chamber 100 adjacent the bottom thereof intermediate the vacuum chamber 110 and the cylindrical degassed drilling mud collection chamber 140. An evacuation chamber is provided which is mounted on the evacuation pump cross brace spider 128 and is defined by an evacuation pump cover plate 124, a cylindrical evacuation pump side wall casing 122 and an evacuation pump base plate 126.
An evacuation pump of any suitable construction, such as one comprising an evacuation pump impeller 130 mounted on the bottom of centrifuge tube 110 is provided which is mounted inside an evacuation pump inlet venturi 132 leading to a degassed drilling mud discharge line 134.
An inlet line 144 is provided which preferably terminates inside the evacuation chamber 120. In this embodiment, the top of the inlet line 144 is spaced from the bottom of the slotted centrifuge tube 110 so that the rotating centrifuge tube 110 can rotate freely without bearing upon the top of the inlet line 144. The resultant "controlled seepage" of drilling mud from the inlet tube 144 into the evacuation chamber 120 does not seriously adversely affect the performance of the drilling mud degasser and obviates the needs for bearings and seals at the bottom of the slotted centrifuge tube 110.
A donut-shaped scheduling float 150 is annularly mounted about the centrifuge tube 110 in the vacuum chamber 100 and is provided with a lower flange 151 which is designed to seat upon a plurality of lower float stops 152 and to bear against a plurality of upper float stops 154.
As will be hereinafter explained in greater detail, drilling mud contaminated with gas is drawn into the degasser of the present invention through the inlet line 144 and centrifically accelerated inside centriguge tube 110 and then sprayed through the slots 116 at the top of centrifuge tube 110 into the vacuum chamber 100 where the sprayed drilling mud impacts against the side wall 104. As a consequence, contaminating gas is separated from the drilling mud and the degassed drilling mud flows downwardly into the evacuating chamber 120. A portion of the degassed drilling mud accumulated in the evacuation chamber 120 will be drawn by the evacuation pump inlet venturi 132 into the evacuation pump chamber 120 and discharged therefrom through the degassed drilling mud discharge line 134.
It will be apparent that drilling mud will also accumulate in the evacuation chamber 120 and the vacuum chamber 100 and that the level of the degassed drilling mud in the vacuum chamber 100 will be determined by the rate of charge of drilling mud through the inlet line 144 and the centrifuge slots 116 relative to the rate of discharge of degassed drilling mud through the degassed drilling mud discharge line 134. If gas contaminated drilling mud flows through the inlet line 144 faster than degassed drilling mud is withdrawn through the evacuation pump inlet venturi 132, the drilling mud level will rise until the lower float flange 151 of the scheduling float 150 abuts the upper float stops 152. As the float 150 rises, the open area defined by the slots 116 in the centrifuge 110 is reduced to thereby achieve a balance between the rate at which gas contaminated drilling mud is delivered to the degassing chamber 100 and the rate at which degassed drilling mud is withdrawn through the degassed drilling mud discharge line 134. If the rate of discharge through the line 134 is excessive, the drilling mud level in the vacuum chamber 100 will tend to fall thus increasing the open area of the slots 116 in the venturi tube 120 to permit a greater flow of drilling mud into the degassing chamber 100.
The contaminating gases liberated by the action of the centrifuge tube and the spraying of the drilling mud into the vacuum chamber 100 will be withdrawn from the vacuum chamber 100 by way of the vacuum hose 82.
In order to prevent entrainment of foam or liquid droplets into the hose 82, a foam separation impeller 156 of any suitable construction comprising, for example, a plate having vanes formed at the outside peripherial edges thereof may be mounted on the output shaft 77 so that the out flowing gas will follow a tortuous path which will permit the occluded foam and the droplets of liquid to accumulate and flow back into the vacuum chamber 100.
OPERATION OF THE PREFERRED EMBODIMENT
It is necessary to maintain a drilling mud at a predetermined weight per gallon, which will vary from well to well. If the drilling mud is diluted for any reason (e.g., by the adsorption of a gas therein), the weight per gallon of drilling mud will decline and the probability of a blow-out will increase. Drilling mud exiting a bore hole will typically weigh about 2 lbs. per gallon less than the degassed drilling mud charged to the well and in extreme situations can amount to as much as 10 lbs. per gallon.
Degassing is accomplished in accordance with the present invention by using a drilling mud degasser 10 to remove contaminated gases from the drilling mud.
During operations, when the motor 20 is energized, rotation of the motor drive shaft 26 will cause rapid rotation of the vanes (not shown) of the vacuum pump 80 in order to generate an appropriate vacuum such as a vacuum of from about 10 to about 15 inches of mercury in the vacuum chamber 100.
The motor drive shaft 26, is connected to the drive shaft extension 36 through the drive shaft coupling 30 by means of a first key 35 mounted in first exterior keyway 28 and third interior keyway 32 and a second key 37 located in second exterior keyway 38 and fourth interior keyway 34. As a consequence, the toothed planetary drive gear 39 on the lower end of the drive shaft extension 36 will cause rotation of the planetary gears 72 at a rate of rotation equivalent to the rate of rotation of the motor drive shaft 26. However, rotation of the planetary gears about the interiorly toothed ring gear 42 will cause the planetary gear plate 66 to rotate at a second significantly lower rate of speed. Thus, for example, the motor drive shaft 26 may be operated at a rate of about 3,600 revolutions per minute while the planetary gear plate 66 may operate at a much slower rate of about 800 revolutions per minute, or upon any other desired gear ratio established in the planetary gear system inside the gear box 40.
Rotation of the planetary gear plate 66 will cause a corresponding rotation of the output shaft 77 and the centrifuge tube 110 connected thereto by means of centrifuge tube spider 112 and centrifuge spider retaining bolt 114.
The suction created by the centrifuge tube 110 will cause gas contaminated drilling mud to be delivered from the mud tank 8 by way of a inlet line 6 to the degasser inlet line 144 and thence to the centrifuge tube 110. Within the centrifuge tube 110 the gas contaminated drilling mud will be centrifugally accelerated in its travel up the wall of centrifuge tube 110 and will then be expelled through the slots 116 at the top of the centrifuge tube as a sheet of drilling mud which will impact upon the sidewall 104 of the vacuum chamber 100. As a consequence, gas contaminants entrained in the drilling mud will be liberated and will pass about the foam separation impeller 156 into the vacuum hose 82 and the vacuum pump 80 for discharge from the system. The thus degassed drilling mud will collect at the bottom of degassing chamber 100 into the cylindrical degassed drilling mud collection chamber 140. The evacuation pump impeller 130, on rotation by rotation of the venturi tube 110 to which it is attached, will cause degassed drilling mud to flow from the collection chamber 140 through the evacuation pump inlet venturi 132 into the evacuation chamber 120 where it will be pumped by the evacuation pump impeller 130 from the degasser 10 through the degassed mud discharge line 134 leading to the inlet line 2 for the mud pump 4 where it is repressured for delivery to the drill string.
During the course of operations, appreciable friction will be generated by the rotation of the planetary gears 72 and the planetary gear plate 66 within the gear box 40. However, on each rotation of a planetary gear 72 past the groove 45 between teeth 44a and 44b of the gear ring, a pulse of lubricant will be forced from the gear box 40 through the lubricant outlet port 46. The hot lubricant will flow through the outlet line 218 to the lubricant reservoir 200 where it will accumulate and be cooled either by positive heat exchange means (not shown) or by atmospheric convection. A pulse of cooled lubricant will be redelivered to the gear box 40 from lubricant reservoir 200 by lubricant inlet line 216.
As a consequence, the gears in the gear box 40 will be properly lubricated and overheating will be avoided.
In this manner, a reliable degassing operation can be conducted continuously for as long as 1 to 6 months without a need to replace the gear box 40.
EXAMPLE
In order to obtain geological information, a test well was to be drilled to the top of the basement rock formation of a geological province, the basement rock formation being located several miles below the surface of the earth. It was estimated that more than a year of continuous drilling would be required in order to reach the desired depth and that sedimentary gas-containing formations would be penetrated during the drilling opration.
Drilling operations were commenced using a drilling mud degasser of the type disclosed in Burgess U.S. Pat. No. 4,084,946 wherein the gear box of the degasser was lubricated with a high temperature grease suitable for lubricating the gear box at gear box operating temperatures of about 250° F. After about 60 days of continuous drilling the gear box failed and had to be replaced. It was replaced with a gear box of the type illustrated in the drawings herein wherein the gear box was interconnected in the illustrated manner with a lubricant reservoir containing Dextron II transmission fluid.
It was found that with this construction the gear box operated at a significantly lower temperature of about 130° F.
Drilling operations were resumed and in a five month period of continuous drilling no further gear box failures were encountered.
It will be apparent to those skilled in the art that the embodiment illustrated herein is a preferred embodiment which is given by way of illustration only, since the drilling mud degasser may be of any of the many mud pump degasser designs known to those skilled in the art. Accordingly, the preferred embodiment is shown for purposes of illustration only, the scope of the present invention being defined by the appended claims. | A degasser for removing contaminating gases from an aqueous fluid including a motor having a depending drive shaft, a hollow gear box casing having a lubricant inlet port formed therein adjacent the top thereof, a reduction gear arrangement comprising a stationary ring gear fixed to said gear box casing below said inlet port; the ring gear arrangement including a ring gear having a lubricant outlet port formed therein in a groove between two of the teeth, a plurality of reduction gears operatively interconnected to said drive shaft, a lubricant reservoir adjacent the gear box, a lubricant inlet line interconnecitng the lower portion of the lubricant reservoir with the gear box inlet port, and a lubricant outlet line interconnecting the top portion of said lubricant reservoir with the gear box outlet port, whereby each rotation of the reduction gears will force a pulse of lubricant form said gear box through said outlet port and said outlet line to said lubricant reservoir and, whereby, a corresponding pulse of lubricant will flow from said lubricant reservoir through said inlet line to said inlet port for said gear box. | 4 |
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